WO2020038541A1 - Substitut de viande et sa production à partir de matériel végétal - Google Patents

Substitut de viande et sa production à partir de matériel végétal Download PDF

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Publication number
WO2020038541A1
WO2020038541A1 PCT/EP2018/000414 EP2018000414W WO2020038541A1 WO 2020038541 A1 WO2020038541 A1 WO 2020038541A1 EP 2018000414 W EP2018000414 W EP 2018000414W WO 2020038541 A1 WO2020038541 A1 WO 2020038541A1
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WO
WIPO (PCT)
Prior art keywords
protein
meat substitute
plant based
plant
oat
Prior art date
Application number
PCT/EP2018/000414
Other languages
English (en)
Inventor
Otto KAUKONEN
Tuula FÖRBOM
Päivi KUUSISTO
Original Assignee
Raisio Nutrition Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Raisio Nutrition Ltd filed Critical Raisio Nutrition Ltd
Priority to PCT/EP2018/000414 priority Critical patent/WO2020038541A1/fr
Priority to PCT/EP2019/025115 priority patent/WO2020038601A1/fr
Priority to EP19720367.2A priority patent/EP3840583A1/fr
Priority to EP19759501.0A priority patent/EP3840584A1/fr
Priority to PCT/EP2019/025284 priority patent/WO2020038611A1/fr
Publication of WO2020038541A1 publication Critical patent/WO2020038541A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
    • A23J3/00—Working-up of proteins for foodstuffs
    • A23J3/14—Vegetable proteins
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
    • A23J3/00—Working-up of proteins for foodstuffs
    • A23J3/22—Working-up of proteins for foodstuffs by texturising
    • A23J3/26—Working-up of proteins for foodstuffs by texturising using extrusion or expansion
    • 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
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/104—Fermentation of farinaceous cereal or cereal material; Addition of enzymes or microorganisms
    • A23L7/107—Addition or treatment with enzymes not combined with fermentation with microorganisms
    • 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
    • A23L7/00—Cereal-derived products; Malt products; Preparation or treatment thereof
    • A23L7/10—Cereal-derived products
    • A23L7/117—Flakes or other shapes of ready-to-eat type; Semi-finished or partly-finished products therefor
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P30/00—Shaping or working of foodstuffs characterised by the process or apparatus
    • A23P30/20—Extruding
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23V—INDEXING SCHEME RELATING TO FOODS, FOODSTUFFS OR NON-ALCOHOLIC BEVERAGES AND LACTIC OR PROPIONIC ACID BACTERIA USED IN FOODSTUFFS OR FOOD PREPARATION
    • A23V2002/00—Food compositions, function of food ingredients or processes for food or foodstuffs

Definitions

  • the invention relates to a plant based meat substitute, which is especially usable as a plant based minced meat substitute and to a method for manufacturing the meat substitute.
  • the invention also relates to a plant based meat substitute intermediate product and its
  • the invention further relates to the use of low temperature extrusion in the manufacturing process of the plant based meat substitute intermediate.
  • the plant based meat substitute would contain a high amount of conventional oat material such as whole grain oat flour or oat bran.
  • a product would provide high contents of nutritionally beneficial components e.g. dietary fiber and especially beta-glucan.
  • nutritionally beneficial components e.g. dietary fiber and especially beta-glucan.
  • General dietary recommendations promote the use of a diet with high contents of dietary fibers. For example in Finland, the recommended daily intake of dietary fiber is 25-35 g, where the average intake by both men and women is lower (22 g and 21 g respectively)
  • Beta-glucan containing foods have been awarded health claims e.g. related to the maintenance of healthy cholesterol levels or to the reduction of blood cholesterols levels.
  • EU has approved the following cholesterol lowering health claim for beta-glucan from oat and barley: “Beta-glucan has been shown to lower/reduce blood cholesterol. High cholesterol is a risk factor in the development of coronary heart disease”.
  • the plant based meat substitute would contain a relatively low amount of legume protein because this would improve the taste and thus the consumer acceptance of the product.
  • the bitter beany taste of legume protein would be reduced also by the high content of oat material masking it.
  • the current invention fulfils at least one of these desires.
  • the invention relates to a plant based meat substitute according to independent claim 1.
  • the invention is also directed to a plant based meat substitute intermediate product according to independent claim 27.
  • the invention also relates to a method for manufacturing a plant based meat substitute according to independent claim 31 , as well as a method for manufacturing a plant based meat substitute intermediate product according to claim 39.
  • Figure 1 shows the water absorption (%) of plant based meat substitutes prepared with a low temperature extrusion process (LTF) and a high temperature extrusion process (HTF) in a cooking test.
  • LTF low temperature extrusion process
  • HTF high temperature extrusion process
  • Figure 2 shows the appearance of plant based meat substitutes prepared with a low temperature extrusion process (LTF) and a high temperature extrusion process (HTF) after 10 minutes of cooking.
  • LTF low temperature extrusion process
  • HTF high temperature extrusion process
  • Figure 3 shows the water absorption (%) of plant based meat substitute intermediate products prepared with a low temperature extrusion process (LTI) and a high temperature extrusion process (HTI) after 30 minutes of soaking in water.
