RU2818286C2 - Method for preparing bacon analogue product and bacon analogue product - Google Patents

Abstract

FIELD: meat industry.

SUBSTANCE: method of producing a bacon analogue product involving: a) obtaining a vegetable protein extrudate by wet extrusion; b) obtaining 10–20 % wt/wt vegetable protein dispersion; c) obtaining a fat simulator by emulsifying a dispersion of a vegetable protein and a lipid phase; d) applying a binding agent to a vegetable protein extrudate or a fat simulator; e) laying out the vegetable protein extrudate, the fat simulator and the vegetable protein dispersion in layers; f) pressing the laid layers; g) heating to obtain a cohesive mass; h) cooling. Binding agent is a dispersion of soya protein isolate, obtained using soya protein isolate, and wherein the binding agent further comprises a transglutaminase solution.

EFFECT: invention makes it possible to produce vegan products with “clean label”, which do not contain ingredients of animal origin.

11 cl, 7 dwg, 8 tbl, 11 ex

Description

Prerequisites for creating the invention

Bacon is one of the most preferred foods in the world. It is used in many traditional dishes and is often served with fried or scrambled eggs, on hamburgers, or as part of pizza.

One of the major trends in nutrition is consumers switching to vegan products that do not contain animal ingredients.

Some existing bacon alternatives can be made at home by marinating strips of tempeh or tofu in various flavorings such as soy sauce or liquid smoke, then frying or baking. Raw food eaters can also use coconut meat as a bacon substitute. You can also use seitan to make vegan bacon. The taste, appearance and texture of these products are essentially very bland.

Additionally, there is a general strong focus on clean label food products. Current products on the market are often made from soy protein and typically contain a long list of ingredients such as eggs, additives, gums and flavorings.

There is a clear need for new bacon alternative products that provide consumers with all the benefits of bacon in terms of taste, texture and appearance, but are also clean label products.

Summary of the invention

The invention generally relates to a method for producing a bacon analogue product, including the production of a protein extrudate, a protein dispersion and a fat simulant; optional application of a coupling agent; laying out protein extrudate, fat simulator and protein dispersion in the form of layers; pressing the laid layers; heating; cooling; and optionally smoking and/or slicing.

The invention further relates to a method for manufacturing a bacon analogue product, including obtaining a vegetable protein extrudate, a vegetable protein dispersion and a fat simulant by emulsification; optionally applying a binding agent, preferably to the vegetable protein extrudate; laying out vegetable protein extrudate, fat simulant and vegetable protein dispersion in the form of layers; pressing the laid layers; heating to obtain a cohesive mass; cooling; and optionally smoking, slicing and/or striping.

The invention further relates to a method for producing a bacon analogue product, comprising producing a vegetable protein extrudate, preferably by wet extrusion; preparing a vegetable protein dispersion, preferably 10-20% (w/w) of a vegetable protein dispersion, preparing a fat simulant by emulsification, preferably by emulsifying the protein dispersion and lipid phase; optionally applying a binding agent to the vegetable protein extrudate or fat simulant; laying out vegetable protein extrudate, fat simulator and protein dispersion in the form of layers; pressing the laid layers; heating to obtain a cohesive mass; cooling; and optionally smoking, slicing and/or striping.

In particular, the invention relates to a method for producing a bacon analogue product, comprising

A. obtaining vegetable protein extrudate by wet extrusion;

b. preparing a 10-20% (w/w) vegetable protein dispersion, preferably a soy protein dispersion;

With. obtaining a fat simulator by emulsifying a dispersion of vegetable protein and lipid phase;

d. optionally applying a binding agent to the vegetable protein extrudate or fat simulant;

e. laying out vegetable protein extrudate, fat simulant and vegetable protein dispersion in the form of layers;

f. pressing the laid layers;

g. heating to obtain a cohesive mass;

h. cooling; And

i. optional smoking, slicing or striping.

The present invention also generally relates to a bacon analogue product containing a protein extrudate, a protein dispersion, a fat simulant and an optional binding agent.

In particular, the invention relates to a bacon analogue product containing:

A. vegetable protein extrudate;

b. a vegetable protein dispersion, preferably a soy protein dispersion;

With. a fat simulant containing a protein isolate dispersion emulsified in a lipid phase; And

d. optional binding agent.

Description of the invention

The invention relates to a method for manufacturing a product - an analogue of bacon, including

A. obtaining vegetable protein extrudate by wet extrusion;

b. preparing a 10-20% (w/w) vegetable protein dispersion, preferably a soy protein dispersion;

With. obtaining a fat simulator by emulsifying a dispersion of vegetable protein and lipid phase;

d. optionally applying a binding agent to the vegetable protein extrudate or fat simulant;

e. laying out vegetable protein extrudate, fat simulant and vegetable protein dispersion in the form of layers;

f. pressing the laid layers;

g. heating to obtain a cohesive mass;

h. cooling; And

i. optional smoking, slicing or striping.

In some embodiments, the plant protein extrudate is produced using a twin or single screw extruder.

In some embodiments, the vegetable protein extrudate is a textured vegetable protein extrudate.

In some embodiments, the plant protein extrudate is a fibrous plant protein extrudate.

In some embodiments, the water content of the plant protein extrudate is at least 45% (w/w).

In some embodiments, the plant protein extrudate is a mixture of more than one plant protein.

In some embodiments, the water content of the vegetable protein extrudate is not less than the glass transition temperature of the vegetable protein extrudate at a consumption temperature of the bacon analogue product of 30 to 60°C.

In some embodiments, the vegetable protein extrudate or fat simulant further comprises a coloring agent and/or flavoring agent, preferably a smoky flavoring agent.

In some embodiments, the vegetable protein extrudate is prepared, preferably in vegetable broth. Typically, the prepared plant protein extrudate is coated with a binding agent.

Typically, vegetable protein extrudate has a maximum tensile strength of 250 to 320 newtons.

In some embodiments, the binding agent is selected from a dispersion of soy protein isolate, soy protein isolate powder, gluten powder, transglutaminase, dietary fiber, and vegetable protein.

The composition of the coupling agent that passes between the vegetable protein extrudate and the fat simulant layers is the most important parameter to ensure good cohesiveness of the product after thawing.

