WO2020038601A1 - Substitut de viande cuite et production de celui-ci à partir d'un matériau végétal - Google Patents

Substitut de viande cuite et production de celui-ci à partir d'un matériau végétal Download PDF

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Publication number
WO2020038601A1
WO2020038601A1 PCT/EP2019/025115 EP2019025115W WO2020038601A1 WO 2020038601 A1 WO2020038601 A1 WO 2020038601A1 EP 2019025115 W EP2019025115 W EP 2019025115W WO 2020038601 A1 WO2020038601 A1 WO 2020038601A1
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WO
WIPO (PCT)
Prior art keywords
plant
protein
meat substitute
based meat
oat
Prior art date
Application number
PCT/EP2019/025115
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 EP19720367.2A priority Critical patent/EP3840583A1/fr
Priority to PCT/EP2019/025284 priority patent/WO2020038611A1/fr
Priority to EP19759501.0A priority patent/EP3840584A1/fr
Publication of WO2020038601A1 publication Critical patent/WO2020038601A1/fr

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    • 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 present application relates to a method for preparing a cooked plant-based meat substitute food product from a plant-based meat substitute intermediate product and to a food product obtainable by this method.
  • the application also discloses 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 present application also discloses a plant-based meat substitute intermediate product and its manufacturing process.
  • the present application further discloses the use of low temperature extrusion in the manufacturing process of the plant-based meat substitute intermediate.
  • the plant-based meat substitute food product 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.
  • E.g. 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 further requirement is that information shall be given to the consumer that the beneficial effect i.e. efficient blood cholesterol lowering is obtained with a daily intake of 3 g of beta-glucan.
  • plant-based meat substitute food product would contain as few additives as possible as so-called clean label food products are in high demand as consumers seek to avoid foods with many additives in the list of ingredients.
  • the intermediate product has a high protein content but is preferably completely or substantially complete plant-based, for example vegetarian or vegan food product. However it was possible to prepare food products from the intermediate product having properties such as nutritional value, appearance, texture, mouthfeel, taste and other properties equal or similar to food products made of minced meat or the like products.
  • the present application provides a method for preparing a cooked plant-based meat substitute food product, the method comprising
  • plant-based meat substitute intermediate product in a form of particles comprising 50-85% by dry weight oat material, plant protein material and 8.5-15% water by weight, preferably 9.0-14%, the meat substitute intermediate product having a protein content of 25-55% by dry weight, 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 present application also provides a cooked plant-based meat substitute food product obtainable with the method.
  • the benefits of using the intermediate product described herein as a raw material for food products includes a very long shelf life of the intermediate product. It remains stable and of good quality even when stored at ambient temperature for several months. This brings flexibility to the production as the cooked plant-based meat substitute food product can be manufactured from the intermediate product according to demand. In addition the intermediate product can be delivered to other production facilities for the final production of the cooked plant-based meat substitute food product.
  • final food products i.e. the cooked plant-based meat substitute food products
  • cooked products such as products cooked in an oven or fried on a pan
  • Such final food products include patties, loafs, balls, sticks and the like.
  • the final food products were firm and did not disintegrate during the preparation, cooking, handling, storing or transporting.
  • the texture of the final food products resembles that of corresponding products made of minced meat.
  • the plant-based meat substitute intermediate product can be stored, transported and provided at a relatively low moisture content, which lowers transportation cost and improves storing, transporting and handling properties of the intermediate product.
  • cooked products such as patties, loafs, balls, sticks and the like described herein
  • the intermediate product is in a form of particles, which are obtained from low temperature extrusion and resemble small pellets. When these particles are soaked in water to absorb the water and obtain the desired water content, they swell and behave differently in the cooking process compared to similar products which are not soaked or products which are not in the form of the pellet-like particles obtained from low temperature extrusion process.
  • the formed patties, loafs, sticks and balls are cooked into food products having appealing appearance, texture and mouth feel. This improves the consumer acceptance of the product
  • the use of the soaked intermediate products enables efficient food production especially in industrial scale, wherein ovens or other cooking devices, such as ones equipped with conveyor belt or the like constructions are used. It is possible to obtain final food products with uniform quality, which is especially important when food products are prepared in industrial scale.