  • LTI low temperature extrusion process
  • HTI high temperature extrusion process
  • the plant based meat substitute contains 50-85% by dry weight oat material.
  • the plant based meat substitute has a protein content of 25-55% by dry weight. It has a dietary fiber content of at least 5.0% by dry weight and a beta-glucan content of at least 2.5% by dry weight.
  • the plant based meat substitute according to the invention further contains 30-55% water by weight.
  • Figure 1 shows the water absorption (%) of plant based meat substitutes prepared with a low temperature extrusion process (LTF) and a high temperature extrusion process (HTF) in a cooking test.
  • LTF low temperature extrusion process
  • HTF high temperature extrusion process
  • Figure 2 shows the appearance of plant based meat substitutes prepared with a low
  • LTF temperature extrusion process
  • HTF high temperature extrusion process
  • Figure 3 shows the water absorption (%) of plant based meat substitute intermediate products prepared with a low temperature extrusion process (LTI) and a high temperature extrusion process (HTI) after 30 minutes of soaking in water.
  • LTI low temperature extrusion process
  • HTI high temperature extrusion process
  • the plant based meat substitute contains 50-85% by dry weight oat material.
  • the plant based meat substitute has a protein content of 25-55% by dry weight. It has a dietary fiber content of at least 5.0 g by dry weight and a beta-glucan content of at least 2.5% by dry weight.
  • the plant based meat substitute according to the invention further contains 30-55% water by weight.
  • the plant based meat substitute is a minced meat substitute.
  • “plant based” in“plant based meat substitute” is here meant that the ingredients are substantially of plant origin, i.e. at least 90%, preferably at least 95% of the ingredients are of plant origin.
  • The“plant based meat substitute” is essentially, such as at least 99% and preferably 100%, free from ingredients of animal origin, such as milk or egg proteins. The advantages of the plant based meat substitute thus include suitability to vegetarian diets.
  • the plant based meat substitute according to the invention is herein also called meat substitute.
  • oat material oat material obtained from whole grain oat.
  • the oat material used in the current invention therefore includes the following materials: whole grain oat flour, oat groats, steel-cut oats, oat flakes, oat bran, oat bran flour, oat endosperm, oat endosperm flour, oat fractions enriched in dietary fiber and oat fractions enriched in beta-glucan or mixtures of any of these.
  • Whole grain oat is the part of the grain from which the hull has been removed.
  • Preferred oat materials are whole grain oat flour, oat bran and endosperm flour or mixtures thereof.
  • the most preferred oat materials are whole grain oat flour and oat bran or mixtures thereof.
  • plant protein material food ingredients containing at least 20 % by weight of protein and being of plant origin. Typically plant protein material contains at least 30% by weight of protein.
  • the protein content of the plant protein material is preferably at least 50%, more preferably at least 60%, even more preferably at least 70% and most preferably at least 80% by dry weight. This means that plant protein concentrates and/or isolates preferably are utilised for providing the plant protein to the meat substitute.
  • plant protein and by corresponding terms identifying the source of the protein, such as e.g.“tuber protein” is meant the protein derived from the material in question. For example 1 kg (dry weight) of a“plant protein material” having a protein content of 80% by dry weight, delivers 800 g of“plant protein” by dry weight.
  • the plant protein material used in the present invention contains preferably at least one plant protein selected from tuber protein, legume protein, seed protein and cereal protein. It was further noticed that excellent plant based meat substitutes could be obtained when the plant protein contains either tuber protein or legume protein or a mixture of them.
  • the plant protein preferably contains at least one of tuber protein and legume protein, and more preferably it contains at least tuber protein.
  • the plant based meat substitute contains plant protein material preferably in an amount of 15- 50%, more preferably 17-47%, even more preferably 20-45% and most preferably 25-43% by dry weight.
  • the plant based meat substitute contains tuber protein in an amount of at most 40%, more preferably at most 30% and most preferably at most 25% by dry weight.
  • the plant based meat substitute contains preferably tuber protein in an amount of at least 6.0%, more preferably at least 8.0% and most preferably at least 10% by dry weight.
  • the tuber protein can contain at least one of potato, sweet potato, yams and cassava protein.
  • the tuber protein contains potato protein and most preferably the tuber protein is potato protein.
  • the plant based meat substitute contains legume protein in an amount of at most 25%, more preferably at most 20% and most preferably at most 15% by dry weight.
  • the plant based meat substitute contains preferably legume protein in an amount of at least 5.0%, more preferably at least 8.0% and most preferably at least 10% by dry weight.
  • the legume protein can contain at least one of soybean, pea, cowpea, chickpea, lentil, kidney bean, mung bean, broad bean, lupine, peanut and e g. brown, white or black bean protein.
  • the legume protein contains pea protein and most preferably the legume protein is pea protein.
  • the plant protein material preferably contains tuber protein and/or legume protein.
  • the amount of tuber and/or legume protein in the meat substitute is preferably 10-35%, more preferably 15- 33% and most preferably 17-30% by dry weight.