In one embodiment, the binding agent contains dietary fiber and vegetable protein.

In one embodiment, the total wt.% content of dietary fiber and vegetable protein in the binding agent is less than 40 wt.%.

In one embodiment, at least 50 wt.% of the dietary fiber is soluble, preferably from 50 wt.% to 70 wt.% of the dietary fiber is soluble, preferably about 60 wt.% of the dietary fiber is soluble.

In one embodiment, dietary fiber and plant protein are present in a ratio of about 67:33.

In one embodiment, the dietary fiber is potato fiber.

In one embodiment, the vegetable protein is potato protein.

In one embodiment, the dietary fiber is potato fiber and the plant protein is potato protein.

Typically, the coupling agent further contains an enzyme solution, the enzyme being selected from transglutaminase, tyrosinase and an oxidase, for example polyphenol oxidase. If the enzyme is a polyphenol oxidase, it is preferably a laccase. Typically, the enzyme solution is a transglutaminase solution, preferably a 10% (w/w) transglutaminase solution.

Preferably, the binding agent contains transglutaminase, dietary fiber and vegetable protein.

In some embodiments, the fat simulant is prepared by emulsifying a mixture of about 30% (w/w) protein dispersion and about 70% (w/w) lipid phase.

In some embodiments, the fat simulant further comprises dietary fiber. This proved important to ensure good cohesiveness of the product after thawing.

In some embodiments, the dietary fiber has a starch content of from 35 wt.% to 40 wt.%.

In some embodiments, the dietary fiber has a water holding capacity of from 7.5 g/g to 12.5 g/g, preferably a water holding capacity of about 10 g/g.

In one embodiment, the fat simulant contains about 5 wt.% dietary fiber, more preferably about 2.5 wt.% dietary fiber.

In one embodiment, the dietary fiber is pea cell wall fiber.

In one embodiment, pea cell wall fiber is dispersed in a mixture of rendered fat to form a solution. In one embodiment, said solution is added under shear stress to the protein dispersion.

In some embodiments, the protein dispersion is a protein isolate dispersion or a protein concentrate dispersion, preferably a protein isolate dispersion.

In some embodiments, the final protein concentration in the emulsifying mixture is about 3% (w/w).

In some embodiments, the protein dispersion is preheated to a temperature of no more than 95°C.

In some embodiments, the protein dispersion is a protein isolate dispersion prepared using a soy, potato, pea, pumpkin, or canola protein isolate, preferably a soy protein isolate.

In some embodiments, the protein isolate dispersion contains 10-20% (w/w) soy protein isolate. Typically, the protein isolate dispersion is about 10% (w/w) or about 14% (w/w) soy protein isolate. Typically, the protein isolate dispersion additionally contains transglutaminase.

In some embodiments, the lipid phase comprises canola oil or a mixture containing about 70% (w/w) canola oil and about 30% (w/w) tallow.

In some embodiments, salt is added to the protein dispersion and emulsifying mixture in the lipid phase.

In some embodiments, heating step g) includes

a. heating to a temperature of about 40°C in the thickness of the product; And

b. heating to a temperature of about 85°C in the thickness of the product.

Typically, heating step g) includes

a. heating to a temperature of about 40°C in the thickness of the product for about 1 hour; And

b. heating to a temperature of about 85°C in the thickness of the product for about 1 hour.

In some embodiments, cooling step h) involves showering with cold water, preferably for about 10 minutes.

In some embodiments, the cohesive mass is smoked in a chamber.

In some embodiments, the cohesive mass is cut into slices.

In some embodiments, the cohesive mass is cut into strips.

In some embodiments, the bacon replica product is fried.

In some embodiments, the invention relates to a method for making a bacon analogue product, comprising

A. obtaining vegetable protein extrudate by wet extrusion;

b. obtaining 14-16% (w/w) soy protein isolate dispersion;

With. obtaining a fat simulator by emulsifying a dispersion of vegetable protein and lipid phase;

d. applying a binding agent to the vegetable protein extrudate or fat simulant, wherein the binding agent is selected from a dispersion of soy protein isolate, soy protein isolate powder and gluten powder and further contains a solution of transglutaminase;

e. laying out vegetable protein extrudate, fat simulant and soy protein isolate dispersion in the form of layers;

f. pressing the laid layers;

g. heating at a temperature of about 85°C to obtain a cohesive mass;

h. cooling; And

i. optional smoking, slicing or striping.

The invention also relates to a product similar to bacon, containing:

A. vegetable protein extrudate;

b. a vegetable protein dispersion, preferably a soy protein dispersion;

With. a fat simulant containing a protein isolate dispersion emulsified in a lipid phase; And

d. optional binding agent.

In some embodiments, the vegetable protein extrudate is a textured vegetable protein extrudate.

In some embodiments, the plant protein extrudate is a fibrous plant protein extrudate.

In some embodiments, the plant protein extrudate is a mixture of more than one plant protein.

In some embodiments, the bacon replica product further comprises a coloring agent and/or flavoring agent, preferably a smoky flavoring agent.

In some embodiments, the binding agent is selected from a dispersion of soy protein isolate, soy protein isolate powder, gluten powder, transglutaminase, dietary fiber, and vegetable protein.

In one embodiment, the total wt.% content of dietary fiber and vegetable protein in the binding agent is less than 40 wt.%.

In one embodiment, at least 50 wt.% of the dietary fiber is soluble, preferably from 50 wt.% to 70 wt.% of the dietary fiber is soluble, preferably about 60 wt.% of the dietary fiber is soluble.

In one embodiment, dietary fiber and plant protein are present in a ratio of about 67:33.

In one embodiment, the dietary fiber is potato fiber. In one embodiment, the vegetable protein is potato protein.

In one embodiment, the dietary fiber is potato fiber and the plant protein is potato protein.

In one embodiment, the binding agent is a mixture of potato fiber and potato protein.

In one embodiment, the binding agent is a mixture of potato fiber and potato protein, the ratio of potato fiber to potato protein being about 67:33.

In one embodiment, the coupling agent further comprises an enzyme solution. Typically, the enzyme solution is selected from a solution of transglutaminase, tyrosinase and oxidase, preferably a solution containing about 10% (w/w) transglutaminase.

