WO2013066197A1 - Imitations de fibres alimentaires congelées provenant de biomatériaux extrudés - Google Patents
Imitations de fibres alimentaires congelées provenant de biomatériaux extrudés Download PDFInfo
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- WO2013066197A1 WO2013066197A1 PCT/PH2011/000020 PH2011000020W WO2013066197A1 WO 2013066197 A1 WO2013066197 A1 WO 2013066197A1 PH 2011000020 W PH2011000020 W PH 2011000020W WO 2013066197 A1 WO2013066197 A1 WO 2013066197A1
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- fibers
- fffms
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- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/20—Reducing nutritive value; Dietetic products with reduced nutritive value
- A23L33/21—Addition of substantially indigestible substances, e.g. dietary fibres
-
- A—HUMAN NECESSITIES
- A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
- A23L—FOODS, FOODSTUFFS, OR NON-ALCOHOLIC BEVERAGES, NOT COVERED BY SUBCLASSES A21D OR A23B-A23J; THEIR PREPARATION OR TREATMENT, e.g. COOKING, MODIFICATION OF NUTRITIVE QUALITIES, PHYSICAL TREATMENT; PRESERVATION OF FOODS OR FOODSTUFFS, IN GENERAL
- A23L33/00—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof
- A23L33/10—Modifying nutritive qualities of foods; Dietetic products; Preparation or treatment thereof using additives
Definitions
- This patent relates to product and process used for the preparation of frozen, wet shredded fibers from extruded biomaterials containing brans and plant fibers intended to be used as frozen food fiber mimetics (FFFMs).
- FFFMs frozen food fiber mimetics
- High protein extruded plant biomaterials are mechanically shredded in hydrated form.
- the fibrous masses from the extrudates with the appropriate pH, microbial quality, and sensory characteristics including odor, taste, and texture are packed and kept in frozen solid blocks for a period of 8 months at ⁇ - 20°C in cold storage with an internal core temperature of -16 to -17°C.
- the FFFMs, as extender or analog, of meat fibers including: beef, poultry, and pork; fish or fishery products; and fruit and vegetable fibers can be applied in food service-prepared recipes and manufactured food products.
- the main function of extrusion cooking of the protein ingredients is to fabricate food fiber mimetics with fibrous plexilamellar structures.
- Food mimetics are manufactured products that imitate the sensory and physical properties of food especially in terms of texture (hand feel and mouth feel) and appearance (McClements and Demetriades, 1998).
- Some common food mimetics are extruded analogs of meat (Hegarty and Ann, 1976; Rizvi et al., 1980; Liu et al., 2005) and fat materials (Funami et al., 1998).
- Fibers are generally defined as bodies of matter having a higher quotient of length relative to its lateral dimensions and which is significantly composed of longitudinally oriented aligned strands (Boenig, 1973). Fibers of high protein extruded food products are formed as a result of alignment of protein units that are opened and dissociated due to machine pressure, shear, and heat (Holay and Harper, 1982).
- US 3,870,805 (Hayes et al., 1975) relates to the hydration of extruded soy meal to remove water- soluble materials and create bland taste in the extrudates followed by mechanical shredding to generate fibrous masses with meat-like characteristics in the product.
- US 4,863,749 (Yamada, 1989) disclosed a procedure to produce texturized vegetable protein resembling meat characteristics by the further hydration, disintegration, washing, dehydration of the texturized material, and finally stuffing into casing, and heat setting the stuffed mixture.
- US 5,225,233 ( Komatsu et al., 1993) presented a process for producing food material similar to meat from texturized soybean protein that is hydrated, disintegrated into fibers, re-molded, dehydrated due to compression, heated in compressed state, and cooled to set.
- US 2008/0044532 Al (Mora Castillo, et al., 2008) described a method to produce an extruded product from co-extrusion of vegetable dough with comminuted meat materials of the following: beef, pork, poultry, fish, or its combination.
- US 7,892,591 B2 (McMindes et al., 2011) related to preparation and use of hydrated and shredded protein composition in vegetable products, fruit products, and restructured meat products.
- This present invention is an advancement of the Philippine patent UM 2-2010-000154 (Chu et al., 2010) and a more recently filed invention patent application PCT/PH2011/000014 (Chu et al., 2011) to the Intellectual Property Office of the Philippines for international filing.
- the first art (UM 2-2010- 000154) described the incorporation of stabilized rice bran as dispersed phase filler to enhance the porosity and water hydration capacity of protein-based extruded meat analog and extender products used by food manufacturers and food service companies as high-protein meat substitutes.
