WO2005044023A1

WO2005044023A1 - Method of producing heat-stable, textured food products from natural raw materials, and products thus obtained

Info

Publication number: WO2005044023A1
Application number: PCT/ES2004/070083
Authority: WO
Inventors: Miguel Angel Palomo Gallardo
Original assignee: Miguel Angel Palomo, S.A.
Priority date: 2003-11-07
Filing date: 2004-10-13
Publication date: 2005-05-19
Also published as: ES2232305B1; ES2232305A1

Abstract

The invention relates to a method of producing heat-stable, textured food products from natural raw materials and to the products thus obtained. More specifically, the invention relates to a multi-step method which can be adapted to any type of natural raw material, whereby the raw materials undergo no prior transformations save trituration. According to the invention, said raw materials are subjected to steps comprising, inter alia, pH correction, sequestration of alkaline-earth metals, texturing, shaping and gelling, in order to produce heat-stable, textured products having a water activity of less than 0.85, a pH of less than 4.6 and different commercial forms, which can be stored for prolonged periods of time owing to the microbiological stability thereof.

Description

PROCEDURE FOR OBTAINING TEXTURIZED AND THERMOSTABLE FOODS FROM NATURAL RAW MATERIALS AND PRODUCTS OBTAINED FROM THE SAME.

Scope of the Invention The present invention is part of the technical sector of the preparation of food processed from natural raw materials, of both vegetable and animal origin and of application in the manufacture of healthy foods. The products obtained can have different shapes ranging from the band or tape, suitable for filling other products, to be configured with specific shapes: letters, figures, contours, etc.

Description of the State of the Art Thermoset textured foods based on dehydrated natural raw materials are known. Said starting raw material determines the final properties of the product obtained, moving it away from the characteristics of a natural and therefore healthy product. Thus, to achieve a natural smell it is necessary to add aromas reminiscent of the product as it is found in nature to the starting raw material (dehydrated). The same goes for its coloration. A textured food product whose starting raw material is a dehydrated strawberry, will require the addition of a strawberry aroma and a dye that mimics the strawberry color: cochineal red or annato, for example. Many patents are known that describe procedures aimed at obtaining products of this type. The applicant himself in ES2009190 protected a procedure for obtaining a thermostable hydrocolloid for the filling of olives. In this same line there are 5 patents ES2003212, ES531904, ES463565, ES396968, US4296140, ES477399, ES2142233, ES2046138, WO92 / 03938. All of them are based on a previously transformed raw material: dehydrated, acidified, lyophilized, etc., which makes it lose a good part of its original organoleptic characteristics (smell, taste, color, etc.) that are present in the natural state, when not too much of your vitamin intake. Patents are also known (W096 / 23422, EP0697176) that process food products in the form of homogenized doughs, conforming them according to certain final forms and using procedures also used in other technical sectors such as

15 extruded in the field of plastics (US5384142). The texture of products of natural origin by means of alginates and / or guar gum is also known in the State of the Art (ES448251, ES2078881, ES2000012), as well as its gelation by means of a bath in a solution of calcium chloride (ES2019538). In other patents the texturing and

The gelation occurs at the same stage (ES2046448). In other cases, after texturing, certain forms of the textured mass are obtained and subsequent to gelation (ES2008834). There are also technologies for extrusion of plant-based pasta (potatoes) that do not require texturing or

25 gelation (GB 1495194). Finally, patents that gel the crushing of raw material of natural origin have been described, without prior texturing of the homogenization mass (ES428899) One of the concerns that operate in the preparation of this type of food is its microbiological stability, that is, to prevent the development of microorganisms during the storage process prior to consumption. For this, it is important to control the final pH and water activity of the product obtained (WO01 / 10228). There is a clear demand in the market for natural products, whose previous treatment preserves their organoleptic properties, especially their taste and color, as similar as possible to the original state. Also these products of natural origin must be textured, thermostable and microbiologically safe. The combination of all these factors and their optimization in the final product obtained is the object of this invention. Thus, for example, when it is intended to optimize the alginate gelation process, the reaction rate is maximized at pH> 5. However, sanitary regulations advise that the pH of the final products does not exceed 4.6 to prevent the passage of spore into a vegetative form of the microorganisms present in the raw material of origin. Similarly, the presence of high concentrations of calcium in the natural starting raw material interferes with the texturing due to alginates. The color is due to the dyes present in the original raw materials. In the products obtained in the invention, attempts are made to avoid oil-fat emulsions / aqueous phase, which, however, are necessary to solubilize said fat-soluble dyes, as well as the presence or addition of vitamins, to achieve healthier and dietary foods. Well, all these problems are solved with the present invention by calculating a series of parameters and combining a whole series of stages of a process whose versatility allows adapting it to each natural raw material, without processing it beyond a crushed In the known state of the art, however, the natural raw material is processed previously, to solve the problems that would appear otherwise during the texturing process and that it would not solve.