In some embodiments, the fat simulant comprises about 30% (wt/wt) protein dispersion containing the protein isolate and about 70% (wt/wt) lipid phase. Typically, the protein dispersion is a protein isolate dispersion or a protein concentrate dispersion, preferably a protein isolate dispersion. Typically, the protein isolate dispersion is a soy, potato, pea or canola protein isolate dispersion, preferably a soy protein isolate dispersion. Typically, the protein isolate dispersion contains 10-20% (w/w) soy protein isolate.

In some embodiments, the protein isolate dispersion contains about 10% (w/w) soy protein isolate or contains about 14% (w/w) soy protein isolate. Typically, the protein isolate dispersion additionally contains transglutaminase.

In some embodiments, the lipid phase is canola oil or a mixture containing 70% (w/w) canola oil and 30% (w/w) tallow.

In some embodiments, the bacon replica product contains 45 to 48% water, 12 to 16% canola oil, and 8 to 10% wheat gluten.

In some embodiments, a bacon analogue product is or can be produced by a method in accordance with the present invention.

In some embodiments, the bacon replica product does not contain any animal products. A bacon-like product typically does not contain egg ingredients, such as egg whites.

In some embodiments, the bacon replica product contains no additives. The product is an analogue of bacon, as a rule, does not contain hydrocolloids. The product is an analogue of bacon, as a rule, does not contain methylcellulose. The product is an analogue of bacon, as a rule, does not contain gums. The product is an analogue of bacon, as a rule, does not contain alginates. The product is an analogue of bacon, as a rule, does not contain modified starch.

The invention also relates to the use of a binder or binding agent in the production of a bacon analogue product.

Detailed Description of the Invention

Definitions

As used herein, the term “about”, when applied to numerical values, means numbers in a range, such as -30% to +30% of the number in question, -20% to +20% of the number in question, or -10% to + 10% of the number in question, or -5% to +5% of the number in question, or -1% to +1% of the number in question. It should be understood that all numeric ranges herein include all whole and fractional numbers included in the range. Moreover, these numerical ranges should be considered to support the claim referring to any number or subset of numbers within that range.

The products described herein may not contain any element not specifically described herein. Thus, a description of an embodiment using the term “comprising” includes a description of embodiments “consisting essentially of” and “consisting of” the specified components. Likewise, the methods described herein may not include any step not specifically described herein. Thus, a description of an embodiment using the term “comprising” includes a description of embodiments “consisting essentially of” and “consisting of” the specified steps. Any embodiment described herein may be combined with any other embodiment described herein unless specifically and expressly stated otherwise.

Unless otherwise defined, all technical and scientific terms and any abbreviations used herein have the same meaning as commonly understood by one of ordinary skill in the art of the invention. Although any compositions, methods, products or other means or materials similar or equivalent to those described herein may be used in the practice of the present invention, preferred compositions, methods, products or other means or materials are described herein.

As used herein, the term "additive" includes one or more of hydrocolloids (e.g., carboxymethylcellulose, methylcellulose, hydroxypropylmethylcellulose, konjac gum, carrageenans, xanthan gum, gellan gum, locust bean gum, alginates, agar, gum arabic, gelatin, karaya gum, gum cassia, microcrystalline cellulose, ethylcellulose); emulsifiers (eg lecithin, mono- and diglycerides, PGPR); whitening agents (eg titanium dioxide); plasticizers (for example, glycerin); anti-caking agents (eg silica).

Vegetable protein extrudate

The vegetable protein extrudate according to the invention can be produced using a twin screw extruder. The resulting structured product may have substantially aligned fibers. The dough can be prepared in a mixer with a mixing speed of about 30 rpm.

The extrudate ingredients can be prepared, for example, using pea protein isolate and wheat gluten.

In one embodiment, the extrudate contains wheat gluten, preferably 10 to 30 wt% wheat gluten, more preferably 10 to 20 wt% wheat gluten, more preferably 12 to 18 wt% wheat gluten, most preferably about 14.2 wt.%. This turned out to be important for achieving good cohesiveness after grilling.

The extrudate ingredients can be prepared, for example, using pea protein isolate, wheat gluten, soy protein isolate, canola oil and a coloring ingredient.

The extrudate ingredients can be prepared, for example, using pea protein isolate, wheat gluten, starch, salt or iodized salt (NaCl), pea protein isolate, soy protein isolate (for example, Supro 37 from Dupont Solae) and canola oil.

The mixture can be mixed for about 3 minutes until a smooth dough forms. It can then be pumped, for example, at a speed of about 15 kg/h.

The extruder slot head can be attached to the extruder outlet. The extruder head temperature can be maintained below 100°C. To adjust the color and aroma of the extruded product, flavorings and coloring ingredients can be added to reproduce the organoleptic properties of pork. For example, they can be introduced as an emulsion at the end of the extrusion process.

The vegetable protein extrudate must have a water content above 45 g/100 g. This ensures the hydration of the protein.

The extrudate must remain at a moisture content above the glass transition humidity of the protein used or protein mixture used at the consumption temperature (30-60°C) (after frying or baking) of the finished product. To determine the minimum glass transition moisture of a semi-finished textured product, the protein with the lowest glass transition moisture at 50°C should be considered.

If the moisture content of the protein extrudate after extrusion is below the minimum value, then the protein extrudate can be rehydrated either by soaking in water or boiling in broth before frying or cooking. This provides a non-fragile texture to the finished product - bacon.

The minimum moisture content should be determined depending on the protein composition of the extrudate.

Vegetable protein gel

Vegetable protein dispersions can be prepared using soy protein, such as soy protein isolate (SPI) dispersion. SPI dispersions can be made with about 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 or 20% (w/w) SPI. Dispersions can be prepared by mixing SPI powder and coagulants with water. For example, dispersions can be prepared in a small food processor. Every 30 seconds, the dispersion can be further stirred by hand. The protein dispersion can be poured into one or more receiving vessels. It can then be heated for a period of about 30 minutes at 70, 80, 85 or 90°C. Any temperature between 70 and 90°C can be used.