  • the cooked plant-based meat substitute food products i.e. the final food products contain a relatively low amount of legume protein.
  • the bitter beany taste of legume protein is thus reduced compared to many prior art meat substitutes.
  • the high content of oat material also masks the bitter beany taste.
  • legume protein sources usually contain varying levels of fermentable oligosaccharides, classified as FODMAP compounds which are not suitable for low FODMAP diets. Oat has a very low content of FODMAP compounds compared to other cereals and especially in comparison to legumes and thus is suitable for low FODMAP diet.
  • the meat substitutes are made of legume materials, such as soy or broad bean, or of wheat based ingredients.
  • 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
  • Figure 4 shows final cooked patties made from the second plant-based meat substitute (left) and from the intermediate product (right).
  • Plant-based meat substitute obtained from the intermediate product may be adjusted into different water contents and further processed.
  • the cooked plant- based meat substitute food product and the preparation thereof, as claimed in the present claims, relate to the first cooked plant-based meat substitute food product. This product is explained in paragraph“The cooked plant-based meat substitute products”.
  • the present application also discloses a second cooked plant-based meat substitute food product, which may be used as a reference product.
  • One example discloses a second plant-based meat substitute containing oat material, plant protein material and water.
  • 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.
  • This second plant-based meat substitute obtained from the intermediate product further contains 30-55% water by weight.
  • plant-based meat substitute intermediate product with a high level of dietary fiber and beta-glucan as well as a high content of oat material could be produced opposite to prior teachings. This was accomplished by using a low temperature extrusion process for producing a meat substitute intermediate product. Such an intermediate product showed optimal water absorption properties and resulted in a meat substitute food products that had similar textural properties as corresponding meat products.
  • the plant-based meat substitute food products produced according to the invention showed good textural properties and did not absorb too much water nor disintegrated in a cooking test.
  • the cooked plant-based meat substitute food product is a meatball substitute, a meat patty substitute or a meatloaf substitute. It may also be called a plant-based substitute for meatballs, patties and meatloaf products.
  • “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 or vegan diets.
  • the plant- based meat substitute is therefore meat-free, preferably dairy-free, egg-free, and/or may also be soy-free, and it is preferably a vegetarian or vegan food product.
  • 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 intermediate product 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 intermediate product 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 intermediate product 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 intermediate product 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 weight ratio of oat material to the legume protein is at least 2:1 , preferably at least 2.7:1 , more preferably at least 3.6:1 , and most preferably at least 3.8:1.
  • the weight ratio of oat material to legume protein in the plant-based meat substitute intermediate product is at least 2.0:1 , preferably at least 2.7:1 , more preferably at least 3.6:1 , and most preferably at least 3.8:1. Also preferably the weight ratio of oat material to legume protein in the cooked plant-based meat substitute food product is at least 2.0:1 , preferably at least 2.7:1 , more preferably at least 3.6:1 , and most preferably at least 3.8:1 .
  • the weight ratio of oat material to legume protein material in the plant- based meat substitute intermediate product is at least 1.0:1 , preferably at least 1.1 :1 , more preferably at least 1.2:1 and most preferably at least 1.3:1.
  • the weight ratio of oat material to legume protein material in the cooked plant-based meat substitute food product is at least 1.0:1 , preferably at least 1.1 :1 , more preferably at least 1.2:1 and most preferably at least 1.3:1. It was surprisingly noticed plant-based meat substitute intermediate products, and thus also cooked plant-based meat substitute food products, having a high weight ratio of oat material to legume protein materials could be produced.
  • a high weight ratio of oat material to legume protein material is beneficial in low FODMAP products, because the legume protein materials contain high levels of FODMAP compounds and the oat material has a very low or non-existent content of FODMAP compounds.
  • cooked plant-based meat substitute food product is meant a plant-based meat substitute of any size and three-dimensional form such as meatball, patty, stick or meatloaf type of products. They can be made of the plant-based meat substitute intermediate product disclosed herein.
  • the cooked plant-based meat substitute food product does not contain animal meat and preferably not egg either. Preferably it is also dairy-free.