- This invention consists of product and process used to prepare FFFMs as food fiber equivalents.
- High protein extrudates of plant biomaterials with brans and plant fibers with at least 60% calculated theoretical protein of its dry extrusion base mixes (DEBMs) are mechanically wet shredded to produce the food fibers.
- the main ingredients of the DEBMs are plant protein material sources like, but not limited to, peanut flour, soy concentrate, and pea protein isolate.
- Other significant ingredients of the DEBMs are carbohydrate material sources, brans, and plant fibers.
- Food fiber mimetics can be produced, but not limited to it, from high protein extrudates ranging from 35 - 45 mm and 60 - 70 mm lengths formed as chunks and nuggets, respectively.
- the dry high protein extrudates are subjected to full hydration, mechanical shredding, packing, and molding prior to freezing as FFFMs.
- the object of freezing procedure is to achieve an internal core temperature of -16° to -17°C in FFFMs.
- the FFFMs in blocks stored at ⁇ -20°C have a shelf life of at least 8 months and with very acceptable overall acceptability rating, moderately fresh grain odor and taste, moderately soft, juicy, and elastic texture when used as food analog or extender in food-service prepared recipes and manufactured products.
- the FFFMs of this patent are declared as food fiber equivalents of meat, fish and fishery products, fruits and vegetable fibers.
- the FFFMs as extenders, are used to extend expensive food materials, like meat fibers, and is added in combination with the food ingredients to lower down the cost of a prepared and processed food formulations.
- the FFFMs as analogs, are used to substitute entirely food materials in a formulation.
- the high protein DEBMs 1 and 2 of FFI products 1 and 2 consist mainly of mixed and sieved protein and carbohydrate material sources with brans and plant fibers.
- FFI products intended to be FFFMs are plant protein material sources with > 60% calculated theoretical protein.
- the plant protein material sources may include the following powders in Table 1, but not limited to it, as the major protein source or its various combinations.
- Plant carbohydrate material sources may include, but not limited to, cassava starch, cornstarch, millet flour, quinoa flour, rice flour, rye flour, semolina flour, sorghum flour, tapioca starch, potato starch, and wheat flour.
- Brans may include, but not limited to, oat bran, rice bran, wheat bran, white corn bran, and yellow corn bran.
- Plant fibers may include, but not limited to, coconut meat fiber, oat fiber, potato fiber, and soya fiber.
- the DEBMs of FFI, Philippines are categorized based on total protein content of its plant protein ingredients. These ingredients are those that have at least 15% (db) declared protein by the ingredient suppliers.
- the calculated theoretical protein content of DEBMs is the sum of declared protein contents of considered plant protein sources in the DEBMs (Table 1).
- the DEBMs and their calculated theoretical proteins serve as working guide for the groupings of FFI Philippine extrudates.
- Table 2 shows the two high protein FFI major products containing >60% calculated theoretical protein and intended to be FFFMs 1 and 2.
- x Theoretical protein is the summation of supplier declared percent protein of the ingredients in a formulation xx Ratio of plant protein source to carbohydrates source in DEBM, refers to the preceding cited plant protein and carbohydrate ingredients for extrusion dry formulae
- the calculated ratio of plant protein source to carbohydrate source in DEBMs do not indicate a direct relationship to the expressed theoretical protein of the products due to differences in protein contents of various plant sources used (i.e., isolate soy protein has 90% protein and wheat gluten has 75% protein).
- the FFI-1 and FFI-2, intended to be developed to FFFM-1 and FFFM-2 are produced using twin screw extruder.
- the extruder has 5 temperature settings and processing temperatures are fixed at 30°C at Zone 1 and at 90°C for Zones 2 to 5. Screw speed is maintained at > 1500 rpm and cutter speed from 300 to 320 rpm. Water input and feed rate are 60 - 70 kg/h and 120 - 140 kg/h, respectively.
- the high protein FFI-1 and FFI-2 extrudates intended to be wet shredded from fibers prior to freezing can be produced, but not limited to it, in FFI, Philippines as chunks (35 - 45 mm length) for short fibers and nuggets (60 to 70 mm length) for long fibers.
- Full hydration of extrudates is achieved when chunks or nuggets absorbed the liquid medium in the form of water or edible broths or its combinations done after 1 hour of static hydration or 15 minutes of agitated hydration with vacuum in a hydrating environment with excess liquid.
- the hydrated extrudates are then mechanically shredded by using mechanical force to separate, fracture, or cut hydrated extrudates into a plurality of fibers mimicking food strands.