Description of the invention

Accordingly, the present invention provides a method of obtaining thermoset textured foods from natural raw materials characterized by comprising the following steps: a) shredding of the foods that are to be textured that are in solid form; b) optional homogenization of the fat content of the crushing of the previous stage; c) optional elimination or reduction of the microbiological load of the homogenate obtained, preferably by initial pasteurization; d) correction of the pH of the product of the previous stages until it is less than 4.6; e) sequestration of alkaline earth metals; í) emulsion of the lipid phase; g) addition of at least one texturizing compound and optional addition of at least one thickening compound, vitamins, proteins or dietary products, as well as preservatives, pH regulators, antioxidants, sweeteners or aromas; h) mixing, homogenization and dispersion of the mixture formed, by combining pressure, temperature and stirring; i) conformation in bands or molds that have geometric shapes, letters of any alphabet, numbers of any numerical system or any other type of figure; j) gelation of the bands or shapes obtained in the previous stage; k) optional cutting or stamping of gelled products so that they acquire the desired geometric shapes; 1) optional treatment for further reduction or elimination of the microbiological load of the products obtained, preferably by a final pasteurization process; m) optionally aseptic packaging of the products obtained, which is produced in a liquid medium useful for the preservation of said products.

The application of the process of the invention allows obtaining solid textures, whose organoleptic characteristics of color and taste have been little altered, with a pH lower than 4.6, and a low water content (water activity <0.85 ) ,. The combination of low pH and reduced water activity increases the microbiological stability of the final product obtained, increasing its life time and facilitating its conservation. Thus, with these products there is the possibility of using them where until now they had been used dehydrated for safety reasons. Solid structured products are obtained. Although we talk about sauces, for example, we refer to solid products flavored with said sauce. The products obtained have certain ranges of texture, which allow their treatment in industrial machinery, sensation on the palate, if it is difficult to chew it, if it is too soft. How The final objective is that the texture is the most appropriate for the application to which it will be used. The products obtained, in addition, have been shaped by a gelation process so that they can adopt any type of desired shape, (strip by extrusion, punching, molding, etc.), thus making it possible to prepare more fun meals. In addition, the structures obtained are thermostable, because the texturizing element, sodium alginate, once formed the definitive polymeric structure, thermostable properties. That is, when heating the product once textured, there is no modification of its physical properties, so it can be subjected to heating (boiling, baking, frying) or cooling (cooling, freezing) without losing its organoleptic and mechanical properties. This is how we present a cheese that does not melt when heat is applied or sauces that present a solid form do not melt or fluidize when heated. A further advantage is that the thermostability of the structure allows the final products obtained to be subjected to a pasteurization process, without altering the texture obtained, thereby prolonging its useful life and facilitating its conservation at room temperature, achieving in the pasteurized textured products of the invention a shelf life between 3 and 5 years, depending on the product. The design of the procedure also allows food to be prepared nutritionally to suit and taste of the buyer, by adding both the products that the food in question lacks or has lost in the process, as desired, as well as components considered "healthy or dietary" that improve the nutritional contribution of the product (vitamins, proteins) or turn them into what is now called "healthy foods": (folic acid, omega 3 fatty acids) .... In this sense, we claim the possibility of incorporating these ingredients into solid-structure foods ( vegetables, fish, fruits) and in other foods that originally do not present this solid structure (sauces) but that after the texturing do. The added ingredient (vitamin, protein ...) is present inside the polymeric structure of the textured product, presenting itself as a more intrinsic element in its composition. The design of the procedure allows its use to obtain textured foods from foods both in their natural state (vegetables, vegetables, fruits, other vegetables, meats, fish), as well as their derivatives obtained by usual processes in the food industry ( meat products, dairy products or fish processing products). Examples of foods and food derivatives that can be split to be textured are:

Fish:

"Anchovy" Caper "Almonds

"Salmon" Gherkin "Soy and derivatives

- Tuna "Ginger" Meat Products

"Anchovies" Spices "Olives" Oil "Vinegar

FINAL PRODUCT As a final result we will obtain a structured based on alginic salts with the desired shape and texture, such as, among others:

VEGETABLES

FISH Marinated Salmon Pickled Tuna Anchovy

FRUITS AND DRIED FRUITS Orange Lemon Apricot Peach Strawberry Almond

DAIRY Blue Cheese Cabrales Cheese

SAUCES Mojo Picón Harisa Gazpacho White Garlic Mustard

The products obtained can also have different applications:

APPLICATIONS OF THE PRODUCTS OBTAINED

"Stuffed Olives

"Pizzas Toppings (Pizza stuffing and decoration)

"Salad Dressings

"Salads

"Sauces

" Prepared food:

"Croquettes

"Empanadillas

"Burritos

"Lasagna ^m Meat Industry

• Prepared Soups

• Ice creams "Dairy Desserts

"Pastries

"Stuffed for candies

"Fillers for chocolates

This list of products is neither exhaustive nor limiting.

In accordance with all this, the most characteristic aspects to define the textured products of the invention are summarized in the following points:

> Product made from raw material from I ^to quality, all its ingredients being 100% natural. Homogeneity in physicochemical characteristics *> Color * Taste * Shape *> Texture

> Microbiological stability * Reduction of the pH of the product itself below 4.6 *> Water activity of the textured final product below 0.85 The possibility of using this product where dehydrated had been used for reasons of microbiological safety *> Heat treated products (without being pasteurized) * _* * Product life: From 3 to 5 years at room temperature if losing their properties (in case of pasteurization).