  • the cooked plant-based meat substitute food product may contain other ingredients, for example spices, additives such as stabilizer(s), flour(s), vegetable pieces, puree(s) such as vegetable purees and the like.
  • the final food products are heat treated i.e. cooked, for example by frying or cooking in oven.
  • the term“cooking” may include any suitable heat-treatment, such as frying, baking, roasting and the like, which may or may not include contact with a heat source, such as one or more heating element(s), heating surface(s) and the like.
  • the cooked plant-based meat substitute food product has a weight ratio of oat material to legume protein material of at least 1.0:1 , preferably at least 1.1 :1 , more preferably at least 1.2:1 and most preferably at least 1.3:1. Also preferably the weight ratio of oat material to legume protein in the cooked plant-based meat substitute food product is at least 2.0:1 , preferably at least 2.7:1 , more preferably at least 3.6:1 , and most preferably at least 3.8:1.
  • a high ratio of oat material to legume protein material contributes to a lower level of FODMAP compounds and higher levels of dietary fiber and beta-glucan in the cooked plant-based meat substitute food product.
  • 100 g of the cooked plant-based meat substitute food product contains at least 1.0 g, preferably at least 1.2 g, more preferably at least 1.3 g, still more preferably at least 1.4 g and most preferably at least 1.6 g beta-glucan.
  • 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 intermediate product 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 intermediate product 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 plant-based meat substitute intermediate product 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 intermediate product 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 intermediate product 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 intermediate product 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 intermediate product 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 intermediate product 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 intermediate product 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 intermediate product 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 intermediate product does not contain added hydrocolloids such as pectin, gelatin and alginate.
  • the plant-based meat substitute intermediate product may contain at least one additional component, such as one or more of the ones described herein.
  • 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 intermediate product 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 pm.
  • 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 intermediate product 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 intermediate product 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%, furthermore 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.
  • Beta-glucan is part of the dietary fiber content.
  • the plant-based meat substitute intermediate product 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 intermediate product 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 intermediate product and food product obtained from it 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 substitute intermediate products easily provides the recommended daily intake of beta-glucan in one serving.
  • One example of a second plant-based meat substitute obtained from the intermediate products contains water in an amount of 30-55%, preferably 35-53% and most preferably 40-50% by weight.
  • This optimal water content in the second 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 intermediate products disclosed herein are 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 temperature extrusion step, at least one drying step, a wetting step and a heat treatment step.
  • the present application discloses 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) by dry weight as the second final plant-based meat substitute of an example. Thus, only the water content differs.
  • the plant-based meat substitute intermediate product 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 is herein meant an intermediate product in the process of manufacturing the plant-based meat substitute products.
  • 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-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, and the cooked plant-based meat substitute food products of the embodiments.
  • the plant-based meat substitute intermediate product has preferably any one of the features described earlier related to the dry matter of the second 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 second plant-based meat substitute (i.e. components and their amounts).
  • the plant-based meat substitute intermediate product 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.
  • One example discloses a method for manufacturing a second 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,
  • step b) cooling the heat treated particles to storage temperature to produce the meat substitute.
  • the method includes step b).
  • a crosslinking enzyme and/or a protein deamidating enzyme is added.
  • 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).
  • additional component e.g. spices, salts, vitamins, minerals and health improving agents such as an additional cardiovascular health improving agent other than oat beta-glucan.
  • the heat treating step g) preferably comprises
  • the plant-based meat substitute intermediate product and the plant-based meat substitutes 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.
  • an extruder comprising a barrel, at least one screw and at least one nozzle.
  • it can be a twin-screw extruder.
  • 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.
  • the present application discloses a manufacturing process of the plant-based meat substitute intermediate product.
  • Disclosed is also 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:
  • 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,
  • 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 present application also discloses the use of a low temperature extrusion process in the manufacturing process of a plant-based meat substitute or an intermediate product thereof.
  • the present application also discloses 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.
  • This use of a low temperature extrusion process can be utilised for producing the plant-based meat substitute and/or plant-based meat substitute intermediate product.
  • the present application discloses a process for producing a plant-based meat substitute and the intermediate product thereof.
  • a low temperature extrusion process and a drying process in the manufacturing of a plant-based meat substitute or an intermediate product thereof.