In some cases, SPI dispersions are made with 14–16% (w/w) SPI. A heating temperature of about 85°C can be used. SPI dispersions can be heated for a period of about 30 minutes. CaCl ₂ , MgCl ₂ or CaSO ₄ can be added in concentrations from 1 to 5%. One or more of CaCl ₂ , MgCl ₂ and CaSO ₄ can be added to the soy protein dispersion, for example, about 14% SPI. Transglutaminase, MgCl ₂ and/or CaCl ₂ can be added in concentrations of, for example, 3 to 5%.

The samples can then be cooled to room temperature and stored at around 2°C.

The hardness of SPI gels can be analyzed at room temperature by puncture testing using a texture analyzer such as Instron Model 3365. Testing can be performed using a cylindrical stainless steel geometric element (13 mm diameter) penetrating the samples at a speed of 1.5 mm/ from up to 75% deformation.

Fat simulator (emulsion gel)

A fat simulant (emulsion gel) can be prepared, for example, by emulsifying about 70% (w/w) of the lipid phase and about 30% of the SPI dispersion. SPI variance can be around 10%. The resulting total concentration may be about 3% SPI in the emulsion. The lipid phase may contain canola oil, or it may contain about 70% canola oil and about 30% solid fat. Solid fat can be melted in butter. You can use a food processor to make the emulsion. The oil phase can be slowly added to the SPI dispersion with constant stirring. After mixing all the oil, you can add about 1% sodium chloride and about 0.75%, for example, 10% transglutaminase solution (about 25 mg TG/g SPI). The emulsion can then be poured into flexible aluminum molds and heat treated, for example in a heating chamber. First, it can be heated to a temperature of about 40°C in the thickness of the product. The temperature can be kept constant for a period of about one hour. This allows transglutaminase to react. The product can then be heated at approximately 90°C in a chamber. To deactivate the enzyme and ensure protein gelation, the temperature within the product must reach about 85°C. The product can then be cooled with a cold shower for a period of about 10 minutes. After this, it can be stored at a temperature of about 2°C.

Binder or binding agent

The binder or coupling agent can be applied to the vegetable protein extrudate or fat simulant. The coupling agent can be applied or used as a coating to the plant protein extrudate, such as a prepared plant protein extrudate. The binding agent may be selected, for example, from soy protein isolate dispersion, soy protein isolate powder, gluten powder, transglutaminase, dietary fiber and vegetable protein.

In one embodiment, the binding agent contains dietary fiber and vegetable protein. In one embodiment, the total wt.% content of dietary fiber and vegetable protein in the binding agent is less than 40 wt.%. In one embodiment, at least 50 wt.% of the dietary fiber is soluble, preferably from 50 wt.% to 70 wt.% of the dietary fiber is soluble, preferably about 60 wt.% of the dietary fiber is soluble. In one embodiment, dietary fiber and vegetable protein are present in a ratio of about 67:33. In one embodiment, the dietary fiber is potato fiber. In one embodiment, the vegetable protein is potato protein. In one embodiment, the dietary fiber is potato fiber and the plant protein is potato protein. In one embodiment, the binding agent comprises potato fiber and potato protein, wherein the ratio of potato fiber to potato protein is about 67:33.

The coupling agent may further comprise an enzyme solution. The enzyme may be selected from transglutaminase, tyrosinase and oxidase, for example polyphenol oxidase. Transglutaminase can be used, for example, at a final product concentration of 0.35 to 0.5% (w/w) or about 0.42% (w/w).

In one embodiment, the binding agent contains potato fiber, potato protein and transglutaminase.

The binding agent may be a soy protein isolate dispersion, for example 16% (w/w). In some embodiments, the emulsion gel (fat simulant) may be heated in situ and added to the extrudate prior to the heating step. In this case, SPI dispersions should not be used as a binder.

The binding agent may be gluten coated on the prepared extrudate, or a combination of transglutaminase solution and gluten powder, or a combination of transglutaminase solution and soy protein isolate powder coated on the prepared extrudate.

The extrudate can be coated first with a 10% (w/w) transglutaminase solution and then with gluten powder or SPI powder, or can be directly coated with gluten or SPI powder.

The extrudate can be cooked in vegetable broth. It can be cooked at a temperature of about 90°C. The extrudate can be cooked for a period of about 15 minutes. This can be done to change the texture and taste.

Layer-by-layer laying

The extrudate and fat simulant can be cut and placed in layers, for example, in a flexible aluminum mold. A layer of extrudate can be added followed by a specified amount of SPI dispersion. The dispersion can be evenly distributed on top as evenly as possible. Then you can add fat simulant. The form can be closed with a second similar form. To press the product when heated, a weight can be placed on top. Heating can be continued for a period of about 1 hour at a temperature of about 40°C and then for a period of about 1 hour at a temperature of about 85°C. After heating, the product can be cooled to room temperature. It can then be stored at around 2°C.

Examples

Example 1

Preparing the ingredients

To prepare protein dispersions, soy protein isolate Supro EX 37 HG IP (protein content of at least 90% in terms of dry matter according to the manufacturer) from Solae Europe S.A. was used. (Geneva, Switzerland). Additionally, transglutaminase (TG) (Activa WM transglutaminase, supplied by Ajinomoto Foods Europe SAS), glucono-δ-lactone (Roquette Frères, France), calcium sulfate (ThermoFisher (Kandel) GmbH, Germany), chloride calcium and magnesium chloride (Carl Roth GmbH + Co. KG, Germany), ferrous sulfate (Sigma Aldrich, Germany) and gluten (Weizengluten vital, supplied by Kröner Stärke GmbH, Ibbenbüren, Germany). Canola oil used for emulsion gels was purchased from MEGA - Das Fachzentrum für die Metzgerei und Gastronomie eG (Stuttgart, Germany). Solid fat and vegetable protein extrudate were produced using internal resources.

Soy protein gels were prepared. SPI dispersions of 10, 12, 14, and 16% (w/w) SPI were prepared by mixing the SPI powder and coagulants with tap water in a small food processor for 30 seconds on level 1 and for an additional 60 seconds on level 2. Every The dispersion was additionally stirred manually with a spoon for 30 seconds (to remove lumps from the wall). The protein dispersion was poured into ten 30-mL Nalgene beakers and heated for 30 minutes at 70, 80, 85, or 90°C in a preheated water bath. After cooling to room temperature, samples were stored in a cold storage room at 2°C.