> Not subject to seasonal variations. > Thermostable product - can be heated (boiled, baked, fried etc.) and cooled (chilled, frozen) without losing its organoleptic, mechanical properties ... New product - innovating in food applications *> Preparing funnier meals -> Regular forms, figures ... * t * Texturing of liquid products (Sauces, creams) * Possibility of including "healthy or dietary" elements in food -> Folic Acid, Omega 3, vitamins We can incorporate vitamins, proteins or vitamins in the product itself any other component that gives the product an added value relative to what are now called "healthy foods". *> Fat reduction.

> Ease of handling in the destination industrial facilities. *> Aseptic containers of various sizes: 20, 200 and 1000 Kg * Product cut to the final application size -> no further handling required

> Products without any waste *> 100% yield *> Ready to use, without manipulation In addition, the design of the procedure allows its automation, being able to control phases such as the addition of the components of the formulation, cutting, pasteurization or the packaging by means of a PLC, which in turn is connected in real time to a central Scada system in which all significant data is stored. All these characteristics are conferred by their production process. Of the characteristics of the products obtained, a large part of them are achieved by the addition in the mixing stage as alginate texturizers. With the aim of reducing water activity, the addition of thickeners may also be necessary, among which are the gums (Guar and Xantan) that act as water sequestrants, so that using higher or lower concentrations of gums and alginates and combinations between them, we can form more or less strong reticular structures that retain water as we are interested. In some cases, the initial viscosity of the natural raw material used makes it unnecessary to add any thickener to the mixture. As used in the present invention, in accordance with its usual technical definition, the activity between water vapor pressure of the culture substrate (P) and the water vapor pressure of water is called water activity pure (P0): Wa = P / P0 The value of the water activity gives us an idea of the amount of water metabolically available. The value of the water activity is related to that of the relative humidity (RH) as follows: HR = Wa x l00 When a microorganism is in a substrate with a lower water activity than what it needs, its growth is stop This growth arrest does not usually lead to the death of the microorganism, but it remains in resistance conditions for a more or less long time. In the case of spores, the resistance phase can be considered virtually unlimited. The vast majority of microorganisms require very high water activity values to be able to grow. In fact, the minimum activity values for different types of microorganisms are, for guidance, the following: bacteria wa> 0.90, yeasts wa> 0.85, filamentous fungi wa> 0.80. As can be seen, filamentous fungi are capable of growing on substrates with a much lower (much drier) water activity than is allowed by the growth ^* of bacteria or yeasts. For this reason, deterioration of foods with low water activity (for example, cheese or syrups) can be caused by molds (filamentous fungi) and not by bacteria.

Water activity analysis method An electric conductivity hygrometer ("Novasina") is used. The sample, approximately 5 gr, is introduced into the device in a capsule and measurements are made over time, until a constant value is reached. The constant value that the equipment marks the value of the water activity.

Another key process for achieving the characteristics of the products of the invention is gelation. Gelification is produced by the exchange of mono ions for divalents, so that it is necessary to control the presence of these cations in the previous mixture, separating by chemical procedures the excess of divalent cations that would prevent correct gelation. The equilibrium of the dissociation reaction of alginates of inorganic cations with production of alginic, manuronic and guluronic acids and hydroxides of the salt cations is very conditioned by the pH and acidity of the medium, so it is necessary to control and correct it for get a mechanically correct gel. That is why the process incorporates a pH correction step, so that final products are obtained that have a pH of less than 4.6, preferably less than 4.4, for which the acid addition (citric) , lactic, etc.) in solution. The presence of alcohols and fats also conditions the reaction equilibrium. Therefore, the procedure incorporates an optional stage, prior to mixing, of homogenization of fat content. Due to the presence or addition of fatty products, oils, etc. In some raw materials and formulations, we resort to the use of emulsifiers to obtain a single homogeneous phase and ensure their maintenance. The emulsifiers used are for example: polysorbates, esters of fatty acids, lecithins, etc. in proportions of 0 to 5%.

TEXTURE OF THE PRODUCTS One of the most important characteristics of the products of the invention is that we can control the texture and thus be able to manufacture them always homogeneous and according to the client's request. The measurements have been made on a Stable Micro Systems brand Texturometer, model TA.XT2Í / 25 with operating software for Windows, and which has the following characteristics:

> Force range ^± 25 Kg with the possibility of exchanging another different load cell with force range of ^± 5 Kg.> Resolution / sensitivity: lg. Test speed 0.1 mm / s - 10 mm s, adjustable in ranges of 0.1 mm / s. > Distance range 0.1 - 295 mm, with a resolution of 0.1 mm. The variables to be measured are: speed, distance, force, time. Operating modes: measurement of force, distance and time in stress tests, compression, repetition, cyclic tests, etc ...> More than 70 probes and test accessories for any type of analysis.

> Computer program for the interpretation of the results (Texture Expert).