  • 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%.
  • This use of a low temperature extrusion process can be utilised for producing the plant-based meat substitute and/or plant-based meat substitute intermediate product.
  • the present invention relates to a method for preparing a cooked plant-based meat substitute food product, which may be called as the first plant-based meat substitute, the method comprising providing plant-based meat substitute intermediate product in a form of particles comprising 50-85% by dry weight oat material, plant protein material and 8.5-15% water by weight, preferably 9.0-14%, the meat substitute intermediate product having a protein content of 25-55% by dry weight, 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.
  • This intermediate product and manufacturing thereof has been explained above.
  • the plant-based meat substitute intermediate product particles are obtained from a process including a low temperature extrusion step and at least one drying step.
  • the method further comprises adjusting the water content of the plant-based meat substitute intermediate product into the range of 40-70% by weight, such as 45-60%, 45-55%, 50-60% or 55-65% by weight.
  • This may be carried out by combining or treating the intermediate product with water, such as by soaking or otherwise wetting the intermediate products in an aqueous solution, preferably for at least 1 hour, for at least 3 hours, for at least 6 hours or for at least 10 hours.
  • the intermediate products may be soaked or wetted for 1-24 hours, such as 6-24 hours, preferably 10-24 hours.
  • the aqueous solution may be water or water containing one or more spice(s), one or more salt(s), and/or one or more additives or other ingredients disclosed herein.
  • the intermediate products may be gently mixed during the treatment with water. After adjusting the water content, the intermediate product has absorbed water and is swollen. It may be mixed with other necessary ingredients, such as ingredients needed for preparing a dough or the like mixture which may be formed into portions of desired size and shape.
  • One ingredient may be binder material, such as starch based binder material, for example modified starch, which may be corn starch, potato starch, wheat starch or other suitable starch.
  • the binder material may be also in a form of bread, cracker or the like material obtained from cereal, for example bread or cracker flour or crumbles or the like.
  • puree comprising vegetables, tuber, fruit, or the like material, which may have an impact on the texture, taste, colour, and/or appearance of the final product.
  • purees include sweet potato puree, other tuber puree(s), vegetable puree(s) and tomato puree(s).
  • spices and other ingredients disclosed herein may be included, such as oil in the range of 0-10% by weight, such as 1-10% or 1-7%.
  • the composition of the mixture for example the water content, binder content, oil content and/or content of other ingredients having an impact on the structure, texture and moldability of the formed dough, may be adjusted to obtain a mixture which is moldable and can be formed into desired sizes and shapes, also by industrial scale devices or machinery.
  • the method comprises forming a mixture comprising the soaked plant- based meat substitute intermediate product, one or more binder material, such as starch or starch-containing material, and optionally one or more other ingredient such as one or more puree(s) and/or one or more spice(s).
  • the mixture is formed and/or used or cooked in short time after adjusting the water content of the intermediate products, such as during the same day or for example in 0-12 hours or 0-6 hours after adjusting the water, for example with soaking or other suitable wetting process.
  • the mixture may be mixed by using a suitable mixer, for example an industrial scale mixer.
  • the method comprises forming the mixture into one or more portion(s).
  • the portion may refer to a patty, a loaf, a stick or a ball, or to an amount of the mixture required to form such a form.
  • These products may be similar as corresponding products made of minced meat.
  • a patty may refer to a flattened, round or substantially round or elliptical serving of the food product.
  • the method comprises cooking the portions to obtain a cooked plant-based meat substitute food product.
  • the cooking may be carried out in an oven, a pan, or the like device providing heat and/or heated surface(s), for example dry heat.
  • the cooking may be carried out by using a device of industrial scale, such as one including a conveyor.
  • the device includes a conveyor and the portions are conveyed to an oven unit, which may include one or two heating elements or surfaces, such as one below and one above the portions.
  • the cooked plant-based meat substitute food product obtained with the method described in previous and by using the intermediate products prepared and disclosed herein was evaluated by several experienced food professionals and compared to other products prepared from different raw materials.
  • the samples coded LTI in examples 1-4 relate to the plant based meat substitute intermediate product.