The hardness of the SPI gels was analyzed at room temperature by puncture testing using a texture analyzer (Instron, model 3365, Instron Engineering Corporation Ltd, Canton, USA). Tests were carried out using a cylindrical stainless steel element (diameter 13 mm), penetrating the samples at a speed of 1.5 mm/s until a deformation of 75%. For each gel sample, 10 samples were tested.

A fat simulator (emulsion gel) was prepared. The emulsion consisted of 70% (w/w) oil phase and 30% 10% SPI dispersion, resulting in a total SPI concentration of 3% in the emulsion. The oil phase either contained pure canola oil or was prepared with 70% canola oil and 30% solid fat, which was melted into liquid oil. A small food processor was used to make an emulsion by slowly adding the oil phase to the SPI dispersion with constant stirring. After mixing all the oil, 1% sodium chloride and 0.75% 10% transglutaminase solution (25 mg TG/g SPI) were added. Then the emulsion was poured into flexible aluminum molds and heat treated in a heating chamber. The emulsion was first heated to a bulk temperature of 40°C, which was kept constant for one hour to allow the transglutaminase to react. The product was then heated at 90°C in a chamber until the core reached a temperature of 85°C and cooled with a cold shower for 10 min before being stored at 2°C.

The fat simulant was glued to the extrudate using a binder. SPI dispersions with 16% (w/w) SPI were prepared as described herein and used as a binder. The extrudate and fat simulant were cut (in the appropriate form) to size and layered into a flexible aluminum mold 12.2 cm long by 8.3 cm wide. The extrudate layer was first added and then a specified amount of SPI dispersion was distributed over it as evenly as possible. Finally, a fat simulant was added. The mold was covered with a second similar mold and aluminum foil to prevent water from entering, and a certain weight was placed on top to provide a surface mass density of 8 g/cm ² to compress the product while heating in a water bath. The samples were heated for 1 hour at 40°C and then for 1 hour at 85°C in 2 different water baths. After heating, the sample was cooled to room temperature and stored at 2°C.

In some embodiments, the emulsion gel (fat simulant) was heated in situ. For this embodiment, a fresh emulsion was prepared as described herein and added to the extrudate prior to the heating step. In this case, SPI dispersions were not used as a binder. To prepare tensile test specimens, 35 g of emulsion gel was dispensed into a flexible aluminum mold and a single layer of extrudate was placed on top. Heating and cooling of the samples was carried out as described herein.

Another option for modifying the bonding was to coat the extrudate with gluten or SPI powder and TG solution. Before adding the extrudate to the emulsion gel in aluminum form, it was either first coated with a 10% transglutaminase solution and then either gluten or SPI powder, or directly coated with one of the powders.

In some embodiments, the extrudate was cooked in vegetable broth at 90°C for 15 minutes to alter texture and flavor. After 15 minutes in the broth, the extrudate absorbed 25% of the liquid.

Example 2

Extrudate preparation

A twin screw extruder (TSE) was used to prepare a structured product having aligned fibers based on wheat gluten in combination with pea proteins. The dough was prepared in a Planetaria Tekno mixer at 30 rpm by mixing the following ingredients as shown in Table 1.

Table 1

Ingredients %wb Pea Protein Isolate (Roquette) 12.00 Pea Protein Isolate (Cosucra) 12.00 Live wheat gluten 10.40 Water 53.80 Pea protein TVP GRINDED 7.80 Iodized Salt NaCl 0.50 Base note aromatic (meat/pork) 1.70 Vitamin and mineral premix 0.05 Aromatic substance with head note (meat/pork) 0.12 Supro 37 Soy Protein Isolate 0.90 Rapeseed oil 0.69 Red beet dye P-WS 0.06

The mixture was stirred for three minutes to form a homogeneous dough. The dough was then pumped into the first cylinder of the extruder at 15 kg/h.

The extruder slot head was connected to the extruder outlet. The temperature of the slot head was maintained below 100°C. Flavoring and coloring ingredients were added to the extruder to adjust the color and taste of the extruded product to replicate the organoleptic properties of pork.

After equilibrating extrusion and slot die flow and temperature, a textured product was obtained with fibers aligned on average perpendicular to the dough flow as it exited the slot die.

Example 3

Tensile tests

The adhesive properties of the bonded fat and extrudate samples were analyzed by tensile testing using a texture analyzer. Twenty patches with a diameter of 2 cm were cut from each sample. The upper and lower outer surfaces of the patches were glued to stainless steel posts of the same diameter using cyanoacrylate glue. The posts holding the samples were placed in the grip of the texture analyzer and moved apart at a constant speed of 1 mm/s, while the maximum force and area under the curve were recorded.

Example 4

Development of a prototype production method

Various embodiments were tested during the development of the bacon prototype. Different molding systems were also tested. The same aluminum molds as in the previous experiments were tested with a weight on top, as well as ham cooking molds (Fa. Adelmann GmbH, Germany) with the ability to apply pressure to the bacon during heating. Up to ten alternating layers of extrudate and fat simulant were placed into the molds. When using the in situ fat simulant heating method, the emulsion gel was distributed into a mold and the extrudate was pressed into the gel in an irregular configuration. The bacon prototypes were placed in a heating chamber and initially heated to a core temperature of 40°C, which was kept constant for one hour. The product was then heated to a temperature of 85°C in the bulk of the product at a temperature of 90°C in the chamber, then cooled with a cold shower for 10 minutes before storing at 2°C.

The prototypes were inspected for adhesion and overall appearance. To study slicing and frying performance, bacon prototypes were cut into thick 2mm slices using a slicer and then pan-fried until browned.

Example 5

Effect of temperature and SPI concentration on gel hardness

The hardness of heat-produced SPI gels was studied at different concentrations, heating temperatures, and with different coagulants. The goal was to find better conditions to obtain solid gels that were expected to form good structures between the extrudate and the fat simulants, resulting in good cohesive strength of the bacon prototypes.

In fig. Figure 1 shows the effect of heating temperature on the hardness of soy protein gels with 10, 12, 14 and 16% SPI heated for 30 minutes, respectively.