The probes acquired for carrying out texture analysis tests on our product are the following:

> Warner Bratzler blade plus your guide (ref. HDP / BS).

> Tension clamps with eccentric closure (ref. A / TGT). 50 mm diameter cylindrical probe (ref. P / 50).

> Work base with two interchangeable platforms (ref. HDP / 90). > Calibration weight M 1 of 5 Kg with wooden case (347-53).

CUTTING RESISTANCE For this test, a representative portion of the final textured thickness controlled between 2.5-2.8 mm or 3.4-3.7 mm is taken depending on the type of sample. The dimensions of the sample are tried to control so that they do not represent an extra variable in the performance of the different tests. For this test the sample dimensions are 45 mm long x 25 mm wide.

A Warner Bratzler HDP / BS blade is used. The guide corresponding to said blade is placed on the Work Base, and on it the product sample perpendicular to the base groove. A certain compression force is applied until the blade cuts the product completely, moment in which a peak of strength or maximum resistance is obtained. The test parameters are: Pre-test speed: 1 mm / s. Test speed: lmm / s. Post-test speed: 10 mm / s. Distance traveled by the blade: 10 mm. Trigger Type: Auto Trigger Force: 15 g. Stop test in trigger return. • Do not detect rupture (continue with the test until 10 mm). Express strength in grams. Express distance / capacity in millimeters. The results of the different tests are computerized obtaining the maximum force peaks in each case. The data is treated statistically by calculating the mean maximum strength of the test.

FLEXION A sample of dimensions 90 x 25 mm and controlled thickness between 2.5-2.8 mm or 3.4-3.7 mm is taken depending on the type of sample. For this test, a 50 mm diameter P / 50 model cylindrical probe is used. A flat platform is placed on the work base. The sample bends over itself creating a loop at one end whose diameter is 8 mm, and is placed on the flat platform. A certain compression force is applied until the internal faces of the loop are touched by the pressure exerted by the cylindrical probe, at which point the test must be stopped. The test parameters are: • Pre-test and test speeds: 1 mm / s.

• Post-test speed: 10 mm / s.

• Distance traveled by the probe: 5.0 mm. (adjustable).

• Trigger Type: auto • Trigger Force: 15 g.

• Stop test in trigger return.

• Do not detect rupture (continue the test until it travels 5 mm).

• Express strength in grams.

• Express distance / capacity in millimeters. The results of the different tests are computerized obtaining the maximum force peaks in each case. The data is treated statistically by calculating the mean maximum strength of the test.

TENSION BREAK The sample dimensions are 90 x 25 mm and controlled thickness between 2.5-2.8 mm or 3.4-3.7 mm depending on the type of sample. Tension clamps with eccentric closure model A / TGT are used. In the base one of the tweezers is placed and the other at the end of the trigger. The sample is held at its ends with the tweezers and a certain tension force is applied, causing the sample to stretch until it breaks. The test parameters are:

• Pre-test speeds: 1 mm / s.

• Test speed: 5 mm / s

• Post-test speed: 10 mm / s. • Distance traveled by the probe: 70 mm.

• Trigger Type: auto • Trigger force: 15 g. • Stop test in trigger return. • Rupture detected activate trigger return (do not complete the distance of 70 mm). 5 • Sensitivity with which it detects rupture: 100 g. • Express strength in grams. • Express distance / capacity in millimeters. The results of the different tests are computerized obtaining the maximum force peaks in each case. The data is treated statistically by calculating the mean maximum strength of the test.

EXTERNAL DELBUCLE LINKUP RUPTURAPORTENSION The sample dimensions are 200 mm x 25 mm and controlled thickness between 2.5-2.8 mm or 3.4-3.7 mm depending on the type of sample. In this

15 test tension clamps with eccentric closure model A / TGT are used. On the base one of the clamps is placed but the other is not placed at the end of the trigger. In its place we place a self-made accessory that simply consists of a 3 mm diameter cylindrical tube placed horizontally, and through which the paste is folded forming a

20 loop The two ends are made to coincide by holding both with the clamp of the base. A certain tension force is applied, fundamentally causing a stretch of the outer face of the loop, where the tape begins to break. The test parameters are: • Pre-test speeds: 1 mm / s. 25 • Test speed: 5 mm / s • Post-test speed: 10 mm / s. • Distance traveled by the probe: 70 mm.

• Trigger Type: auto

• Trigger force: 15 g.

• Stop test in trigger return. • Rupture detected activate trigger return (do not complete the distance of 70 mm).

• Sensitivity with which it detects rupture: 100 g.

• Express strength in grams.

• Express distance / capacity in millimeters. The results of the different tests are computerized obtaining the maximum force peaks in each case. The data is treated statistically by calculating the mean maximum strength of the test. The texture values are as follows: Cut resistance: 500 - 2500 g. Flexion: 100-400 g. Tension rupture: 250 - 1500 g. Tension rupture in the outer wall of the loop: 400 - 2000 g.

