WO2023131380A1

WO2023131380A1 - Method for producing a plant-based moulded protein item, which can be cooked by heat treatment, such as baking, deep frying, grilling or the like, and plant-based protein end-product produced therefrom by cooking

Info

Publication number: WO2023131380A1
Application number: PCT/DE2023/100007
Authority: WO
Inventors: Friedrich Meuser; Felix Bischoff; Thomas Roick; Vincent VIDA
Original assignee: Terramark Markencreation Gmbh
Priority date: 2022-01-07
Filing date: 2023-01-06
Publication date: 2023-07-13

Abstract

The invention relates to a method for producing a plant-based moulded protein item, which can be cooked by heat treatment, such as baking, deep frying or the like, in the case of which firstly a dry wheat-gluten pre-product is processed, together with a dry dietary-fibre pre-product which preferably originates from a secondary stream of the wheat-starch extraction process or of the reprocessing of beer grain from barley malt, also in the form of a fibre-containing dry protein product, with water to form a plastically deformable dough. The dough is brought into the desired shape, such as a small ball, patty or the like, characterised in that vital wheat gluten is used as the dry wheat-gluten pre-product and a fine-fibre product having sharp-edged fine-fibre particles is used as the dry dietary-fibre pre-product. Preferably the fine-fibre-containing products according to the invention are used for this purpose. The dough pieces are then cooked by deep frying, baking or the like to form the end products. The end products can be protein products (small balls) or products enriched with protein (bread).

Description

Terramark Markencreation GmbH, Wachmannstrasse 1B, 28209 Bremen

A process for producing a vegetable protein preform which can be cooked by heat treatment such as baking, frying, roasting or the like, and a finished vegetable protein product produced therefrom by cooking

The invention relates to a method for producing a vegetable protein preform that can be cooked by thermal treatment, such as baking, frying, roasting or the like, in which a wheat gluten dry precursor is mixed with a dietary fiber dry precursor to form a combination dry precursor, which is mixed with water to form a plastic malleable dough is prepared and shaped into the desired shape, such as a boulette, meatball or the like, from which a ready-to-eat vegetable protein end product is produced by cooking, such as baking, frying, roasting or the like, or the combination dry intermediate product in such a process for the production of bread and protein-enriched end products.

DE-PS 30 39 430 already discloses a process for obtaining fiber-rich and protein-rich fractions from brewer's spent grains, in which particles of different sizes are produced from wet spent grains by mill-drying and these are then separated by sieving. During the drying process, the wet spent grains are crushed into coarse shell fragments (“dietary fiber fraction”) and fine protein particles (“protein fraction”) in a stream of hot air during the sudden drying process. The ground-dried mass flow is fractionated by sieving into fractions of different relative ingredient composition. The fractions are re-comminuted to the extent that this is necessary for the application in accordance with the patent. The targeted application of the manufacturing process results in the fine-fiber-containing draff protein products and the draff fine-fiber products. The products thus obtained

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spare blade can be used in different ways for nutritional purposes, eg for the production of baked goods.

In this regard, it should be noted that in the dewatered spent grains, the spent grain proteins are present as an amorphous mass. They are separated from the fibrous particles accompanying them and pulverized in the drying process known as flash drying due to the sudden evaporation of water that occurs from them. The particles of the powder are water-insoluble, denatured proteins.

In contrast, the fragmentation of the glumes and grain surface layers, which are elastic when moist, takes place in a much more complex manner because of their organized cellular structure. Although the fibrous components are dried at the same time as the protein, they can only be partially comminuted to the particle size of the protein powder in the drying and comminution process, which takes place within a few seconds, due to their morphological structural characteristics and the resulting comminution properties. Therefore, the comminution of the fibrous components can be placed in a functional relationship with the comminution tool, the ultra-rotor and its structural design and mode of operation. This relationship can be used to optimize the yield of protein product and its composition of comminuted, fibrous components in terms of quantity, size and shape of the particles by carrying out test plans.

The possibilities given for this are to be explained here using three grain-drying protein products, all three of which had gone through the same manufacturing process and in which a sieve mesh size of 200 μm (products A and B) and 150 μm (product C) was screened off. One of the two products was additionally post-shredded using the same ultrarotor in its application as a sieve-less impact crushing machine.

Product C is used to compare the comminution effect with the two first-mentioned products with regard to the morphological structural features of the protein particles and the fibrous particles, which can be seen in the associated distribution density curve and were made visible with light microscopic and scanning electron microscopic (SEM) images.