The appearance of gels with 12, 14 and 16% SPI was assessed. All gels had a smooth structure with a flat surface. Gels with 12% SPI showed low stability, while more concentrated gels were more stable. A slight improvement in stability could be detected when the temperature was increased from 70 to 80°C at all three concentrations. The hardness of 10, 12, 14 and 16% soy protein isolate gels heated to 70, 80 and 90°C for 30 minutes, respectively, was also tested. Increasing the SPI concentration had a pronounced effect, while temperature did not significantly affect the gel hardness. Gels with 14% and 16% SPI formed solid gels with hardnesses ranging from 1.93 ± 0.24 to 2.35 ± 0.14 N and from 4.73 ± 0.97 to 5.75 ± 0.33 N Dispersions with 10 and 12% SPI formed weak gels with hardness values from 0.12 ± 0.01 to 0.88 ± 0.05 N. Thus, gels with 14 and 16% SPI and a heating temperature of 85 were chosen for additional experiments. °C.

Example 6

Effect of adding a coagulant on gel hardness

In fig. 2(A) shows the effect of adding CaCl ₂ , MgCl ₂ , CaSO ₄ and FeSO ₄ at concentrations ranging from 1 to 5% to a 14% SPI soy gel. The addition of salts changed the hardness of the gels in all samples. With the addition of _CaSO4, the gel hardness increased to a maximum of 2.70 ± 0.11 N at 1% concentration and then decreased to values below the hardness of the SPI gel without impurities. Conversely, the hardness of CaCl ₂ and MgCl ₂ gels first decreased at 0.3% concentration and then increased to hardness values of 2.72 ± 0.25 N and 3.18 ± 0.14 N, respectively, at 5% salt concentration. When FeSO ₄ was added, the hardness first decreased or remained constant at concentrations ranging from 0.3 to 3%, and then increased to a value of 5.76 ± 2.51 N at 5%.

The effect of adding transglutaminase, glucono-δ-lactone and salts to the 14% SPI gel is shown in FIG. 2 (B). The addition of transglutaminase provided the hardest gel with 13.68 ± 1.77 N. All gels with other coagulants showed increased gel hardness, ranging from 2.48 ± 0.11 to 5.76 ± 2.51 N. Gels with transglutaminase, MgCl ₂ and CaCl ₂ at 3 and 5% concentrations and CaSO ₄ at 0.3 and 1% concentrations appeared smooth and uniform, whereas gels with glucono-δ-lactone and other salt concentrations appeared solid but were unstable and had a crumbly texture. Unlike other coagulants, FeSO ₄ salt changed the color and odor of gels at concentrations from 1 to 5%. The color became red-brown. It is noteworthy that the outer surface was darker than the inner parts. In addition, the gels had an unpleasant smell of blood. For this reason, it was concluded that ferrous sulfate is not suitable for use as a coagulant.

Example 7

Tensile testing of bonded fat simulant and extrudate samples

The best adhesion method for a bacon prototype was evaluated. The previously analyzed SPI gels were first tested as a binder between two layers. Several modifications were then tested in the production of bonded fat and extrudate samples with the same tensile test due to unsatisfactory results.

In the graph in Fig. Figure 3 shows the maximum force and area under the curve of fat and extrudate samples bonded with SPI adhesive measured during a tensile test. To study the effect of the amount of binder, 29.6 mg/cm ² (3 g per sample), 39.5 mg/cm ² (4 g per sample) and 59.3 mg/cm ² (6 g per sample) were tested. Moreover, the effect of binder type was tested using the most commonly known binder species containing 0.42% TG. No differences were observed depending on the amount of binder in the samples in terms of maximum force and area under the curve. In contrast, the addition of TG to the coupling agent resulted in a higher maximum force (2.70 ± 0.93 N) and a larger area under the curve (2.44 ± 0.71 mJ). This shows that the TG binder resulted in better adhesion between the fat simulant and the extrudate as higher forces and more energy were required to stretch the samples. All samples with a binder without impurities ruptured in the binder phase, while samples bonded with TG binder showed rupture in the fat simulant phase and the binder phase. Moreover, the binder phase was observed as a separate film of gel on the extrudate that was easily shed, demonstrating that the gel did not form a strong dispersed structure with the other layers.

During preparation for the tensile test, the adhesion of the samples with pure SPI binder was already very weak, making it difficult to cut them into patches without falling apart. This, and the fact that the values were too low to obtain reproducible values, may also explain the high standard deviations obtained in the tensile test.

Example 8

Bonding Modifications

To modify adhesion, the extrudate and emulsion gel were gelled and heated in the same step (in situ heating of the emulsion gel) instead of using gelled and preheated fat simulants. In addition, the samples were modified by coating the extrudate with TG solution, SPI powder and/or gluten powder and by pre-cooking the extrudate.

In fig. Figure 4 shows that samples with in situ heated emulsion gels and no binder already exhibit higher maximum force (2.53 ± 0.87 N) and area under the curve (1.81 ± 0.87 mJ) than samples with pre-heated emulsion gels. heated emulsion gels and SPI binder. Additional coating of the extrudate with SPI powder did not have a beneficial effect on adhesiveness, while coating with gluten powder resulted in stronger adhesiveness within the sample. Although the maximum force is lower than for samples without an additional bonding system, the stronger adhesive capacity is reflected in a large area under the curve of 2.71 ± 1.25 mJ. This can also be observed in specimens after tensile testing. In contrast to the first two options, the gluten-coated samples showed discontinuity within the fat phase, and not just at the interface between the extrudate and the fat simulant.

Better results in terms of adhesiveness were obtained by combining the prepared gluten-coated extrudate and the combination of coating with TG solution and gluten powder. Both options showed the highest values of 2.93 ± 0.63 N and 5.59 ± 0.95 mJ for the sample with the prepared extrudate and 3.09 ± 0.87 N and 5.15 ± 0.58 mJ for the sample with the solution TG. This correlates with the visual observation that rupture during stretching mainly occurred in the fat phase, confirming the high adhesive capacity between the two phases.

Coating the extrudate with only 10% (w/w) TG solution reduced adhesion compared to the sample without binder. The maximum force of 1.29 ± 0.71 N was comparable to the sample coated with gluten powder (1.09 ± 0.63), but lower than that of the sample without binder (2.53 ± 0.87 N), and the area under the curve had the lowest value of 0.86 ± 0.62 mJ in this series of tests. Samples coated with a TG solution were destroyed at the interface due to weak adhesion between the phases.