  • the plant based meat substitute contains cereal protein in an amount of at most 40%, more preferably at most 30% and most preferably at most 20% by dry weight.
  • the plant based meat substitute contains preferably cereal protein in an amount of at least 6.0%, more preferably at least 8.0% and most preferably at least 10% by dry weight.
  • the cereal protein is preferably selected from at least one of rice, barley, rye, corn, wheat and oat protein.
  • the cereal protein is a non-oat cereal protein, i.e. it is a cereal protein excluding oat protein.
  • the cereal protein is more preferably selected from the group consisting of rice, barley, rye and corn protein or mixtures thereof.
  • Most preferably the cereal protein is rice protein.
  • the plant based meat substitute contains seed protein in an amount of at most 40%, more preferably at most 30% and most preferably at most 20% by dry weight.
  • the plant based meat substitute contains preferably seed protein in an amount of at least 6.0%, more preferably at least 8.0% and most preferably at least 10% by dry weight.
  • the seed protein is preferably selected from at least one of rapeseed, hemp seed, sunflower seed, flax seed, pumpkin seed, sesame seed and melon seed protein. Most preferably the seed protein is rapeseed protein.
  • the plant based meat substitute preferably contains potato and pea protein, preferably at a weight ratio of 1 :30-30:1 , more preferably 1 :9-9: 1 and most preferably 1 :1-9:1.
  • the content of pea protein in the meat substitute should not be too high. It was surprisingly found that by using a suitable blend of potato and pea protein in addition to the oat material a meat substitute having a high fiber and beta-glucan content, and similar colour and sensory attributes as lightly fried or cooked minced meat could be obtained.
  • Another preferred plant based meat substitute could be obtained using a plant protein material containing rice and pea protein, preferably at a weight ratio of 1 :30-30: 1 , more preferably 1 :9- 9:1 and most preferably 1 :1 -9:1.
  • the plant based meat substitute according to the present invention contains oat material in an amount of 53-83%, more preferably 55-80% and most preferably 57-75% by dry weight.
  • the oat material contains oat bran in an amount of 25-75% and whole grain oat flour in an amount of 25-75% by weight of the oat material.
  • the plant based meat substitute according to the invention is essentially free of food additives and thus fulfills the requirements of clean label food products.
  • food additives such as hydrocolloids can be avoided.
  • the plant based meat substitute of the invention does not contain added hydrocolloids such as pectin, gelatin and alginate.
  • the plant based meat substitute may contain at least one additional component.
  • additional component is herein meant e.g. spices, salts, vitamins, minerals and health improving agents such as an additional cardiovascular health improving agent other than oat beta-glucan.
  • the plant based meat substitute according to the invention can have an oat protein content of 5.0-25%, preferably 6.0-20% and most preferably 7.0-16% by dry weight.
  • the oat material is preferably selected from the group consisting of whole grain oat flour, oat groats, steel-cut oats, oat flakes, oat bran, oat bran flour, oat endosperm, oat endosperm flour, oat fractions enriched in dietary fiber and oat fractions enriched in beta-glucan or mixtures thereof. More preferably oat material is selected from whole grain oat flour, oat bran and endosperm flour or mixtures thereof.
  • the oat material is selected from whole grain oat flour and oat bran or mixtures thereof.
  • the oat bran has a particle size distribution as follows: at least 50% by weight of the particles are retained on a sieve of 530 p .
  • the oat material of the meat substitute according to the invention has a protein content of preferably at most 19% and more preferably at most 18% by dry weight. This measure relates to the protein content of total oat material used in the plant based meat substitute.
  • the oat material consists of a mixture of whole grain oats and oat bran
  • the preferred protein content of the mixture is at most 19% and more preferably at most 18% by dry weight.
  • no oat protein concentrate or oat protein isolate is used in the meat substitute.
  • the oat material has a total lipid content of at least 4.0 %, preferably at least 5.0% of dry weight.
  • the plant based meat substitute according to the invention preferably has a carbohydrate content of 20-50%, more preferably 22-45% and most preferably 25-43% by dry weight.
  • the plant based meat substitute according to the present invention preferably has a beta-glucan content of at least 2.8%, preferably at least 3.0%, more preferably at least 3.5%, even more preferably at least 4.0%, still more preferably at least 4.5%, further more preferably at least 4.7% and most preferably at least 5.0% by dry weight.
  • the amount of beta-glucan is preferably at most 12%, more preferably at most 10% and most preferably at most 8.0% by dry weight of the meat substitute.
  • the plant based meat substitute preferably has a dietary fiber content of at least 7.0%, preferably at least 9.0%, more preferably at least 10%, even more preferably at least 1 1%, still more preferably at least 12% and most preferably at least 13% by dry weight.
  • the amount of dietary fiber is preferably at most 40%, more preferably at most 30% and most preferably at most 25% by dry weight of the meat substitute.
  • the weight ratio of protein to beta-glucan in the meat substitute according to the present invention is at most 20: 1 , more preferably at most 15:1 and most preferably at most 10: 1.