  • the samples coded LTF relate to the second plant-based meat substitute.
  • 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. 10%, first with hot air in a steam oven for 1 hour and then in ambient temperature in a drying cabin (ES 60, Sandore s.n.c., Italy).
  • 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).
  • 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.
  • Textures of the FITF 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 FITF sample made with Recipe 1 had more compact and firm particle texture than the FITF samples 2- 5, but the FITF sample 1 had too intense dark brown colour, gritty and dry mouthfeel and bitter taste.
  • FITF 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. Based on the panel evaluation it was obvious that the low temperature extrusion combined with 50-85% of oat materia!
  • 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 e.g. 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.
  • Example 1 To evaluate the cooking tolerance of the plant-based meat substitute products obtained in the Example 1 , 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.
  • the 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. Surprisingly, the water absorption of the low temperature extruded intermediate (LTI) samples remained practically unchanged despite the increase in the amount of oat material in the recipe.
  • the water absorption of the intermediate product becomes important especially when setting up the industrial scale soaking, packaging and autoclave or other 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 second 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.
  • Table 7 A patty recipe without spices
  • the intermediate product particles and water 2 (50%/50% by weight) were combined and particles were let to swell overnight.
  • the dry ingredients were mixed, water 1 was added and mixed. Then the purees and vinegar were added and mixed with a spoon. The soaked intermediate product was added and mixed with a Hobart mixer by using a blade mixer for 1 minute at speed 1.
  • Patties were formed (about 90 g) and cooked in a combination oven at dry heat at 160°C for 25 minutes. The patties were cooled in a refrigerator. Evaluation:
  • the dry ingredients were mixed, water was added and mixed. Then the purees and vinegar were added and mixed with a spoon.
  • the second meat substitute product was added and mixed with a Hobart mixer by using a blade mixer for 1 minute at speed 1.
  • Patties were formed (about 90 g) and cooked in a combination oven at dry heat at 160°C for 25 minutes. The patties were cooled in a refrigerator.
  • the second meat substitute food product and water 2 were combined.
  • the water content of the second meat substitute food! product was 39% by weight, so 9.81 % of water was added to obtain a water content of 50% by weight.
  • the intermediate product and water were combined in equal amounts by weight.
  • the patties produced from the second meat substitute product were improved in comparison to test 2A. However, the structure was still too loose to keep the patty intact in industrial scale production and handling. The patty disintegrated into many pieces upon light physical touching.
  • the patties made from the intermediate product holds moisture and has good texture, and crispy surface, wets well and are more homogenous and solid, in general more patty-like and not floury.
  • the particles can be detected, but they do not disturb the mouthfeel. Instead the particles give a nice texture corresponding to the texture of meat-based patties.
  • Figure 4 shows pictures of the patties made from the second meat substitute product (left) and from the intermediate product (right).

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Abstract

La présente invention concerne un procédé de préparation d'un produit alimentaire de substitution de viande à base de plante cuite, consistant à fournir un produit intermédiaire de substitution de viande à base de plante sous la forme de particules, comprenant de 50 à 85 % en poids sec de matériau d'avoine, de matériau de protéine végétale et de 8,5 à 15 % d'eau en poids, le produit intermédiaire de substitution de viande ayant une teneur en protéines de 25 à 55 % en poids sec, une teneur en fibres alimentaires d'au moins 5,0 % en poids sec et une teneur en bêta-glucane d'au moins 2,5 % en poids sec, à ajuster la teneur en eau du produit intermédiaire de substitution de viande à base de plante dans la plage de 40 à 70 % en poids, à former un mélange comprenant le produit intermédiaire de substitution de viande à base de plante trempé, un ou plusieurs matériaux liants, à former le mélange en une ou plusieurs parties, telles que des galettes, des tranches, des bâtons ou des boules, et à cuire les parties pour obtenir un produit alimentaire de substitution de viande à base de plante cuite. La présente invention concerne également un produit alimentaire de substitution de viande à base de plante cuite pouvant être obtenu avec le procédé.
PCT/EP2019/025115 2018-08-24 2019-04-18 Substitut de viande cuite et production de celui-ci à partir d'un matériau végétal WO2020038601A1 (fr)

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