WO2022079452A1

WO2022079452A1 - Plant-based meat analogue food

Info

Publication number: WO2022079452A1
Application number: PCT/GB2021/052688
Authority: WO
Inventors: Amadeus Driando AHNAN; Fabio RINALDO; Thalis BUSSIERE; Elvira SUKAMTOH; Lidwina Krisna CHRYSANTI
Original assignee: Better Nature Ltd
Priority date: 2020-10-16
Filing date: 2021-10-18
Publication date: 2022-04-21
Also published as: EP4228423A1; GB202016454D0

Abstract

The present invention relates to plant-based foods having favourable organoleptic properties, typically meat-like properties, and a method and kit of making a plant-based meat analogue food. In one particular aspect, the invention provides a method of making a plant-based meat analogue food, comprising the steps of: (a) boiling particulate vegetable material having an average diameter of about 0.5mm to about 4mm; (b) drying the boiled particulate vegetable material; (c) shaping the dried product of step (b) and inoculating the shaped product with at least one mycelium-producing fungus, or inoculating the product of step (b) with at least one mycelium-producing fungus and shaping the inoculated product; (d) incubating the shaped product of step (c) at around 25˚C to around 40˚C for at least 12 hours; and (e) cooking the incubated product to make the plant-based meat analogue food.

Description

PLANT-BASED MEAT ANALOGUE FOOD

Field of the Invention

The present invention relates to plant-based foods having favourable organoleptic properties, typically meat-like properties. More specifically, the invention relates to a plant-based meat analogue food produced by solid-state fermentation of particulate plant material, and a method and kit of making the plant-based meat analogue food.

Background of the Invention

The formulation of plant-based meat alternatives typically currently involves mixing textured vegetable proteins with other ingredients to create meat-like texture, taste, and aroma profiles that can include compactness, chewiness, and umami-taste. This approach is often seen as sub-optimal, and in particular not wholesome or natural, because the ingredients are produced using chemical extraction, isolation, and/or synthesis processes.

In a different area of food production, ancient fermentation processes that originated in Indonesia such as tempeh fermentation and oncom fermentation, have been used to transform various beans, grains, and legumes into compact cakes that have favourable textures and increased umami flavour profiles. Moreover, the fermentation processes can increase the protein, vitamin, mineral, and bioactive compound contents, as well as decrease the antinutritive content such as phytate in soybeans. A simple review of tempeh production is provided by Steinkraus, Food Technology Vol 32 1978 pages 79-80 “Tempeh - An Asian Example of approp ate/intermediate food technology.

However, such traditional solid-state fermentation processes are not optimised for creating meat alternatives. For example, the typically chunky texture of products such as tempeh is different from the texture of meat. Furthermore, not every substrate and fermentation culture can produce favourable meat-like texture, flavour, and aroma profiles.

US 3,885,048 describes the preparation of simulated meat, fish and dairy products from soybean tempeh that has been “broken up”, mixed with other flavourings and ingredients, and extruded into a meat substitute. GB-A-2007077 refers to US 3,885,048 and notes that the product that results from US 3,885,048 does not resemble a meat patty because of the visible presence of large particles of soybeans in the product. GB-A-2007077 describes a food product produced by fermenting a partially-gelatinised particulate starch-based material. GB-A-2007077 also describes the addition of meat products such as beef dripping, to arrive at a meat substitute. WO-A-2020/174120 describes food compositions such as baked products and smoothies comprising quinoa and optionally other grains, and the fermentation of these compositions. WO-A-2013/087558 describes a vegetable-based gluten product having the texture of minced meat, which is produced by fermenting gluten-based plant material such as wheat, barley, rice or rye.

There remains a need for wholesome, natural plant-based foods that resemble the properties of meat.

Summary of the Invention

The present invention relates generally to plant-based foods that have a flavour, texture, aroma and/or appearance that is considered by humans to be favourable. The plant-based food typically resembles meat. Plant-based foods that resemble meat are sometimes referred to herein as meat analogues.

The inventors have observed that solid-state fermentation of beans, seeds, grains, and legumes results in a food with favourable organoleptic properties. By carrying out these investigations, the inventors have identified that organoleptic advantages are provided by solid state fermentation of particulate non-meat food materials. Accordingly, the careful selection and processing of particulate non-meat food materials allows for the texture, colour, appearance, taste and/or smell of a plant-based meat analogue to be carefully controlled and pre-determined.