  • the weight ratio of protein to dietary fiber in the meat substitute is preferably at most 6.0:1 , more preferably 5.0:1 and most preferably 4.0:1.
  • Plant based meat substitute products providing substantial levels of dietary fiber and beta-glucan into the diet when simultaneously acting as a main protein component in the food are currently rare or non-existing.
  • the plant based meat substitute according to the present invention possess the both before mentioned nutritional benefits, and when regularly consumed it can substantially increase the dietary fiber and beta-glucan intake in the consumers’ diets and make it easier for the consumers to meet the recommended daily intake of dietary fiber.
  • the meat substitutes according to the invention easily provides the recommended daily intake of beta-glucan in one serving.
  • the plant based meat substitute according to the present invention contains water in an amount of 30-55%, preferably 35-53% and most preferably 40-50% by weight.
  • This optimal water content in the plant based meat substitute results in a similar appearance, texture and mouthfeel as compared with e.g. pan-fried and mildly browned minced meat commonly used in several food recipes.
  • the water content is measured by normal dry matter laboratory analyses of the plant based meat substitute product and reflects the overall water retained in the product.
  • the water content includes the water retained in the plant based meat substitute product derived from the water contained in the solid ingredients, such as flours, as well as the water added.
  • the plant based meat substitute according to the present invention is obtainable by a process including a low temperature extrusion step.
  • the process includes a low temperature extrusion step and a heat treatment step.
  • the process includes a low
  • Another object of the present invention is to provide a plant based meat substitute intermediate product containing oat material, plant protein material and water.
  • This intermediate product contains the same ingredients (oat material, plant protein material and optional additional components) as the final plant based meat substitute by dry weight. Thus, only the water content differs.
  • the plant based meat substitute intermediate product according to the present invention has a long shelf life also at ambient storage temperatures.
  • the plant based meat substitute intermediate product provides flexibility in the logistic chain and demand control.
  • the plant based meat substitute intermediate product is also more cost efficient to transport to multiple production sites e.g. in different markets/countries compared to transporting the plant based meat substitute product containing more water.
  • plant based meat substitute intermediate product an intermediate product in the process of manufacturing the plant based meat substitute.
  • the plant based meat substitute intermediate product contains 50-85% by dry weight oat material.
  • the meat substitute intermediate product has a protein content of 25-55% by dry weight. It has a dietary fiber content of at least 5.0% by dry weight and a beta-g!ucan content of at least 2.5% by dry weight Further the meat substitute intermediate product contains 8.5-15% and preferably 9.0-14% water by weight.
  • This intermediate product is suitable for manufacturing a meat substitute, preferably a minced meat substitute.
  • the plant based meat substitute intermediate product has preferably any one of the features described earlier related to the dry matter of the plant based meat substitute (i.e. the compositions given as % by dry weight).
  • the plant based meat substitute intermediate product has preferably any one of the features described earlier related to the selection and amounts of components in the plant based meat substitute (i.e. components and their amounts).
  • the plant based meat substitute intermediate product according to the invention is obtainable by a process including a low temperature extrusion step and at least one drying step. These steps are disclosed in more detail in the disclosure of the methods of manufacturing the plant based meat substitute and the meat substitute intermediate product in the following.
  • a third object of the present invention is to provide a method for manufacturing a plant based meat substitute by extruding a mixture containing plant protein material and oat material, wherein the method comprises at least the following steps: a) preparing a mixture of the plant protein material and the oat material and water, preferably the water content of the mixture being 35-55%, more preferably 38- 53% and most preferably 40-50% by weight of the mixture, b) optionally adding a crosslinking enzyme and/or a protein deamidating enzyme to the mixture, to any of the components or their blends or to the water, preferably production sites e.g. in different markets/countries compared to transporting the plant based meat substitute product containing more water.
  • plant based meat substitute intermediate product an intermediate product in the process of manufacturing the plant based meat substitute.
  • the plant based meat substitute intermediate product contains 50-85% by dry weight oat material.
  • the meat substitute intermediate product has a protein content of 25-55% by dry weight. It has a dietary fiber content of at least 5.0 g by dry weight and a beta-glucan content of at least 2.5% by dry weight Further the meat substitute intermediate product contains 8.5-15% and preferably 9.0-14% water by weight.
  • This intermediate product is suitable for manufacturing a meat substitute, preferably a minced meat substitute.
  • the plant based meat substitute intermediate product has preferably any one of the features described earlier related to the dry matter of the plant based meat substitute (i.e. the
  • the plant based meat substitute intermediate product has preferably any one of the features described earlier related to the selection and amounts of components in the plant based meat substitute (i.e. components and their amounts). These features are also disclosed in claims 3-22 and 24-25).
  • the plant based meat substitute intermediate product according to the invention is obtainable by a process including a low temperature extrusion step and at least one drying step. These steps are disclosed in more detail in the disclosure of the methods of manufacturing the plant based meat substitute and the meat substitute intermediate product in the following.