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spare blade The distribution density curves of the particles of products A and B show that there was a significant shift in particle size towards smaller particles as a result of the post-crushing (Figures 1A and 1B). The shift ranged from a fraction of particle sizes < 100 pm from 62.4% (Figure 1A) (product A) to 96.3% (Figure 1B) (product B), with all particles < 200 pm in this second case were, while in the first case 5.2% were larger.

The comparison of the distribution density of the particles of products A and B with product C (Figure 1C) shows that by reducing the sieve mesh size under otherwise constant conditions, larger particles, which must have been the more difficult to comminute under the process conditions, remained in the sieve residue. Consequently, the relations shifted both in the distribution density of the fractions and in the yield of the products and the relative composition of the main ingredients characterizing them, the protein and dietary fibers.

The distribution density curve for product C indicates that only 56.8% of the particles were <100 pm and 10% were >200 pm. The protein content of the spent grains protein product was 46.9%, practically the same as that in Sample A. The yield of protein from the grains in the grains protein product of sample C was 50%, however, significantly lower than that realized with the grains protein product of sample A of 69.1%.

The shift in the distribution density curve reveals a wide range in the effect of comminution on the formation of the number of fibrous particles and thus the increase in their surface area and formation of their morphological shape. The adjustment of these characteristics to the fibrous products serves to optimize their function in producing the desired protein end products.

The husk and grain surface layer fractions that occur as sieve residues when sieving the ground-dried spent grains must also be crushed to particle sizes < 200 μm in order to be used for their intended purpose. This can advantageously be done in the same way as described above for the spent grains protein product or the spent grains fine fiber product. However, the comminution result is different from that of the spent grains protein product in that the fine fiber product lacks the finely chopped (powdered) portion of the spent grains protein. The draff fine fiber product (Figure 1D) corresponds more closely to this Fine wheat fiber product (Figure iE), because in both the protein content of the starting raw material, the barley malt and the wheat flour, was removed due to the process (draff processing and starch production). In both cases it is the endosperm protein, that of barley and that of wheat.

Figure 1D shows the distribution density for such an intermediate product selected as an example for the production of a spent grains fine fiber product. The intermediate product came from the production of a low-protein sieve fraction of the husks and the shell components in the spent grains and had a protein content of 10.9%. This means that this fraction contained practically no protein from the barley endosperm. The mass of all particles under the curve can therefore largely be assigned to the fiber fraction.

The course of the curve indicates uniform particle size reduction, which is caused by the cellular morphological structural characteristics of the husks and shell parts. The particles were crushed (broken up) along the cell wall structures, as shown in the micrographs below (Figure 2B).

The proportion of particles > 200-400 μm of 10% also shows that the material to be comminuted with the present degree of comminution did not yet meet the requirement of being able to be used for the purpose intended by the patent. However, the result is essential for explaining the inventive concept.

Finally, with regard to the intended use of the wheat fiber product made from bran particles, it must be stated that this assumes the particle properties required for this through the process developed for its production (cf. p. x). However, the size of the particles and their shape are already largely predetermined by their origin from the wheat flour, because it is technically unavoidable in the production of wheat flour that a small proportion of the bran produced in the process passes into the flour. Since all flour particles must be <200 μm, all bran particles present in the flour fulfill the essential prerequisite for their later intended use.

During the refining of the starch, the bran particles are separated from the much smaller starch grains by wet sieving and, using the process developed for this purpose, are separated into the

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spare sheetsj Refined wheat fiber product. The mill-drying with the ultra-rotor used to dry the product serves to dry and pulverize the fine wheat fiber product.

The light microscopic images of such a fine wheat fiber product (Figure 2C) clearly show the cellular structure of the bran particles and their comminution in the longitudinal and transverse direction of their morphological arrangement in the cell layers. As a result of this arrangement, the cell layers were mainly crushed into rectangular bodies that had rectangular fracture edges (with edge angles of 90° to 100°). The particles consisted of one or more layers of cells. The particle size derived from the microscopic magnification of 200 ranged up to 250×125×50 μm for the single-layer particles (L×W×H).

This three-dimensional structure of the particles fulfills the requirement that when the wheat fine fiber product is used according to the invention, the cooking dough piece cannot puff up because the broken edges of the particles act like tear-off edges. This results from the all-round, elastic stretching of the vital wheat gluten over the entire surface of the solid, non-stretchable particle, which, together with the escape of water vapor from the gluten, results in relative movements on the particle surface. This leads to the formation and transport of small vapor bubbles at the sharp edges of the particles due to the effect of the same as tear-off edges. Due to the large number of particles and their size and shape, on which the total surface area of the particles in terms of an effective area depends, these are discharged over the surface of the dough piece from the inside to the outside.