A first aspect of the invention provides a method of making a plant-based meat analogue food, comprising the sequential steps of:

(a) boiling particulate vegetable material having an average diameter of about 0.5mm to about 4mm;

(b) drying the boiled particulate vegetable material;

(c) shaping the dried product of step (b) and inoculating the shaped product with at least one mycelium-producing fungus; or inoculating the product of step (b) with at least one mycelium-producing fungus and shaping the inoculated product;

(d) incubating the product of step (c) at around 25°C to around 40°C for at least 12 hours; and

(e) cooking the incubated product to make the plant-based meat analogue food.

The particles of material used according the invention typically have an average diameter of about 0.5mm to about 4mm, although larger or smaller particles may be used in some embodiments for example between about 0.1 mm to about 10mm. The average diameter may be assessed as the D3,2 or D4,3 mean diameter. The average diameter is typically assessed as the D4,3 mean diameter. The particulate material used in the invention is typically particulate vegetable material. Suitable particulate vegetable materials are beans, seeds, grains or legumes. Mechanically- processed versions of vegetable materials may also be used, for example chopped, ground, grated, milled or crushed material. Accordingly, the vegetable material can be any part of a plant that is chopped, ground, milled, crushed, grated, powdered, grated, granulated or otherwise broken down to form suitable particles or granules according to the invention. While the vegetable material is typically seeds, beans, grains, pulses or legumes that may or may not be mechanically processed for use in the present invention, the use of mechanically processed flowers, fruits, stems, nuts, leaves, pods, roots, rhizomes or tubers is also provided. Multiple types of plant tissue can be used, for example mechanically-granulated leaves and seeds, or roots and fruits. A typical example of a mechanically-processed vegetable material is flour.

The particulate vegetable material may typically comprise one or more of quinoa seeds, soy grits or soy flour. In some embodiments, the particulate vegetable material comprises approximately equal parts of quinoa and soy grits. In certain embodiments, the quinoa and soy grits each form at least 35wt% of the ingredients used according to the invention. In certain embodiments, the quinoa and soy grits each form at least 40wt% of the ingredients used according to the invention, for example around 40wt%, around 42.5wt%, around 44wt% or around 45wt% of each. As shown in the examples, equal parts of quinoa seeds and soy grits provide particularly beneficial results, in particular when flavoured with yeast extract and vinegar, and coloured with beetroot juice.

In step (a) the particulate material is boiled, typically in water such as salted water. The water may contain other components, such as dye or seasoning. The boiling may be for at least 60 seconds, at least about two minutes, or at least about five minutes. Typically, the boiling step lasts for at least about ten minutes. In some embodiments, the boiling lasts at least about 20 minutes or at least about 30 minutes. The boiling time that is required will depend on the desired outcome and the material that is being boiled, and the determination of an appropriate boiling time will be apparent to the skilled person. Quinoa may typically be boiled for around 10 minutes while soy grits may be boiled for longer, for example around 30 minutes.

The drying of step (b) includes partial drying and complete drying. The step is achieved when at least some moisture is removed. The drying step may be achieved by simple draining and/or blotting to remove excess water. More typically, the drying step comprises allowing the boiled material to dry by evaporation of water that remains following draining. This may comprise at least five minutes, at least 20 minutes, at least 30 minutes or around an hour, or more, of drying time. This drying step may be carried out at ambient temperature, or a warm temperature of 25°C or more, for example at least 30°C. The drying step may involve movement of air over the boiled material as it dries, and/or agitation of the drying material.

Step (b) may further comprise mixing the ingredients and/or adding one or more colourings or flavourings. These may be added before drying, during drying, shortly before the end of the drying step (e.g. within the last about 10% of drying time), or after drying. The colourings or flavourings may be natural plant-derived colourings or flavourings, optionally selected from one or more of cider vinegar, lactic acid, beetroot juice, beet concentrate, yeast extract, yeast flakes, and liquid caramelized sugar.

Cider vinegar, beetroot juice and yeast extract are shown in the Examples as being particularly beneficial natural colours and flavours. The yeast extract may be entirely or partly substituted with yeast flakes in some embodiments, and/or with other sources of umami flavour such as dehydrated mushroom powder. Liquid caramelised sugar may also be beneficially included, as shown in the Examples.

In some embodiments, colouring and/or flavouring is added before or during step (a), between step (a) and step (b), during step (b), between step (b) and step (c), or during step (c).