- the wet shredded extruded biomaterials as fibrous masses are packed in various weights, but traditionally in 15 to 20 kg weight per bag.
- the packed products are manually compressed and molded into blocks and frozen using either slow or quick freezing methods.
- Slow freezing may involve the storage of molded blocks in a cold storage room at ⁇ - 20°C while quick freezing consists of processing the molded blocks in a blast freezer with forced cooled air at ⁇ - 30°C.
- the target core temperature of a completely frozen food fiber mimetics in blocks is -16° to -17 0 C.
- the hurdle of freezing in food preservation is used to extend shelf life of food fiber mimetics.
- the freezing curve of a freshly molded FFFMs in block (15 kg/bag sample block, 55 cm x 45 cm x 15 cm) exposed to ⁇ -20°C, showed a rapid decline in core temperature within 6 hours from temperatures of 28° ⁇ 2°C going to near 0°C, which is technically expressed as loss of sensible heat of the material being cooled.
- Super cooling and release of latent heat of crystallization of the material can be achieved immediately about 6 th hour of freezing.
- the core temperature of the block will be at slightly just below 0°C and the temperature will stay constant up to about 15 th hour of freezing. Ice and solute cooling will start after the 15 th hour.
- the core temperature of the frozen block now classified as FFFMs, will decline further to -16° to -17°C up to 24 th hour.
- the FFFMs with the core temperature of -16° to -17°C will be kept at ⁇ -20°C until ready for delivery.
- the thawing rates of FFFMs with core temperature of -16° to -17°C at 0-5°C and 10-15°C thawing environments are about 0.70°C/h and 0.90°C/h, respectively (Table 4).
- Stereo microscopic evaluations (Leica EZ4 D, Germany, 200x magnification) of fibers from FFFMs include transparency, crimpling, and thickness.
- the individual fibers for microscopic evaluation are teased off from hydrated extruded chunks (35-45 mm) and nuggets (60-70 mm) of FFI-1 and FFI-2.
- the fiber characteristics are described by panelists using a 100 mm line scaled in % change per fiber parameter mentioned.
- the transparency rating of the fibers is related to the transmission of light through the individual fiber under the stereomicroscope (200 x magnification, full incident and transmitted light illumination, and work distance of 30 mm).
- the ratings for transparency are: fully transparent (0% on scale), translucent (50% on scale), and fully opaque (100% on scale) ratings.
- Fiber crimpling is defined as presence of small ridges in individual fibers and is rated as without ridges (0% on scale), separated ridges (50% on scale), and close ridges (100% on scale).
- the thickness dimension between the two surfaces of the individual fiber is rated as: thin (0% on scale), medium thickness (50% on scale), and thick (100% on scale) if height of material is ⁇ 0.20 mm, 0.20 to 0.35 mm, and > 0.35 mm, respectively.
- the fiber characteristics of FFI-1 extrudates with corn and rice bran at 0.5% incorporation intended to become FFFMs are assessed using stereomicroscope at 200x magnification (Table 5). Table 5. Fiber assessment of FoodFlow, Inc. high protein formulation 1 (FFI-1) with 0.5%
- the high protein FFI-1 and FFI-2 extrudates which are intended to be FFFMs have the following individual fiber characteristics: translucent, has separated ridges, and medium thickness (0.20 to 0.35 mm). Translucency of the fibers indicates the biomaterials are well cooked and plasticized. The ridges of the fibers favored the creation of void spaces between neighboring fibers which can aid in retention of hydration liquid in the extruded materials. Fibers of medium thickness can be easily be separated from bundles of fibers without easily breaking the fibers. These fiber characteristics can also be obtained from FFFMs derived from FFI-1 and FFl-2 with incorporated other types of brans and plant fibers.
- FFFMs prepared from protein extruded biomaterials of FFI, Philippines.
- Microbial parameters, pH, and sensory characteristics of the FFFMs defined the shelf life of the frozen final product in blocks stored at ⁇ -20°C. Microbial parameters considered were total plate count (TPC) (Matu rin and Peeler, 2001); total coliform count (TCC) (Feng et al., 2002); and yeast and mold count (YMC) (Tournas et al., 2001).
- TPC total plate count
- TCC total coliform count
- YMC yeast and mold count
- FFFMs Sensory characteristics of FFFMs from extruded biomaterials were also assessed to determine the product shelf life.
- the FFFMs that were subjected to sensory evaluation were fresh and freshly thawed shreds and its pasteurized (82°C for 1 minute); and sterilized (121°C ; 15 psi for 1 hour) counterparts.