I MANUFACTURING PROCEDURE

A. CRUSHING Foods to be textured that are presented in solid form need to be prepared by grinding and crushing them, by using highly powerful cutting and shearing machinery, until obtaining a very fine texture, similar to a cream (cremogenated). East The process is carried out continuously, using colloidal mills in a wet way between 3000 and 9000 rpm with different sizes of blades, as required by the raw materials fed. Depending on the starting food, the cremogenate obtained will be dosed into the mixing, homogenization and dispersion system or will need to undergo a previous pasteurization and homogenization process. Examples of products that require only ground and crushed, among others:

- Jalapeño - Tomato

- Garlic

- Onion

- Caper

- Gherkin - Pumpkin

- Ginger

- Black olive

- Apricot

- Peach - Strawberry

- Almond

B; HOMOGENEIZATION (optional): Both the foods to be textured that have the form of liquids and the finely crushed forms obtained from the previous stage can optionally undergo a process of homogenization of the content in fats to ensure that during the production process and during their lifetime they do not suffer separation between the aqueous-fat phases. For this, a single or two stage piston homogenizer with a working pressure between 0 and 200 atmospheres is used. Said homogenizer is interspersed in the heating stage of the plate pasteurizer described for the next stage, equally optional.

C: INITIAL PASTEURIZATION (optional): Depending on the nature of the food to be textured, it can be subjected to a pasteurization process prior to dosing and mixing, in order to reduce its microbiological load. For this purpose, there is a plate pasteurizer, in which a homogenizer has been interleaved in line in the product heating stage. The heat treatment system has four distinct stages: heating, pasteurization, maintenance and cooling, after which the cream or solution is in perfect disposition to be dosed into the mixing, homogenization and dispersion system. The pasteurization treatment is carried out at a temperature between

80-110 ° C for a period of time between 20 - 180 seconds. Examples of products that require heat treatment and / or homogenization prior to mixing, after the grinding and crushing process, among others: - Red, green pepper

- Salmon

- Tuna - Anchovy

- Blue cheese

- Cabrales cheese

- Mojo picón

D: PH CORRECTION: The solution resulting from phases A, and optionally B and C passes to the mixer where, in the first place, the pH correction is carried out.

This addition occurs in the mixing, homogenization and dispersion unit, on the product itself so that it is the product itself that has the corrected pH. The final product we manufacture must have a pH below 4.6, preferably below 4.4, for this we use the addition of acids

(citric, lactic, etc.) in the solution and thus be able to obtain the desired pH. The amount of acid added will be different according to the pH of the starting raw material and will move between 0 - 5%. In the case of working with dairy raw materials the pH correction will be made to the final product in the packaging and not to the dissolution in the mixer, by controlling the acidity (g / 1 of acid) of a liquid medium useful for preservation of these products that will be added to them. If the pH of the raw material is below 3.5, a base (for example, sodium hydroxide) will be added to raise the pH between 3.5 and 4.2. The amount of base added will be different according to the pH of the starting raw material and will move between 0 - 5%.

E: SEQUESTRATION OF ALKALINOTERREOS ELEMENTS: This phase will also be carried out in the mixer, when the product is still in solution. In some cases we find, naturally, the presence of alkaline earth elements in the raw materials to be used. Your excess can

5 affect the gelation process, preventing correct gelation, so we proceed to kidnap them completely using carbonates, phosphates, EDTA, citrates, etc. The concentration of sequestrants to be used will vary stoichiometrically to the concentration of alkaline earth elements that contain the raw materials to be used, (equivalent to equivalent).

F: EMULSION W / O - O W (W = WATER: O = OIL) (optional): Due to the presence or addition of fatty products, oils, etc. In some raw materials and formulations, we resort to the use of emulsifiers5 to obtain a single homogeneous phase and ensure its maintenance. The emulsifiers used are for example: polysorbates, esters of fatty acids, lecithins, etc. in proportions of 0 to 5%. The nomenclature O / W implies that the aqueous phase is enclosed in the oil phase and the opposite case in W / O phases. In both cases, one or only homogeneous phase is obtained.

G: ADDITION OF VITAMINS, PROTEINS, ETC: To obtain products with a determined nutritional value, we incorporate antioxidants, vitamins, fibers, proteins, Healt-Foods, etc., 5 together or separately. These components of the final product are preferably added to the container in which the mixture is to be made. You can build nutritionally tailored food and taste of the buyer. Therefore, in this phase the products that are lacking or have lost in the process the food in question are added, as desired.