The shaping and inoculating stages of step (c) may be carried out sequentially or simultaneously.

The solid-state fermentation of the particulate material is typically carried out by one or more mycelium-producing fungus, for example food-safe mycelium-promoting organisms such as Rhizopus spp. In some embodiments, a non-fungal mycelium-promoting microorganism may be used instead of or in combination with a fungus. The non-fungal mycelium-promoting microorganism may be a fungus-like bacteria. The mycelium-producing inoculated microorganism may also comprise one or more microbes, such as bacteria, that do not form mycelium. These may be present to add nutrients such as a B vitamin. For example, incorporating Propionibacterium freudenreichii into fungal fermentation can increase the levels of vitamin B12 in the resulting food product.

The mycelium-producing microorganism typically comprises Rhizopus spp. These are typically selected from Rhizopus oligosporus, Rhizopus oryzae, and/or Rhizopus delemar. The Examples below use Rhizopus oligosporus:Rhizopus oryzae at a ratio of 4:1.

The inoculation may typically comprise inoculating between 1E+5 and 1 E+8 CFU of mycelium-forming fungus inoculant per 100 g of total ingredients.

The shaping step typically involves shaping the product into a burger, patty, sausage, steak or other shape usually associated with meat products. The shaping may be done by hand, or by placing the material into a mould or tray, or by use of a machine such as a sausage-maker. In some embodiments, the inoculated substrate is allocated, aliquoted, injected or pressed into a tray or mould of the desired shape. The plant-based meat analogue food is most typically a burger or patty, although the invention is not limited to this embodiment.

The incubation step (d) typically comprises incubation at about 30°C to about 37°C for about 18 to about 72 hours. This incubation is optionally with aeration, i.e. with replacement or exchange of the air in which the incubation occurs. The incubation step is typically carried out at a relative humidity of around 60% to around 90%.

In certain embodiments, the incubation is carried out at between 30°C and 33°C, for example around 32°C. In some embodiments, incubation at this temperature may be carried out for at least 24 hours. The inventors have observed particularly favourable results from incubation for 30 hours at 32°C.

In certain embodiments, a biphasic incubation is carried out. For example, the incubation can be carried out at a first temperature for a period followed by reducing or increasing the incubation to a second temperature for at least two hours. This may for example be an initial fermentation at 37°C for at least 2, 4, 6, 8, 10, 12 or more hours, followed by fermentation at 35°C or less, typically around 30°C, for 2, 4, 6, 8, 10 or more hours. In an exemplary fermentation of 19 hours, this may comprise 12 hours at 37°C and 7 hours at 30°C. Without wishing to be bound by theory, this lower temperature is thought to assist efficient fermentation by preventing overheating of the fermented product, which generates its own heat during fermentation.

The cooking step (e) typically comprises a temperature of at least 100°C for at least 15 seconds, or at least 150°C for between 15 and 500 seconds, or around 180°C for around 15 seconds. This may optionally be frying step, for example a flash-fry, or deep fry in oil. This step substantially or completely kills and removes the mycelium on at least the surface of the product.

In some embodiments, the method further comprises one or more steps of seasoning the product with seasonings such as salt, pepper, herbs and/or spices. The seasoning may be applied at any stage. Typically, the seasoning may be added in step (c) and/or as a separate step (f). The seasoning may also be present in oil used in a frying embodiment of the cooking step (e).

In some embodiments, a marinade and/or oil can be incorporated into the product in a frying step, typically a deep-frying step, typically in step (e).

In some embodiments, the cooked product is pasteurised to extend its shelf life.

The product produced according to the invention may be packaged for commercial or retail sale. The product may be heated immediately prior to consumption, for example fried or baked. This cooking step typically comprises heating to at least 150°C for at least two minutes or at least five minutes.

The invention provides both the finished, cooked product of method step (e) and also the intermediate product after each stage of the process. In particular, the invention provides the product that results from each of step (c) and step (d) as separate products. The product of step (c) is sometimes referred to as the pre-incubation product or the pre-incubation formulation, while the product of step (d) is sometimes referred to as the post-incubation product.

A second aspect of the invention provides a plant-based meat analogue food obtained or obtainable by the method of the first aspect. The intermediate products of step (c) and step (d) are also provided.