- Sensory characteristics including overall acceptability ratings, and intensity ratings of odor, taste, and texture including chew, elasticity, and juiciness of food fiber mimetics were defined by panelists using the 9-point scale as shown in Figure 2.
- the ratings for the sensory attribute texture are: Chew is considered the number of times required to create a food bolus ready for swallowing through the force action of the panelist back molars.
- Juiciness is rated based on the number of chew actions of molars applied to extract food fluid from the test samples.
- Juiciness intensity descriptors are: dry, neither dry nor juicy, and juicy defined as no liquid extracted from the food after more than 5 chews using panelist back molars, some liquid was extracted from the food after 4-5 chews, and excess liquid extracted after less than or 3 chews.
- Elasticity is the degree to which a strand returns to its original shape with minimal hand pulling.
- Elasticity intensity descriptor are: inelastic, neither inelastic nor elastic, and elastic which describe the individual fibers as strand that breaks easily with minimal hand pulling, strand that stretches with minimal hand pulling but without breaking or recoiling when released, and strand that stretches with minimal hand pulling without breaking but would recoil to its original state when released, respectively.
- Red FFFM-1 as lean beef fiber mimetics was produced from high protein FFI-1 red extrudates with maximum of 5% red colorants subtracted from the percentage of carbohydrate sources (dry basis), extruded as nuggets (60 to 70 mm length), hydrated with preferred liquid, mechanically shredded into fibers, packed, molded, and stored in frozen conditions ( ⁇ -20°C). Red FFFM-1 in block was thawed in chilled conditions (0-5°C) for 12 hours and can be readily used in different food applications as lean beef fiber mimetics.
- Microbial test parameters show log cfu/g of FFFM-1 stored at ⁇ -20°C for 8 months were log cfu/g 4.14, 1.50, and 2.00 for TPC, YMC, and TCC, respectively.
- the experimental data values were found to be within developed microbial limits for the FFFMs stored at ⁇ -20°C up to 8 months set at the following log cfu/g values: 5.00, 4.00, and 3.00 for TPC, YMC, and TCC, respectively (Table 8).
- the sensory characteristics of freshly thawed shreds of FFFM-1 as lean beef fiber mimetics after 8 months of storage at ⁇ -20°C are still the same of those stored only within 1 month (Table 10) .
- the sensory characteristics of fresh shreds and freshly thawed FFFM-1 as lean beef fiber mimetics from 0 to 8 months are above slightly acceptable in overall acceptability rating, very fresh grain odor, and moderately elastic texture.
- the pasteurized and sterilized FFFM-1 as lean beef fiber mimetics stored up to 8 months at ⁇ -20°C are very acceptable in overall acceptability rating, moderately fresh grain odor and taste, and moderately soft, juicy, and elastic texture (Table 11).
- FFFM-2 as tuna shred extender.
- FFFM-2 as tuna shred extender is produced using high protein FFI-2 uncolored, extruded as chunks (35 to 45 mm length), hydrated with preferred liquid, mechanically shredded into fibers, packed, molded, and stored in frozen conditions ( ⁇ -20°C). Uncolored FFFM-2 in blocks are thawed in chilled conditions (0-5°C) for 12 hours and can be readily used in different food applications of fish and fishery products.
- Steamed tuna shreds and freshly thawed FFFM-2 as tuna shred extender are lightly combined. Corn oil, salt and pepper are added. This mixture is canned as tuna shreds in olive oil using adequate heat treatment process for sterilization.
- FFFM-1 as vegetable shred extender is produced using high protein FFI-1 uncolored, extruded as nuggets (60 to 70 mm ), hydrated with preferred liquid, mechanically shredded into fibers, packed, molded, and stored in frozen conditions ( ⁇ -20°C). Uncolored FFM-1 in blocks is thawed in chilled conditions (0-5°C) for 12 hours and can be readily used in different food applications of vegetable shreds.
- FFFM-1 as vegetable shred extender is shown in Table 14.
- Garlic, onion, ginger, and chili are sauteed until fragrant in heated cooking oil.
- the pork is seasoned with salt and pepper and cooked in sauteed mixture until tender.
- the carrot pieces are then added, stirred, and cooked.
- the shredded coconut pith, young bamboo shoots, banana blossoms, freshly thawed FFFM-1 as vegetable shred extender, and coconut cream are added. The mixture is boiled gently until cooked.
- FFFM-1 as fruit shred extender is produced using high protein FFI-1 with maximum of 5% yellow colorants subtracted from the percentage of carbohydrate sources (dry basis), extruded as chunks (35 to 45 mm), hydrated with preferred liquid, mechanically shredded into fibers, packed, molded, and stored in frozen conditions ( ⁇ -20°C). Yellow FFFM-1 in blocks is thawed in chilled conditions (0-5°C) for 12 hours and can be readily used in different food applications of fruit fibers.