  • a third object of the present invention is to provide a method for manufacturing a plant based meat substitute by extruding a mixture containing plant protein material and oat material, wherein the method comprises at least the following steps: a) preparing a mixture of the plant protein material and the oat material and water, preferably the water content of the mixture being 35-55%, more preferably 38- 53% and most preferably 40-50% by weight of the mixture, b) optionally adding a crosslinking enzyme and/or a protein deamidating enzyme to the mixture, to any of the components or their blends or to the water, preferably the crosslinking enzyme being transglutaminase and/or the protein deamidating enzyme being protein glutaminase,
  • the method includes step b).
  • a crosslinking enzyme and/or a protein are crosslinking enzymes and/or a protein
  • the method includes drying step e).
  • the drying step e) preferably comprises several steps with varying air temperatures and relative humidities preferably being within the ranges 80-120 °C and 5-90%.
  • the method includes the wetting step f) and more preferably the wetting step f) proceeds at least partly simultaneously with the heat treating step g).
  • Step f) of the method preferably comprises adding water to the particles and allowing them to soak under gentle agitation.
  • step c) of adding at least one additional component is performed before step g), more preferably before step d).
  • step c) is performed before step g), more preferably during step f).
  • the heat treating step g) preferably comprises
  • the method can be used for producing the plant based meat substitute according to any one of claims 1-26.
  • the plant based meat substitute intermediate product and the plant based meat substitute are manufactured from a mixture containing a plant protein material and oat material in a method comprising several steps.
  • the first step is preparing a mixture by combining water with a plant protein material and an oat material.
  • the plant protein material is at least one selected from legume, tuber, cereal and seed protein
  • the oat material is at least one selected from whole grain oat flour, oat bran, oat bran flour, oat groats, steel-cut oats, oat flakes, oat endosperm, oat endosperm flour, a dietary fiber enriched oat fraction and a beta-glucan enriched oat fraction.
  • additional components can be added at this stage, e.g. crosslinking enzyme(s), spices, vitamins, minerals and health improving agents such as an additional cardiovascular health improving agent.
  • the crosslinking enzyme is transglutaminase.
  • the additional cardiovascular health improving agent can be plant sterols and/or plant stanols added in an amount to deliver e.g. at least 1.5 g plant sterols and/or stanols in the daily consumed amount of the plant based meat substitute.
  • the plant sterols and/or plant stanols are preferably used in their fatty acid ester forms.
  • the protein material, the oat material and the optional additional component(s) can be added separately to the water or the dry ingredients can be mixed together before blending with water to form the mixture.
  • the mixture can contain water in an amount of 35-55%, preferably 38-53% and more preferably 40-50% by weight of the mixture.
  • the mixture is blended thoroughly and fed to an extruder comprising a barrel, at least one screw and at least one nozzle. Preferably it can be a twin-screw extruder. It is also possible to divide the slurry feed to several extruders operating in parallel.
  • the rotating screw conveys the slurry through the barrel and presses it to a homogenous material.
  • the slurry is pressed through at least one nozzle to form at least one string of extrudate and the at least one string of extrudate is cut into particles.
  • the width of the particles can be below 6 mm and preferably below 4 mm, such as about 3 mm.
  • the length of the particles can be below 10 mm, preferably below 7 mm, such as about 5 mm.
  • no heating or very mild heating is applied during the extrusion, i.e. it is performed as a low temperature extrusion.
  • the temperature of the mixture is 25-60 °C, preferably 30-50 °C during the extrusion step. It may even be necessary to provide light cooling.
  • the following process step is drying the particles to a water content of at most 16%, preferably below 14% and most preferably below 12%.
  • the drying can take place as a multistep process where the particles meet varying air temperatures and relative humidities, e g. 80-115°C and 5- 90%.
  • the dried particles i.e. the plant based meat substitute intermediate product can be stored several months without deterioration of the quality before the next process step.
  • the production of the final meat substitute from the intermediate product can be executed several months after the production of the intermediate meat substitute product. It can obviously also be executed immediately after the production of the intermediate product.
  • the intermediate product particles are mixed with water and allowed to soak for a sufficient time such as 30 min to 3 h, preferably about 2 h.
  • the water content of the soaked particles can be at least 30.0%, preferably at least 35.0% and most preferably 35.0-50.0% by weight.
  • the water absorption properties of the dried particles are such that they can absorb the added water during the soaking step.
  • the wetted particles can be heat treated in a chamber at elevated temperature and pressure.
  • the wetted particles can be packed in an airtight enclosure, preferably in hot- sealed plastic bags fulfilling the quality requirements for such heat treatment. Thereafter the bags can be placed for at least 1 hour in a chamber with elevated pressure and temperature of at least 100°C.
  • the final step of the method can include cooling the heat treated particles to storage temperature (ambient) to obtain the plant based meat substitute product.
  • a fourth object of the invention is the manufacturing process of the plant based meat substitute intermediate product.