H: MIXED:

The foods to be textured and the necessary compounds for this, as well as the additional components that you want to add as described in section G and those that are necessary for the processes described in sections D, E and F to be produced, whenever It is necessary to carry out the latter, they are added to a mixing unit in which the process of mixing and dispersing them takes place, until a homogeneous mixture is achieved. The dosage of the components of the formulation is produced by an automatic system composed of a set of hoppers, connected to a common exit point, controlled by a PLC and this in turn connected in real time to a central Scada system in which All significant data is stored. The dosage of water is prior to the addition of the remaining components of the formulation. The main components that are part of the formulation to be mixed are, among others:

It is at this point that alginates are added, mainly responsible for the reduction of water activity, as they have the peculiarity of forming reticular structures where water is retained within said structure and is not free; Therefore, the water available for the growth of microorganisms is significantly reduced. It may also be necessary to add thickeners, including gums (Guar and Xantan) that act as water sequestrants, so that using higher or lower concentrations of gums and alginates and combinations between them, we can form more or less strong reticular structures that retain water as we are interested. In some cases, the initial viscosity of the natural raw material used makes it unnecessary to add any thickener to the mixture. 5 To perform the mixing, the unit has a turbine that produces the dispersion of the product, an anchor that facilitates the. mixing by producing a current flow contrary to that of the turbine, a colloid mill that allows the dispersion and mixing of the long chain polymers that make up the texturizers and thickeners and a positive displacement pump that facilitates the flow of the mixture through of the whole circuit. The process is carried out at a pressure ranging from 0 to -1 atmospheres for which the system has a vacuum pump and at a temperature that ranges between 20 ° C and 45 ° C. The temperature is controlled through a chamber outside the system through which hot or cold water circulates.

15 This whole process is carried out in batch batch (batches) of production in which the average duration of each of them ranges between 6 and 15 minutes in order not to produce excessive shearing of the polymeric structures of the texturizers and, where appropriate, thickener, as this would cause unwanted behavior of the final product.

20 I: CONFORMATION: The product obtained after the mixing process passes to a strip forming line in which the product will be given the desired thickness for the final application. 25 The product is textured forming a band whose thickness and width are bounded but not its length. This pre-gelation step requires great precision since the thickness of the product will be provided with a maximum error of + 300μm, in order to be used and considered valid in certain industrial applications. For the system to have this precision, the band forming line has a series of digital probes that connected to the integral control system allows adjusting the thickness to the desired reference value, as well as detecting any product that is outside rank. Forming can also be done in molds. In this case the mixture will be dosed to the selected molds to give the desired design.

J: GELIFICATION: The gelation is produced by the exchange of mono ions for divalents, so that, in the case of some foods, it may be necessary to have controlled the presence of these cations in the previous mixture, having chemically separated the excess of divalent cations that would prevent correct gelation, as indicated in section E of alkaline earth metal sequestration. Once the band (thickness) of the product is formed or the molds are filled, they will be introduced into the gelation rafts where the sodium-calcium ion exchange takes place, thanks to which the product gelation takes place. In these rafts the gelling principle can be Calcium Chloride, Calcium Lactate, Etc. in concentrations between 10 -25%. A very important aspect is the speed at which the product that is being gelled, since it determines the correct gelation thereof, for time spent in the rafts. In our invention, according to the product, the residence time in the gelation bath ranges between 20 and 30 minutes. In the case of band shaping, the tension exerted on the product must be taken into account. The product moves through the gel rafts due to a series of rollers whose movement is independent of each other so that the ratio of the speeds between them produces a certain tension on the product that affects the final thickness of the same. This whole process is carried out in environmental conditions of temperature and pressure. Depending on the characteristics of the starting food used and the way in which it is desired to present it, the product obtained at this stage can go directly to the packaging process or optional stages in which it is proceeded or cut, to give it desired concrete forms, or to submit it to 15 a final heat treatment, in order to reduce its microbiological load and increase its life time.

K: CUT (optional): Once a band is obtained, the product can be cut as required depending on the specific application of the band. If the product has been formed in a band, it is passed to the cutting area where it is produced. the desired cut for the specific application of the client, for example squares, rectangles, hearts, leaves, butterflies, numbers, letters, etc. Thus, according to what is desired, the band can be fed to a rotating knife machine or it can pass into a die-cutting area where the required shapes or figures are obtained The already cut product is automatically fed to the weighing and packaging system. Like the previous case, this process is governed "by a PLC and the significant data is stored in the global Scada system. Optionally, prior to packaging, the cut product can be subjected to a final pasteurization step.

L: FINAL PASTEURIZATION (optional): The purpose of this process is to reduce the microbiological load of the product so that the life of the product is 3 to 5 years (depending on the product) without the need for refrigeration for storage during this period, keeping intact its organoleptic properties, color and texture .. This process is feasible because it is a thermostable product, not changing the polymeric structures of the product created by gelling by the application of heat. The product is fed to a heat exchanger that continuously performs heating, maintenance and cooling operations. The product is pumped through the equipment through a dual piston pump that has as a fundamental characteristic to keep the pumping pressure in the equipment constant and homogeneous without presenting pressure fluctuations, which allows the heat transmission to be also more homogeneous and the product does not tend to get caked on the way by the team. The pumping is carried out at a pressure that ranges between 8 and 15 bar pressure depending on the type of cut of the product and the product itself. The temperatures and times of heat treatment depend on the type of product to be treated and vary between a temperature of 80 - 105 ° C and a time of 20 - 180 seconds. The heat exchanger is of tube-in-tube type, thus allowing the treatment of particulate products. Overheated water circulates through the outer tube of the heating and maintenance zone allowing greater control of the treatment temperature. On the outside of the cooling zone pipes, cold water from a cooling tower is circulated countercurrently. The cooling zone is an aseptic zone since this is key so that no microbiological recontamination of the product occurs now that it is cooling. For this, the system has a series of vapor barriers that prevent the entry of microorganisms in those susceptible points. The system has a PLC thanks to which the whole process is carried out automatically, controlling and correcting any deviation that the system presents with respect to the established setpoint parameters. In case of not being able to automatically correct any anomalous situation, the system considers the product to be invalid by redirecting it to the starting situation to be reprocessed or if it is not possible, it does not continue processing the product until the situation has been corrected . The heat treatment process is designed to enable the pasteurization of solid particles without causing damage on them for two fundamental reasons: • Use of a positive piston displacement pump that allows the particulate product to be fed to the heat exchanger without it It is damaged during the course of its trip by the tubular treatment units, as there are no pressure oscillations. • The polymer structure itself created gives the particulate product a sufficient and appropriate mechanical resistance to resist the treatment without the end product already treated being damaged.