- Sweetened jackfruit with FFFM-1 as fruit shred extender One test application of yellow FFFM-1 as extender of jackfruit shreds in food service-prepared recipes is in sweetened jackfruit.
- the formulation for sweetened jackfruit with freshly thawed FFFM-1 as fruit shred extender is shown in Table 15.
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JP5794373B1 (ja) * | 2014-10-28 | 2015-10-14 | 不二製油株式会社 | 肉様食感の強い組織状大豆蛋白質素材 |
WO2015190142A1 (fr) * | 2014-06-10 | 2015-12-17 | 不二製油グループ本社株式会社 | Matériau fibreux de protéine de soja procurant une sensation en bouche fortement analogue à la viande |
GB2579913A (en) * | 2018-12-14 | 2020-07-08 | Keohane Seafood Unlimited Company | Process for shelf-life extension of fish |
US20210392929A1 (en) * | 2018-11-01 | 2021-12-23 | Societe Des Produits Nestle S.A. | Process for making a meat analogue product |
WO2022208386A1 (fr) * | 2021-03-30 | 2022-10-06 | Bali Grove Pte Ltd | Procédés de production d'un produit à base de jacquier |
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US3870805A (en) * | 1970-11-04 | 1975-03-11 | Staley Mfg Co A E | Process for preparing texturized protein compositions and the resulting product |
KR800000073B1 (ko) * | 1976-05-27 | 1980-01-30 | 도날드 엘 웬거 | 식물성 단백질로부터 치밀하고 꼬이지 않은 규칙적인 층을 가진 육류대용품을 제조하는 방법 |
JPH05328908A (ja) * | 1992-05-27 | 1993-12-14 | Fuji Oil Co Ltd | 組織状蛋白食品の製造方法 |
US6635301B1 (en) * | 1999-05-18 | 2003-10-21 | Mars, Incorporated | Method and apparatus for the manufacture of meat |
WO2007013146A1 (fr) * | 2005-07-27 | 2007-02-01 | Stc System Japan Co., Ltd | Composition pour aliment transformé de protéine de soja, pâte pour aliment transformé carné ou non carné, et aliment ressemblant à de la viande séchée |
US20070269583A1 (en) * | 2006-05-19 | 2007-11-22 | Mcmindes Matthew K | Protein composition and its use in restructured meat and food products |
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2011
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US3870805A (en) * | 1970-11-04 | 1975-03-11 | Staley Mfg Co A E | Process for preparing texturized protein compositions and the resulting product |
KR800000073B1 (ko) * | 1976-05-27 | 1980-01-30 | 도날드 엘 웬거 | 식물성 단백질로부터 치밀하고 꼬이지 않은 규칙적인 층을 가진 육류대용품을 제조하는 방법 |
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US6635301B1 (en) * | 1999-05-18 | 2003-10-21 | Mars, Incorporated | Method and apparatus for the manufacture of meat |
WO2007013146A1 (fr) * | 2005-07-27 | 2007-02-01 | Stc System Japan Co., Ltd | Composition pour aliment transformé de protéine de soja, pâte pour aliment transformé carné ou non carné, et aliment ressemblant à de la viande séchée |
US20070269583A1 (en) * | 2006-05-19 | 2007-11-22 | Mcmindes Matthew K | Protein composition and its use in restructured meat and food products |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2015190142A1 (fr) * | 2014-06-10 | 2015-12-17 | 不二製油グループ本社株式会社 | Matériau fibreux de protéine de soja procurant une sensation en bouche fortement analogue à la viande |
JP5794373B1 (ja) * | 2014-10-28 | 2015-10-14 | 不二製油株式会社 | 肉様食感の強い組織状大豆蛋白質素材 |
US20210392929A1 (en) * | 2018-11-01 | 2021-12-23 | Societe Des Produits Nestle S.A. | Process for making a meat analogue product |
GB2579913A (en) * | 2018-12-14 | 2020-07-08 | Keohane Seafood Unlimited Company | Process for shelf-life extension of fish |
GB2579913B (en) * | 2018-12-14 | 2023-03-01 | Keohane Seafood Unlimited Company | Process for shelf-life extension of fish |
WO2022208386A1 (fr) * | 2021-03-30 | 2022-10-06 | Bali Grove Pte Ltd | Procédés de production d'un produit à base de jacquier |
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