In conclusion, the adhesive property was essentially improved by heating the emulsion gel inside the extrudate mold through extrudate preparation, TG coating, and gluten powder coating. Promising results for the production of a plant-based bacon prototype can be obtained, in particular, by combining different modification methods.

Example 9

Organoleptic analysis of the product - an analogue of smoked bacon

A descriptive sensory study of a non-smoked bacon analogue was conducted by 25 tasters by comparing it to pork bacon and vegan bacon made from seitan. In addition, the effect of increasing smoking time was investigated in order to adapt the taste of bacon analogues to the taste of meat bacon. In addition, a second sensory analysis was performed to determine the smoke aroma intensity and preference of these samples.

Sensory analysis of 3 different types of bacon showed that meaty bacon was the most preferred - with good bacon flavor, good browning and juiciness, but at the same time too fatty, too salty and not crispy enough. The homemade bacon analog product showed good browning, good crispness and juiciness, but was too fatty, not salty enough and had too little bacon flavor. The preference value for it was slightly lower than for meat bacon (Fig. 5). Seitan bacon was the least preferred. It had good saltiness, but was too dark in color, and its crispness, juiciness, fattiness and bacon flavor were below optimal.

In fig. Figure 5 shows the average sensory analysis values for unsmoked bacon (A), meat-based bacon (B), and “wheat” vegan bacon (C) from seitan, associated with personal expectations for the ideal (optimal) product - bacon. Bacon browning, crispiness, juiciness, fat content, saltiness, and bacon flavor characteristics were rated on a scale from 0 (do not like it at all) to 10 (like it very much).

When bacon analogues were smoked, their surface became darker and more orange. Tasters could note a slight increase in smoke aroma intensity with increasing smoking time, but there was no significant preference between different smoking intensities. The unsmoked sample was generally the least preferred, and the most preferred was the sample that was smoked for 30 min.

Example 10

Effect of potato proteins and fiber, pea cell wall and transglutaminase on the cohesiveness of vegan bacon

The influence of several functional ingredients (potato proteins and fiber, pea cell wall and transglutaminase) on the cohesiveness of vegan bacon prototypes was tested. The concentrations tested for each ingredient are shown in Table 2. The corresponding compositions for each part of the vegan bacon formulation are detailed in Tables 3, 4 and 5. TMAE (textured meat analogue extrudate) is an alternative term for the vegetable protein extrudate used in this document. FAH (fat analogue) is an alternative term for the fat simulant used herein.

Table 2. Concentrations tested during DoE for selected ingredients

TMAE (meat analogue) TMAE/FAH FAH (fat analogue) Binder Transglutaminase Binder Binder Gluten WITH Transglutaminase No binder Reference recipe Reference recipe Reference recipe The standard contains transglutaminase 67/33 Potato mixture (10%) Without TG + 67/33 Potato mixture 2.5% pea cell wall 33/67 Potato mixture (10%) TG + 33/67 Potato mixture 5% pea cell wall

Table 3. Composition of TMAE (textured extrudate - meat analogue)

Ingredient Reference T01 T02 T03 T04 T05 T06 T07 T08 T09 Wheat gluten 17.7% 17.7% 17.7% 17.7% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% Potato fiber 0.0% 0.0% 0.0% 0.0% 6.7% 6.7% 6.7% 3.3% 3.3% 3.3% Potato proteins 0.0% 0.0% 0.0% 0.0% 3.3% 3.3% 3.3% 6.7% 6.7% 6.7% Transglutaminase 5.6% 5.6% 0.0% 5.6% 0.0% 5.6% 5.6% 5.6% 5.6% 0.0% Boiled textured extrudates 76.7% 76.7% 82.3% 76.7% 90.0% 84.4% 84.4% 84.4% 84.4% 90.0%

Table 4. Composition of FAH (fat analogue)

Ingredient Reference T01 T02 T03 T04 T05 T06 T07 T08 T09 10% soy isolate solution 29.2% 29.6% 28.2% 28.9% 29.6% 28.2% 28.9% 29.6% 28.2% 28.9% Fat mixture 68.3% 69.3% 65.8% 67.6% 69.3% 65.8% 67.6% 69.3% 65.8% 67.6% Pea fiber 0.0% 0.0% 5.0% 2.5% 0.0% 5.0% 2.5% 0.0% 5.0% 2.5% NaCl 1.0% 1.1% 1.0% 1.0% 1.1% 1.0% 1.0% 1.1% 1.0% 1.0% 10% transglutaminase solution 1.5% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0% 0.0%

Table 5. Composition of binder between layers

Ingredient Reference T01 T02 T03 T04 T05 T06 T07 T08 T09 10% transglutaminase solution 100.0% 100.0% 63.3% 63.3% 63.3% 100.0% 63.3% 63.3% 63.3% 100.0% Potato fiber 0.0% 0.0% 12.1% 24.6% 24.6% 0.0% 12.1% 12.1% 24.6% 0.0% Potato proteins 0.0% 0.0% 24.6% 12.1% 12.1% 0.0% 24.6% 24.6% 12.1% 0.0%

A total of nine vegan bacon prototypes were produced and evaluated using a variety of techniques, such as tearing rates during slicing and folding and visual assessment of cohesiveness after thawing and grilling. Significant differences between prototypes were found for most of the measured properties, and most of the prototypes had better performance than the reference, as shown in FIG. 6 and fig. 7.

The observed differences between the bacon prototypes can be well explained by changes in binder composition, and in general the following were found.

● The composition of the binder that passes between the TMAE and FAH layers is the most important parameter to ensure good cohesiveness of the product after thawing. Better performance is obtained when a fiber-rich (67/33) potato mixture is used in addition to transglutaminase.

● The composition of TMAE and FAH is the most important parameter to achieve good cohesiveness of the product after grilling. Best results are obtained by adding gluten to TMAE and by adding 5% pea cell wall to FAH. Additional experiments showed that adding 2.5% pea cell wall to FAH produced even better results than 5% pea cell wall by reducing the graininess or "off-taste" sensation in some tasters (data not shown).

● To achieve better results in terms of cohesive strength, the pea cell wall was dispersed in a mixture of melted fat. This solution was added under shear stress to the protein solution.