M: PACKAGING: The packaging conditions will be different depending on whether or not the product has been subjected to the optional final pasteurization process. In the latter case, it is necessary to maintain aseptic conditions. 1) Non-aseptic packaging An automatic control system governed by a PLC manages the process of passing the already gelled product to the weighing and packaging area.

It automatically adds the product and a useful liquid medium to facilitate its conservation, storing all significant data in the Scada system connected in real time with the control system. This packaging is not aseptic and bottles, barrels, etc. are used. The composition of the liquid medium that facilitates conservation will be different depending on the textured food that you want to keep. Suitable examples of liquid media that facilitate preservation are a solution of sodium chloride (2-20%) and citric, lactic acid, etc. (0.2 - 3%), or, for sweet products, sugar, glucose, etc. (10-20%). Its function is to preserve the product. In the case of dairy derivatives, as previously indicated, it is the acidity (g / 1) of this liquid preservative medium that corrects the final pH of the product obtained. Thus, for example, in the case of obtaining a thermo-stable blue cheese hydrocolloid in the form of a tape, an example of Suitable liquid preservative medium would contain between 4 and 10 ° Be and 5-8 g / 1 citric acid.

2) Aseptic packaging In the case of products that have undergone the final optional pasteurization, after having heat treated the product and subsequently cooling it, it is cold-packed online by using an aseptic filler, with the addition of liquid media that They facilitate conservation. This filling system makes it possible to finally have a stable product from the microbiological point of view, maintaining the highest organoleptic properties. The product can be packaged in different formats (aseptic bags of 20 kg, 200 kg, 1,000 kg, etc.) depending on the consumption needs of our customers. The aseptic packaging machine has two moving heads for filling, equipped with vapor barriers at all articulated points and places susceptible to microbiological contamination. The barriers have steam at 115 ° C and the chamber in which the bag to be filled is inserted is pressurized with dry steam. The system is also automatically controlled by a PLC in parallel records all the data of interest and sends them to the central Scada system.

Description of the figures Figure 1: Operational scheme of the process. A: Crushing; B: Homogenization; C: Initial pasteurization; D: pH correction; E: Abduction of alkaline earth elements; F: Emulsion; G: Addition of "healthy or dietary" components (vitamins, proteins, etc.); H: Addition of water and mixed; I: Conformed; J: gelation; K: Cut-die cut; L: Final pasteurized; M: Packaging

Claims

1.-Procedure for obtaining thermostable textured foods from natural raw materials characterized by comprising the following stages: a) Crushing of the natural raw materials used as a base b) Optional homogenization of the fat content of the crushing of the previous stage c) Optional elimination or reduction of the microbiological load of the homogenate obtained, preferably by initial pasteurization d) Correction of the pH of the pasteurized homogenate or of the crushing obtained in the previous stages until it is less than 4.6 and greater than 3.5. e) Sequestration of alkaline earth metals of the homogenate or crushing of the previous stage f) Emulsion of the lipid phase g) Addition of at least one texturizing compound and optional addition of at least one thickener compound, vitamins, proteins or dietary products, as well as preservatives, pH regulators, antioxidants, sweeteners or aromas h) Addition of water, mixing, homogenization and dispersion of the mixture formed, by combining pressure, temperature and stirring. i) Conformation in bands or molds that have geometric shapes, letters of any alphabet, numbers of any numerical system or any other type of figure j) Gelification of the bands or shapes obtained in the previous stage 5 k) Optional cutting or stamping of the gelled products stored according to specific geometric shapes 1) Optional treatment of reduction or subsequent elimination of the microbiological load of the products preferably obtained by a final process of pasteurization0 m) Packaging of the products obtained, aseptic in the case of the products subjected to the stage 1), or with a liquid medium that favors its conservation

2. Method according to claim 1 characterized in that the base raw material5 is selected from: Vegetables and vegetables such as Red Pepper, Hot Red Pepper, Green Pepper, Onion, Garlic, Tomato, Jalapeño, Pumpkin; Fruits such as Lemon, Orange, Peach, Apricot, Strawberry, Pineapple; Dairy products such as Blue Cheese, Roquefort Cheese, Cabrales Cheese; Fish such as Anchovy, Salmon, Tuna, Anchovies and others such as Caper, Gherkin, Ginger, Spices, Olives, Oil, Vinegar, Almonds, Soybeans and derivatives, Meat Products.