A third aspect of the invention provides a plant-based meat analogue food comprising at least 70wt%, at least 75wt% or at least 80wt% fungus-fermented particulate vegetable material having an average diameter of about 0.5mm to about 4mm, wherein the food has a defined shape. This meat analogue food typically has the appearance of a burger, patty, sausage or steak. In some embodiments, the plant-based meat analogue food comprises 70wt% to 95wt% fungus-fermented particulate vegetable material, for example at least 80wt%.

A fourth aspect of the invention provides a kit for making a plant-based meat analogue food, optionally wherein the food is according to the second aspect or the third aspect, comprising separately packaged: (i) particulate vegetable material having an average diameter of about 0.5mm to about 4mm; (ii) fungus; and (iii) optionally one or more colourings or flavourings; and instructions for use.

Brief Description of the Drawings

Figure 1 : Coloured and shaped cooked quinoa as substrate

Figure 2: Fermented substrate

Figure 3: Fermented substrate

Figure 4: Pre-cooked fermented substrate

Figure 5: Pre-cooked fermented substrate (side view)

Figure 6: Cooked and served result

Figure 7: Cooked and served result

Figure 8 to Figure 14 show the use of other particle-sized ingredients including quinoa and soy grits to make the burger.

Figure 8: Cooked quinoa as substrate Figure 9: Soy grit as substrate

Figure 10: Cooked quinoa mixed with soy grit as substrate

Figure 11 : Cooked quinoa mixed with soy grit as substrate, coloured

Figure 12: Vertically-cut look of cooked and served result, disc/patty

Figure 13: Cooked quinoa mixed with soy grit as substrate, coloured and shaped

Figure 14: Vertically-cut look of cooked and served result, bite size

Detailed Description of the Invention

The inventors have investigated the production of plant-based foods having a favourable texture, flavour, aroma and/or appearance. The texture, flavour, aroma and/or appearance are typically meat-like.

The inventors have surprisingly identified that meat analogue foods with favourable organoleptic properties can be produced from particulate plant material such as beans, seeds, grains, legumes or the like, without the need for additives such as binding or gelling agents or for artificial processes such as gelatinisation. This observation led to the realisation that these benefits can be achieved by solid-state fermentation of granular non-meat edible material, not limited only to beans, seeds, grains, legumes or the like.

A particular benefit of the present invention is that the fermentation of the particulate material results in a food having a favourable texture and appearance without the need for additives such as binding agents or gelling agents, or extensive processing. Therefore, the food is entirely natural and minimally processed. In some embodiments, the food of the invention consists of ingredients that do not include binding agents or gelling agents.

The particulate material used in the invention is typically particulate vegetable material. Suitable particulate vegetable materials are beans, seeds, grains or legumes. Mechanically processed versions of vegetable materials may also be used, for example chopped, ground, milled or crushed material. Accordingly, the vegetable material can be any part of a plant that is chopped, ground, milled, crushed, grated powdered, grated, granulated or otherwise broken down to form suitable particles or granules according to the invention. While the vegetable material is typically seeds, beans, seeds, grains, pulses or legumes that may or may not be mechanically processed for use in the present invention, the use of mechanically processed flowers, fruits, stems, nuts, leaves, pods, or roots is also provided. A typical example of a mechanically-processed vegetable material is flour.

The particulate vegetable material may typically comprise one or more of quinoa seeds, soy grits or soy flour. Soy grits are known in the art as coarse ground, cleaned, toasted defatted whole soy beans. As shown in the Examples below, particularly advantageous embodiments contain approximately equal parts quinoa and soy grits, with flavouring provided by yeast extract.

In further embodiments, the particulate vegetable material is or comprises one or more of chickpeas, lentils, white beans, black beans, broad beans, black gram, green gram, yambeans, velvet beans, rice bran, barley, pigeon peas, quinoa, oats, millet, cowpeas, koro benguk (Mucuna pruriens), buckwheat kernels, red sorghum, wheat, fava beans, peas, koro kratok bean {Phaseolus lunatus), jack bean (Canavalia enisformis), okara (filtration residue of soymilk production), finger millet (Eleusine coracana), cottonseed kernels and corn grits.