  • the invention is also directed to a method for manufacturing a plant based meat substitute intermediate product by extruding a mixture containing plant protein material and oat material utilising at least the following steps:
  • the water content of the mixture being 35-55%, more preferably 38-53% and most preferably 40-50% by weight of the mixture,
  • a crosslinking enzyme and/or a deamidating enzyme to the mixture, to any of the components or their blends or to the water, preferably the crosslinking enzyme being transglutaminase and/or the protein deamidating enzyme being protein glutaminase,
  • a serum cholesterol lowering agent other than beta-glucan preferably a serum cholesterol lowering agent other than beta-glucan, more preferably the cholesterol lowering agent being plant stanol and/or plant sterol or their esters,
  • the method includes step B).
  • the drying step E) preferably includes several phases with varying air temperatures and relative humidities, preferably within the ranges 80-120 °C and 5-90%.
  • step C) of adding at least one additional component is performed before step D).
  • additional component is herein meant spices, salts, vitamins, minerals and health improving agents such as an additional cardiovascular health improving agent other than oat beta-glucan.
  • the method can be used for producing the plant based meat substitute intermediate product according to any one of claims 27-30.
  • a further object of the invention is to provide a new type of process for producing a plant based meat substitute and the intermediate product thereof.
  • the invention is also directed to the use of a low temperature extrusion process in the manufacturing process of a plant based meat substitute or an intermediate product thereof.
  • the invention is directed to the use of a low temperature extrusion process in the manufacturing process of a plant based minced meat substitute or an intermediate product thereof.
  • the low temperature extrusion is performed at 25-55 °C, preferably at 30-50 °C.
  • the low temperature extrusion is performed by adding 35-55%, more preferably 38-53% and most preferably 40-50% water by weight of the mixture to be extruded.
  • a still further object of the invention is to provide a new type of process for producing a plant based meat substitute and the intermediate product thereof.
  • the invention is also directed to the use of a low temperature extrusion process and a drying process in the manufacturing of a plant based meat substitute or an intermediate product thereof.
  • the invention is directed to the use of a low temperature extrusion process and a drying process in the manufacturing of a plant based minced meat substitute or an intermediate product thereof.
  • the low temperature extrusion is performed at 25-55 °C, more preferably at 30-50“C.
  • the drying process includes drying the intermediate product to a water content below 16%, more preferably below 14% by weight.
  • the drying includes several steps with varying air temperature and relative humidity, preferably within the ranges 80-120 °C and 5- 90%.
  • Plant based meat substitute products were prepared by using the recipes shown in table 1. The aim was to prepare plant based meat substitute containing at least 50 % by dry weight oat material. As a reference, also a plant based meat substitute containing a lower amount (30 % of dry weight) oat material was prepared (Recipe 1 ).
  • Oat material, plant protein material, salt (table salt) and an enzyme (transglutaminase ACTIVA® WM, Ajinomoto) were weighed according to the recipes in Table 1 , in amounts to obtain 2 kg dry weight of each recipe. The ingredients were blended and the ingredient blend was divided into two equal parts by weight (1 kg).
  • Plant based meat substitute intermediate products were produced with low temperature extrusion in the following manner.
  • the ingredient blend was thoroughly mixed with 40 °C water for 10 minutes to bring the water content of the mixture to 46 %.
  • the mixture was conveyed through a single-screw laboratory extruder (MX-20, Sandore s.n.c., Italy) at a temperature in the range of 35-40 °C.
  • MX-20 Sandore s.n.c., Italy
  • the extrudate was cut to string shape particles of 5-10 mm length upon exiting the die. Thereafter the particles were dried to a water content appr.
  • the particles were dried to a water content of appr. 10 % with hot air in an oven for 1 h and then in ambient temperature in a drying cabin (ES 60, Sandore s.n.c., Italy). These samples were named with prefix HTI.
  • Plant based meat substitute products were produced from the intermediate products LTI and HTI as follows. Water (temperature 20 °C) was added to the intermediate particles in a weight proportion of 40:60. This mixture was let to soak for an hour, then gently agitated and let to soak for another hour. Thereafter this mixture was packed in plastic bags which were heat sealed airtight. The plastic bags were heat treated for 2.5 hours in an autoclave operating at about 2 bar and 110 °C. Thereafter the bags were cooled rapidly to ambient temperature until being used in the experiments. The final products were marked with prefix LTF and HTF depending on which intermediate product, i.e. LTI or HTI, they origin from.
  • the water content of pan-fried and browned minced meat varies typically between 50-60%. Based on initial tests it was realized that to obtain a plant based meat substitute having a mouthfeel resembling pan-fried minced meat, the water content of the plant based meat substitute should be between 28-58 %. The most suitable water content of the plant based meat substitute was found to be 40-50% depending on the recipe. Too high water content causes the meat substitute to have a sticky surface after the heat treatment (autoclave). On the other hand lower amount of water leads to a hard and crispy texture upon pan-frying the plant based meat substitute in vegetable oil.
  • the water content of the LTF and HTF samples was about 43 weight-%, consisting of the water originating from the intermediate products (LTI and HTI, respectively) and the water added in the preparation of the final products.
  • the nutrient compositions of the final products are presented in the Table 3.