3. Method according to any of claims 1 or 2 characterized in that the pH correction, in the case of base raw materials5 of dairy origin is carried out during the storage stage through the liquid medium that favors its conservation added in the packaging instead from in stage d)

4. Method according to any of claims 1 to 3 characterized in that the sequestration of alkaline earth metals in step e) is performed stoichiometrically using sequestrants selected from: carbonates, phosphates, EDTA, citrates or combinations thereof.

5. Method according to any of the preceding claims characterized in that the emulsion of step f) is carried out using emulsifiers in a proportion ranging from 0-5%, selected from: polysorbates, fatty acid esters, lecithins or combinations thereof.

6. Method according to any of the preceding claims characterized in that as a texturizing compound in step g) sodium alginate is added in a concentration between 0.2-5%.

7. Method according to any of the preceding claims characterized in that as an optional thickener compound in step g) at least one of the following is added in a concentration between 0-10% selected: Guar Gum, Xantan Gum, Tara Gum, Gum Garrofin, Arabian Gum, Karaya Gum, Tragacanth Gum, Gellan Gum, Konjac Gum, Starches or combinations thereof.

8.- Method according to any of the preceding claims characterized in that as an optional preservative compound in step g) is added in a concentration between 0-500 ppm, at least one of the following selected from: sorbic acid, benzoic acid, its salts or combinations thereof.

9. Method according to any of the preceding claims characterized in that as an optional pH regulating compound in step g) at least one of the following is added in a concentration selected from: citric acid, lactic acid, acid tartaric, sodium hydroxide, or combinations thereof.

10. Method according to any of the preceding claims characterized in that as an optional antioxidant compound in step g) at least one of the following is added in a concentration selected from: ascorbic acid, BHA, BHT or combinations of the same.

11. Method according to any of the preceding claims characterized in that as an optional sweetener compound in step g) at least one of the following is added in a concentration selected from: sucrose, glucose, saccharin, aspartame or combinations thereof.

12. Method according to any of the preceding claims characterized in that step h) is carried out at a pressure ranging from 0 to -1 atmospheres and at a temperature ranging from 20 ° C-45 ° C, for a time that ranges from 6-15 min.

13. Method according to any of the preceding claims characterized in that the gelation of step j) takes place by passing the product formed in step i) through at least one bath containing at least one gelling solution based on, among others , calcium chloride or calcium lactate.

14. Method according to any of the preceding claims, characterized in that the packaging stage m) employs liquid means that favor conservation selected from: a solution of sodium chloride whose concentration ranges between 2-20% and citric or lactic acid, in concentrations that they range from 0.2-3% or solutions of sugars, particularly glucose, ranging from 10-20%.

15. Method according to any of the preceding claims characterized in that in step g) optionally any of the following compounds selected from among vitamins, proteins, folic acid, omega 3 fatty acids or combinations thereof can be added to the mixture.

16. Textured and thermostable food product obtainable according to the procedure of claims 1 to 15, characterized in that it has been prepared having split from any of the raw materials mentioned in claim 2, with the addition of an optional pH corrector selected from acid citric, lactic acid, tartaric acid, sodium hydroxide or combinations thereof, an optional alkaline earth metal sequestrant selected from carbonates, phosphates, EDTA, citrates or combinations thereof, an optional emulsifier selected from polysorbates, esters of fatty acids, lecithins or combinations thereof, sodium alginate as a texturizing compound, an optional thickener compound selected from Gum Guar, Gum Xantan, Gum Tara, Gum Garrofm, Gum Arabic, Gum Karaya, Gum Tragacanth, Gum Gellan, Konjac gum, starches or combinations thereof, an optional preservative selected from sorbic acid, benzoic acid, its salts or combinations thereof, an optional antioxidant selected from ascorbic acid, BHA, BHT or combinations thereof, an selected optional sweetener between sucrose, glucose, saccharin, aspartame or combinations thereof, an optional aromatic substance, as well as a "healthy or dietary" compound selected from vitamins, proteins, folic acid, omega 3 fatty acids or combinations thereof, and to present a pH below 4.6 and a water activity below 0.85.

17. Product according to claim 16 characterized by being solid, structured.

18. Product according to claims 16 or 17 characterized by having a shear strength ranging from 500-2500 g, a flexion between 100-400 g, a tension break between 250-1500 g and a tension break at the external wall of the loop between 400-2000 g.

19. Product according to any of claims 16 to 18 characterized by presenting geometric shapes, letters of any alphabet, numbers of any numerical system or any type of figure.

20. Use of the products of claims 16 to 19, in any of the following applications: Stuffed Olives Toppings Pizzas (Stuffing and decoration of pizzas) Salad Dressings (Salad dressings) Salad Sauces Prepared food: Croquettes Empanadillas Burritos Lasagna Industry Meat Prepared soups Ice cream Dairy desserts Pastries Fillers for candies Fillers for chocolates