Although especially favourable results have been observed in the Examples with particulate vegetable materials such as seeds, grits and flour, similar benefits may be obtained by fermenting a particulate material that comprises vegetable material and one or more other non-meat products. Typically the vegetable component of that material is greater than 50wt% of the ingredients as added, with the remainder being a non-vegetable non-meat component(s). The non-meat components may be dairy products such as eggs and/or milk, or a fraction thereof such as egg white, egg yolk or skimmed milk powder. An example of a material that comprises vegetable material and other non-meat materials is pasta, which typically comprises wheat flour and eggs. Another example of a material that comprises vegetable material and other non-meat materials is noodles. Noodles can be made with wheat flour and water. Egg noodles comprise wheat flour, eggs and water, while rice noodles are typically made with rice flour, water and optionally tapioca starch. Accordingly, pasta and noodles contain a suitable portion of vegetable material. Particulate or granular versions of the pasta and/or noodles can be fermented according to the invention. The pasta or noodles may be produced in particulate form, or may be chopped, ground, milled, crushed, grated powdered, grated, granulated or otherwise broken down to form suitable particles or granules according to the invention. The particles of pasta or noodles typically have an average diameter of about 0.5mm to about 4mm, although larger or smaller sizes may be suitable such as 0.1mm to 10mm. As above, the average diameter is typically assessed as the D4,3 mean diameter.

Some pastas and noodles can be made entirely from plant-based ingredients, and can be used as particulate material according to the invention.

In certain embodiments, the particulate vegetable material (or material comprising the vegetable material such as pasta or noodles) forms the majority of the food product of the invention. The particulate vegetable material typically provides at least 80wt% or at least 90wt% of all ingredients used in the manufacturing process. The particulate material typically comprises at least two different materials, for example soy grits and quinoa. When two or more particulate materials are used, they are typically included in approximately equal parts.

In one embodiment, the meat analogue product has a meat-like flavour, i.e. it tastes like meat. This typically includes an umami flavour. This flavour may be provided by yeast extract, yeast flakes, or dehydrated mushroom powder, among other umami flavourings.

The meat analogue food of the invention may resemble, or be characterised as, a meat product such as a burger, patty, sausage, steak, or the like. The food may resemble, or be characterised as, a particular cut of meat, for example a chop, steak or wing. The food may be shaped into a geometric shape such as a block, disc, tube, cube, rectangle or similar. Such shapes may be aesthetically attractive or may be convenient for storage, packaging, transport or for use at large scale e.g. in catering.

In some embodiments, the food may resemble, or be characterised as, a particular cut of meat, for example a chop, steak or wing. The food may further be used as an ingredient in other foods, for example as the primary protein content of the food or to replace the traditional meat component of a dish. The food of the invention can, in certain embodiments, be used as an ingredient in a pie, pudding, haggis, pasty, patty, curry, stew, casserole, lasagne, chow mein, burrito, taco, or the like. The favourable texture of the food of the invention makes it suitable for such uses.

Various features of the described invention relate to the combination of (i) the particulate material, for example selecting beans, grains, seeds, legumes or the like with an average particle size that allows the formation of meat-like textures after fermentation; (ii) the method steps and their order, in particular the duration and temperature of the soaking, cooking, inoculating, and fermenting steps; (iii) the type of fermentation culture used.

In certain aspects, the present invention provides a method and a system for creating a food material that has meat-like texture, flavour, and aroma profiles by fermenting size-specified grain, legume, or bean particles using food-safe mycelium-promoting organisms e.g. Rhizopus spp. Some embodiments of the invention generally comprise or consist of methods for soaking, cooking, pulverising, inoculating, fermenting, and seasoning the bean, grain, and/or legume substrates.

Methods are described to produce food products with meat-like sensory and organoleptic profiles through: a. Combinations of soaking, cooking, drying, particle-sizing, mixing, inoculating, packaging, incubating, shaping, and seasoning steps. b. Combinations of substrate, inoculants, and fermentation settings c. The orders of the steps above More particularly, certain embodiments of the invention relate to a method and system for soaking, cooking, pulverising, inoculating, fermenting, and/or seasoning the particulate material to produce compact food materials that have texture, taste, and aroma profiles that resemble meat products. A general and non-limiting process according to the invention is summarised in Table 1 , below. One or more of these steps can be omitted, and one or more steps that are not in this table can be added, as will be apparent to the skilled person. Each step can be varied within practical constraints, as described herein and as will be apparent to the skilled person. Table 1

★Heating 2 and Heating 3 steps are optional. Commercialised product(s) may typically be sold after either Heating 2 or Heating 3

In one embodiment, the particulate material comprises equal parts of quinoa and soy grits. Each may be present at 35wt% or more, or 40wt% or more, of the total weight of all ingredients. Typically, the quinoa and soy grits total no more than 95wt% of all ingredients.