  • a typical serving size of 100 g of the final product contained 1.5-3.8 g beta-glucan (Recipe 1 : 1.5 g and Recipe 5: 3.8 g).
  • Table 3 Nutrient contents of the final products
  • An overall quality rating was calculated for each sample as the mean value of all average ratings given for each property of that sample. The overall average results are presented in Table 4.
  • HTF samples made with Recipes 2-5 were considered to be too expanded and having a too open structure and did therefore not meet quality requirements for a plant based minced meat substitute.
  • the HTF sample made with Recipe 1 had more compact and firm particle texture than the HTF samples 2-5, but the HTF sample 1 had too intense dark brown colour, gritty and dry mouthfeel and bitter taste.
  • HTF samples made with both Recipe 4 and 5 had unpleasant rubbery texture and too intense cereal-like taste for a plant based minced meat substitute.
  • LTF sample made with Recipe 5 was considered to contain more clustered particles (lumps), a bit sticky surface and more cereal-like taste than the LTF samples 1 -4, but it was still rated acceptable.
  • Plant based meat substitutes should be suitable for use in cooking, and preserve good sensory properties such as texture after cooking.
  • the water absorption-% in the cooking should be low.
  • Typical water absorption-% for fried minced meat is b ⁇ r below 10%, depending on the fat content of the meat.
  • somewhat higher water absorption-% in cooking is acceptable, as the initial water content of the plant based meat substitutes is lower than that of the minced meat.
  • the texture of the plant based meat substitute should remain essentially intact and not get too wet after cooking.
  • the plant based meat substitute used in cooking should retain a good mouthfeel.
  • the LTF and HTF samples from Example 1 were cooked in boiling water, and the water absorption of the samples, as well as the amount of sediment formed during the cooking were determined. Cooking in boiling water imitates the use of the product e.g. in preparation of sauces and soups. 100 g of the sample was added to boiling water and stirred a couple of times with a spoon. The sample was boiled for 10 min. (measured from the addition of the sample) in a kettle without a lid. Right after the 10 min. boiling time, the water was sieved and preserved. The sample was let to drain for 3 minutes in the sieve and weighted thereafter (drained weight).
  • the initial weight of the sample (100g) was subtracted from the drained weight, and the result was divided by the initial weight and multiplied by 100 to get the water absorption-% of the sample.
  • the results of the cooking test are presented in Figure 1.
  • a 100ml measuring glass was filled with the preserved well mixed boiling water to the 100 ml mark. After 14 hours the amount of the sediment on the bottom of the measuring glass was registered to indicate the level of detrimental disintegration of the sample.
  • the amount of sediment was higher in the HTF samples compared to the corresponding LTF samples, e.g. recipe 4 showed a sediment level of 24 ml for HTF and 16 ml for the LTF sample.
  • intermediate product should have a suitable water absorption capacity.
  • Water absorption (%) of the LTI and HTI samples from Example 1 were determined as follows. 20 g sample was added to 200 ml of 20 °C water in a glass beaker and mixed cautiously. The beaker was stirred every second minute during the next 30 minutes. The sample was poured to a sieve and let to drain for 30 seconds. The sieve was shaken lightly for 1-2 seconds. The drained sample was weighted, and the weight of the initial sample was subtracted from the weight of the drained sample to obtain the amount of water. The amount of water was divided by the initial weight (i.e. about 20 g) and multiplied by 100, to get the water absorption-%. The results are presented in Figure 3.
  • the water absorption-% of the high temperature extruded intermediate (HTI) samples started to increase rapidly when the amount of oat material was 50 % of the dry weight or more.
  • the water absorption of the intermediate product becomes important especially when setting up the industrial scale soaking, packaging and autoclave cooking processes.
  • the water absorption level of 70-80 % from the weight of the intermediate product obtained by low temperature extrusion process is optimal when the aim is to achieve the most desired water content of 40-50 % in the final product.
  • With optimal water absorption level the soaking process is easy to control and the water is evenly distributed throughout the intermediate product. If the water absorption of the intermediate product is excessive with respect to desired water content in the final product, it can result in uneven water distribution and the particles may become soft and get easily disintegrated during the soaking and packaging process steps. In this situation a functioning industrial scale soaking and packaging process delivering constant product quality would be almost impossible to set up.
  • Plant based meat substitute intermediate and final products were prepared by low temperature extrusion as described in the example 1 and by using the recipes shown in table 4.
  • the recipes contained 68% of dry weight oat material and 31% of dry weight plant protein material and 1 % of dry weight salt.
  • the oat material and the plant protein material used were the same as in the Example 1.
  • the proportion of tuber (potato) and legume (pea) protein varied between the recipes.
  • the intermediate products were named with prefix LTI and the final products with prefix LTF.
  • the water absorption level of about 70-80 % from the weight of the intermediate product would be optimal when the aim is to achieve the most desired water content of 40-50 % in the final product. All intermediate products yielded acceptable water absorption (%). However, the most optimal water absorption level was obtained with the recipes 2 and 3 containing 20% and 25% of dry weight tuber protein.