The conditions that produce bacon with the best possible cohesiveness are shown in Table 6. In addition to the above results, it is interesting to note that adding transglutaminase to TMAE does not provide any benefit.

Table 6. Summary of the best conditions to obtain a product with good cohesiveness

TMAE binder TG in TMAE FAH binder TMAE/FAH binder Slicing Test Characteristics No or 5% pea cell wall 67/33 cards. mixture (PB) + TG Specific Gravity Test Characteristics Gluten or 67/33 PB No or 5% pea cell wall 67/33 PB + TG Folding Test Characteristics Gluten 67/33 PB + TG Cohesiveness after thawing Gluten or 67/33 PB No or 5% pea cell wall 67/33 PB + TG Cohesiveness after grilling 67/33 PB 5% pea cell wall 33/67 PB + TG Hardness after grilling 5% pea cell wall Best Consensus Gluten or 67/33 PB (depending on goals) No
(no value added) 5% pea cell wall 67/33 PB + TG

The darker the color, the more important the factor (with respect to hardness, the assumption is that "the harder the better")

Example 11

Effect of using agglomerated and fibrous extrudate

The effects of using an agglomerated extrudate with small unaligned fibers (in formulation 1 below) and a fibrous extrudate with longer aligned fibers (in formulations 2 and 3 below) were also tested.

Table 7

Recipe 1 Recipe 2 Recipe 3 wt.% Extrusion - TMAE Manufacturing Pea protein 32.4% 32.4% 32.4% Live wheat gluten 13.9% 13.9% 13.9% Salt NaCl 0.3% 0.3% 0.3% Water 53.5% 53.5% 53.5% Texture We used agglomerated TMAE Fibrous TMAE used Fibrous TMAE used Cooking frozen TMAE Water 96.00% 96.00% 96.00% Salt NaCl 4.00% 4.00% 4.00% Absorption of solution during cooking and after draining 26.0% 25.7% 28.7% Meat recipe TMAE - boiling in salted water and draining 80.2% 80.2% 82.3% Wheat gluten 11.4% 11.4% 11.7% Flavoring additive "Umami" 1.97% 1.97% 1.97% "Meat Bacon" 1.25% 1.25% 1.25% Flavoring additive “Smoke” 0.48% 0.48% 0.48% Canola oil 4.7% 4.7% 2.4% Making a fat analogue Supro 37 Soy Protein Isolate 2.9% 2.9% 2.9% Demineralized water 26.1% 26.1% 26.1% Shea stearin 20.3% 20.3% 20.3% Canola oil 47.3% 47.3% 47.3% Pea cell wall 2.5% 2.5% 2.5% Salt NaCl 1.0% 1.0% 1.0%

The amounts of each ingredient in the finished bacon product are presented in Table 8.

Table 8

Vegan bacon Recipe 1 Recipe 2 Recipe 3 Water 45.20% 45.63% 47.48% Canola oil 15.74% 14.74% 12.89% Wheat gluten 8.44% 8.71% 8.95% Pea protein 14.18% 14.72% 14.52% Live wheat gluten 6.08% 6.33% 6.23% Shea stearin 5.25% 4.78% 4.75% Flavoring additive "Umami" 1.46% 1.51% 1.51% Salt NaCl 1.00% 0.99% 1.08% Flavoring additive “Meat bacon” 0.93% 0.96% 0.96% Supro 37 Soy Protein Isolate 0.75% 0.68% 0.68% Pea cell wall 0.65% 0.59% 0.59% Flavoring additive "Smoke" 0.36% 0.37% 0.37% TOTAL 100.00% 100.00% 100.00%

Agglomerated TMAE had a maximum force ranging from 100 to 250 N. Fibrous TMAE had a maximum force ranging from 250 to 320 N.

A sensory evaluation was obtained for sliced bacon produced using each formulation.

Agglomerated TMAE Formulation 1 did not have the desired texture. The vegan bacon pieces had good cohesive strength during production, but the fibers were judged to be too small and a loss of bite mark was observed in sensory evaluation.

Fibrous TMAE Formulation 2 had the desired texture. The fibers were longer and in sensory evaluation it had a better bite mark and better cohesive strength on cooked bacon slices.

Fiber TMAE formulation 3 is similar to formulation 2, but with less oil. Compared to formulation 2, better cohesive strength of the vegan bacon was observed during the production process, and it had the same bite mark during sensory evaluation.

Claims (23)

1. A method for producing a bacon analogue product, including: a) obtaining vegetable protein extrudate by wet extrusion; b) obtaining 10-20% w/w. vegetable protein dispersions; c) obtaining a fat simulant by emulsifying a dispersion of vegetable protein and a lipid phase; d) applying a binding agent to the vegetable protein extrudate or fat simulant; e) laying out the vegetable protein extrudate, the fat simulant and the vegetable protein dispersion in the form of layers; f) pressing the laid layers; g) heating to obtain a cohesive mass; h) cooling, wherein the binding agent is a soy protein isolate dispersion prepared using soy protein isolate, and wherein the coupling agent further comprises a solution of transglutaminase. 2. The method according to claim 1, wherein the vegetable protein dispersion obtained in step b) is a soy protein dispersion. 3. The method according to claim 1 or 2, comprising step i) of smoking, slicing or cutting after cooling step h). 4. Method according to paragraphs. 1-3, wherein the vegetable protein extrudate is a textured vegetable protein extrudate. 5. Method according to paragraphs. 1-4, wherein the vegetable protein extrudate is a fibrous vegetable protein extrudate. 6. Method according to paragraphs. 1-5, in which the water content of the vegetable protein extrudate is at least 45% w/w. 7. Method according to paragraphs. 1-6, in which the fat simulant is obtained by emulsifying a mixture of 30% w/w. vegetable protein dispersion and 70% w/w. lipid phase. 8. The method of claim 7, wherein the protein dispersion is a protein isolate dispersion prepared using soy, potato, pea or canola protein isolate. 9. The method according to claim 8, in which the protein isolate dispersion contains 14% w/w. soy protein isolate. 10. The method according to claim 9, in which the protein isolate dispersion additionally contains transglutaminase. 11. Method according to paragraphs. 1-10, in which the heating step g) includes: a) heating to a temperature of 40°C in the thickness of the product and b) heating to a temperature of 85°C in the thickness of the product.