One exemplary pre-incubation product comprises around 40wt% to around 45wt% each of quinoa and soy grits to a total of around 80wt% to about 90wt% of all ingredients. In another example, each of the quinoa and soy grits may be present at around 42wt%, around 43wt% or 44wt% of the total weight on ingredients, to a total of around 84%, 86wt% or 88wt% of all ingredients in the pre-incubation product. The wt% amounts in the final cooked product may be reduced slightly (for example by 1wt%, 2wt%, 5wt% or up to 10wt%, typically no more than 5wt%, of the values provided) by the presence of any additional flavours, colours, marinades and/or oil that can optionally be incorporated into the product post-incubation, for example in a deep-frying step. Accordingly, in some embodiments the meat analogue food (after cooking) comprises at least 70wt% of particulate vegetable material, for example around 35wt% each of two materials such as quinoa and soy grits. In some embodiments the meat analogue food (after cooking) comprises at least 80wt% of particulate vegetable material, for example around 40wt% each of two materials such as quinoa and soy grits.

In these typical embodiments, beetroot juice or beetroot concentrate is a typical colouring and is included at 2wt% or more, 3wt% or more, or 4wt% or more, for example around 6wt% of the pre-incubation product. Vinegar such as cider vinegar can be included as a flavouring, added at 2wt% or more, or 3wt% or more, for example at least 4wt% and typically around 4.5wt% of all ingredients. At least 0.1 wt% of yeast extract, typically at least 0.25wt% yeast extract and most typically at least around 0.5wt% e.g. about 0.7wt% yeast extract can be included. As an alternative to the yeast extract, yeast flakes can be included at 0.5wt% or more, for example at least 1wt% or around 1 ,5wt%, or more. Caramelised sugar at 0.25wt% or more, 0.5wt% or more, typically around 1wt%, may be included. The caramelised sugar may optionally be in place of an equivalent amount of beetroot juice, for example 5wt% beetroot juice and 1wt% caramelised sugar instead of 6wt% beetroot juice.

In these typical embodiments, the starter culture (mycelium-producing fungus) is a combination of Rhizopus oligosporus:Rhizopus oryzae (4:1).

The key processing steps of these typical embodiments are:

Boiling:

Quinoa boiled 10 min

Soy grits boiled 30 min

Fermentation:

19 hours: 12 hours 37°C, 7 hours 30°C

Or

30 hours at 32°C

Heating:

Short deep-frying after fermentation (180°C, 15 sec)

As shown in the Examples below, these formulations and processing steps result in particularly advantageous foods with beneficial organoleptic properties.

The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well as the singular forms, unless the context clearly indicates otherwise.

The terms “comprising,” “having,” “including,” and “containing” are to be construed as open- ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Where appropriate, the open-ended terms such as “comprising” may be replaced with the closed-ended term “consisting of’ when a narrower definition is required.

Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein.

All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one having ordinary skill in the art to which this invention belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

In describing the invention, it will be understood that a number of techniques and steps are disclosed. Each of these has individual benefit and each can also be used in conjunction with one or more, or in some cases all, of the other disclosed techniques. Accordingly, for the sake of clarity, this description will refrain from repeating every possible combination of the individual steps in an unnecessary fashion. Nevertheless, the specification and claims should be read with the understanding that such combinations are entirely within the scope of the invention and the claims.

New methods for creating a food are discussed herein. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be evident, however, to one skilled in the art that the present invention may be practiced without these specific details.

The present disclosure is to be considered as an exemplification of the invention, and is not intended to limit the invention to the specific embodiments illustrated by the figures, description and Examples below.

All citations and referenced documents are incorporated by reference in their entirety, as if each individual disclosure had been separately and expressly incorporated.

Examples

A detailed investigation into the production of textured food products using various plant materials, natural flavourings and natural colourings was carried out, as summarised in Table 2 below. Each of these pre-incubation compositions is provided as a separate embodiment of the invention, along with combinations of features from different compositions. One or more ingredients from each exemplified composition can optionally be omitted or substituted for an equivalent. Table 3 then shows an exemplary formulation for the pre-incubation product, which provides favourable organoleptic results.