  • the final products containing 20% or 25% of dry weight tuber protein resulted in lower water absorption (%) compared to the final product containing 25% of dry weight legume protein, which is beneficial for the plant based meat substitute.

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Abstract

L'invention concerne un substitut de viande à base de plante, comprenant un matériau d'avoine et un matériau de protéine végétale, qui est spécialement utilisable en tant que substitut de viande hachée à base de plante, ainsi qu'un procédé de fabrication du substitut de viande. L'invention concerne également un produit intermédiaire de substitut de viande à base de plante comprenant un matériau d'avoine et un matériau de protéine végétale et son procédé de fabrication. L'invention concerne en outre l'utilisation d'une extrusion à basse température dans le processus de fabrication de l'intermédiaire de substitut de viande à base de plante et du substitut de viande à base de plante.
PCT/EP2018/000414 2018-08-24 2018-08-24 Substitut de viande et sa production à partir de matériel végétal WO2020038541A1 (fr)

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PCT/EP2018/000414 WO2020038541A1 (fr) 2018-08-24 2018-08-24 Substitut de viande et sa production à partir de matériel végétal
PCT/EP2019/025115 WO2020038601A1 (fr) 2018-08-24 2019-04-18 Substitut de viande cuite et production de celui-ci à partir d'un matériau végétal
EP19720367.2A EP3840583A1 (fr) 2018-08-24 2019-04-18 Substitut de viande cuite et production de celui-ci à partir d'un matériau végétal
EP19759501.0A EP3840584A1 (fr) 2018-08-24 2019-08-26 Substitut de viande et sa production à partir de matériau végétal
PCT/EP2019/025284 WO2020038611A1 (fr) 2018-08-24 2019-08-26 Substitut de viande et sa production à partir de matériau végétal

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WO2022146619A1 (fr) * 2020-12-30 2022-07-07 The Livekindly Company Switzerland GmbH Analogue de viande à base de plante à fibres de type muscle
WO2022195015A1 (fr) * 2021-03-19 2022-09-22 Dsm Ip Assets B.V. Produit analogue de la viande
WO2022218863A1 (fr) 2021-04-12 2022-10-20 Novozymes A/S Procédé de production d'un produit analogue à la viande
WO2023096495A1 (fr) * 2021-11-29 2023-06-01 Coöperatie Koninklijke Avebe U.A. Protéine végétale texturée
EP4205552A1 (fr) 2021-12-30 2023-07-05 BK Giulini GmbH Produits analogues à la viande et aux fruits de mer
WO2023126522A1 (fr) 2021-12-30 2023-07-06 Bk Giulini Gmbh Produits analogues de la viande et des fruits de mer
WO2024008294A1 (fr) * 2022-07-07 2024-01-11 Oatly Ab Produit extrude et son procede de fabrication
US12004539B2 (en) 2022-01-31 2024-06-11 The Livekindly Company Switzerland GmbH Methods for creating of high fibrousness, high moisture extrudates
WO2024121191A1 (fr) 2022-12-06 2024-06-13 Novozymes A/S Procédé de production d'un succédané de viande utilisant une protéine-désamidase

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CN114680224B (zh) * 2020-12-25 2023-11-14 中粮集团有限公司 一种植物蛋白肉的加工方法
US11484044B1 (en) 2021-05-28 2022-11-01 Nowadays Inc., Pbc Modification and extrusion of proteins to manufacture moisture texturized protein
WO2023085315A1 (fr) * 2021-11-09 2023-05-19 天野エンザイム株式会社 Activateur de digestibilité pour composition contenant une protéine botanique
WO2023085316A1 (fr) * 2021-11-09 2023-05-19 天野エンザイム株式会社 Procédé de production d'un produit alimentaire contenant une protéine végétale texturée

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WO2022146619A1 (fr) * 2020-12-30 2022-07-07 The Livekindly Company Switzerland GmbH Analogue de viande à base de plante à fibres de type muscle
WO2022195015A1 (fr) * 2021-03-19 2022-09-22 Dsm Ip Assets B.V. Produit analogue de la viande
WO2022218863A1 (fr) 2021-04-12 2022-10-20 Novozymes A/S Procédé de production d'un produit analogue à la viande
WO2023096495A1 (fr) * 2021-11-29 2023-06-01 Coöperatie Koninklijke Avebe U.A. Protéine végétale texturée
EP4205552A1 (fr) 2021-12-30 2023-07-05 BK Giulini GmbH Produits analogues à la viande et aux fruits de mer
WO2023126522A1 (fr) 2021-12-30 2023-07-06 Bk Giulini Gmbh Produits analogues de la viande et des fruits de mer
US12004539B2 (en) 2022-01-31 2024-06-11 The Livekindly Company Switzerland GmbH Methods for creating of high fibrousness, high moisture extrudates
WO2024008294A1 (fr) * 2022-07-07 2024-01-11 Oatly Ab Produit extrude et son procede de fabrication
WO2024121191A1 (fr) 2022-12-06 2024-06-13 Novozymes A/S Procédé de production d'un succédané de viande utilisant une protéine-désamidase

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