Table 4 shows exemplary process steps used to process the product of Table 2 or 3. One or more of these process steps can optionally be omitted or substituted for an equivalent. Table 2: Example of formulation iteration

Table 3: Example of formulation (pre-incubation)

Table 4: Associated process steps

Additional experiments are carried out as follows:

1. Vary Substrate: a. different ratios of quinoa and soybeans b. Cereals c. Flours

2. Vary Colouring agent: a. Beet concentrate b. Caramelised sugar

3. Include other food additives: a. Lactic acid b. Vinegar

Claims

CLAIMS:

1. A method of making a plant-based meat analogue food, comprising the steps of:

(b) drying the boiled particulate vegetable material;

(d) incubating the shaped product of step (c) at around 25°C to around 40°C for at least 12 hours; and

(e) cooking the incubated product to make the plant-based meat analogue food.

2. A method according to claim 1, further comprising:

(f) seasoning the cooked product; and/or

(g) pasteurising the cooked product; and/or wherein colouring and/or flavouring is added to the particulate vegetable material, before or during step (a), between step (a) and step (b), during step (b), between step (b) and step (c), or during step (c).

3. A method according to claim 1 or claim 2, wherein the particulate vegetable material in step (a) comprises beans, seeds, grains or legumes, or a mechanically-processed version thereof, and/or forms at least 80wt% or at least 90wt% of all ingredients.

4. A method according to claim 3, wherein the particulate vegetable material comprises one or more of quinoa seeds, soy grits or soy flour.

5. A method according to claim 4, wherein the particulate vegetable material comprises approximately equal parts of quinoa and soy grits, optionally wherein each is at least 40wt% or at least 42.5wt% of the total ingredients.

6. A method according to any preceding claim, wherein the inoculated fungus in step (c) comprises Rhizopus spp, optionally selected from Rhizopus oligosporus, Rhizopus oryzae, and/or Rhizopus delemar, and optionally Rhizopus oligosporus: hizopus oryzae 4:1.

7. A method according to any preceding claim, wherein:

- step (b) further comprises mixing the ingredients and/or adding one or more colourings or flavourings, optionally natural plant-derived colourings or flavourings, optionally selected from one or more of cider vinegar, lactic acid, beetroot juice, beet concentrate, yeast extract, yeast flakes, and liquid caramelized sugar; and/or

- step (c) comprises the inoculation of 1 E+5 to 1 E+8 CFU of fungus inoculant per 100 g of total ingredients; and/or

- the inoculated fungus in step (c) comprises non-fungal microbes; and/or

- step (d) comprises: incubation at about 30°C to about 37°C for 18 to 72 hours, optionally with aeration, optionally wherein the incubation is carried out at a first temperature in this range for a period followed by reducing the incubating to a second temperature for at least two hours; and/or

- step (e) comprises a temperature of at least 100°C for at least 15 seconds, or at least 150°C for between 15 and 500 seconds, or around 180°C for around 15 seconds.

8. A method according to any preceding claim, wherein step (b) comprises shaping the product into a burger, patty, sausage or steak.

9. A method according to any preceding claim, comprising the step of packaging the resulting product.

10. A method according to any preceding claim, further comprising the step of heating the product immediately prior to consumption.

11. A plant-based meat analogue food obtained or obtainable by the method of any preceding claim.

12. A plant-based meat analogue food comprising at least 70wt% fungus-fermented particulate vegetable material having an average diameter of about 0.5mm to about 4mm, wherein the food has a defined shape.

13. A plant based meat analogue food according to claim 12, which is a burger, patty or sausage.

14. A plant based meat analogue food according to claim 12 or claim 13, wherein: the particulate vegetable material is as defined in any of claims 3 to 5; the fungus is as defined in claim 6.

15. A plant-based meat analogue food according to any of claims 12 to 14, comprising one or more natural colourings or flavourings, optionally plant-based colourings or flavourings, optionally one or more of lactic acid, cider vinegar, beetroot juice, yeast extract, yeast flakes, and liquid caramelized sugar.

16. A plant-based material according to any of claims 12 to 15, wherein the particulate vegetable material comprises equal parts quinoa and soy grits totalling between 80wt% and 95wt% of all ingredients, and comprising yeast extract at 0.1 wt% to 1wt% of all ingredients, and optionally comprising liquid caramelised sugar at between 0.5wt% and 1.5wt% of all ingredients.

17. A kit for making a plant-based meat analogue food, optionally according to any of claims 11 to 16, comprising separately packaged: (i) particulate vegetable material having an average diameter of about 0.5mm to about 4mm; (ii) fungus; and (iii) optionally one or more colourings or flavourings; and instructions for use.

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