This description of the function of the fine fiber particles for the cooking of the dough pieces also applies to the spent grain fine fibers, both in their form as a component of the spent grain protein product(s) and the spent grain fine fiber product (e). It is obvious that this applies in principle to all edible fine fibers with comparable structural properties.

The light micrographs of the particles of the intermediate product for the spent grains fine fiber fraction (Figure 2B) show that they have a similar structure to the previously shown wheat fine fiber particles (Figure 2C). However, the particles are

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spare blade sometimes somewhat larger because the post-comminution process was not yet brought to the optimum level necessary for the application for reasons of presentation in this patent specification.

Particles from the aleurone layer of barley are conspicuously frequent compared to particles from wheat bran. Instead of a linear course, these particles show a jagged course for the break edges, which apparently resulted from the irregular arrangement of the aleurone cells. Many aleurone cells were open and empty, so that the resultant rough surface structure and increase in surface area favors the execution of the cooking process associated with evaporation of water according to the invention.

The scanning electron micrographs (SEM) of the intermediate particles (Figure 2D and 2E) show the wide range of different sizes and shapes of the dry particles. This spectrum becomes narrower with increasing degree of comminution with regard to the size and shape of the particles and at the same time the number and the total surface area of the particles increase. The recordings show that there were practically no endosperm protein particles among the fiber particles (Figure 2E) and consequently the protein analytically determined in the fiber product was assigned to the aleurone protein.

The relative composition of protein particles and fine fiber particles in the SEM of the spent grain protein product, which was also not brought to the technical optimum for the aforementioned reason, was correspondingly reversed (Figure 2D). About a quarter of the product consisted of roughage. Therefore, the ratio of the mass of fiber particles and protein particles was estimated at about 1:3. In addition to setting the particle size of the fine fibers in the spent grains protein product, the setting of this ratio is important for optimizing the cooking of a dough piece consisting of vital wheat gluten and the spent grains protein product.

Exemplary embodiments of the invention are explained in detail below with reference to the tables and figures.

It shows: Fig. 1 ("Figure 1"):

The distribution density of the particle sizes of (A) spent grain protein product (Product A), ground on a 5-stage Ultra-Rotor system and sieved over 200 pm;

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(B) spent grain protein product (Product B), ground on a 7-stage Ultra-Rotor system with additional post-grinding;

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(C) Grain protein product (Product C), ground on a 5-stage Ultra-Rotor system and sieved above 150pm;

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(D) Spent grain fine fiber product, ground on a 5-stage Ultra-Rotor plant;

figure 5

(E) Wheat bran, ground on a 5-stage Ultra-Rotor system and sieved over 500pm;

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(F) Wheat protein, dried in a ring dryer with additional post-grinding;

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Light micrographs of (A) wheat A starch;

8 Optical micrograph of spent grain fine fiber:

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Light micrograph of (C) wheat fine fiber;

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Scanning electron micrographs of the grain protein product;

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Scanning electron micrographs of the spent grain product;

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Ready-to-eat boulette, cooked by frying a piece of dough produced according to the method according to the invention;

figure 13

Section through the boulette of Fig. 12:

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Boulette made by frying a dough piece made according to the invention from wet gluten and spent grain protein product (unseasoned pan-frying on oil); and

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Section through the Boulette according to Fig. 14.

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spare blade The products used in Table 1 below for the production of the protein end product show their relevant composition of ingredients, among which their content of fine fibers, which was analytically determined as the content of insoluble dietary fiber, and protein content together with the distribution density and the size of the particles are of outstanding importance Are important for carrying out the method according to the invention.

Table 1: Average dry matter composition of the ingredients of the products required for the manufacture of the protein end products

. . .. . ^ff

Fiber (%) ²⁾ nc 66 69.2 23.4

Protein (%) 75.0 16 16.7 48

Fat (%) 5.0 2.5 6.8 13.5

Ash (%) 1.0 2.5 4.5 3.3

Table 2: Yield of protein product from the spent grains and yield of protein from the same in the protein product and its protein content, shown as a function of variable process parameters selected as examples

,, . . - _ _x . . _x setting

Variable process parameters unit A B C

Water content of spent grains [%] 66.8 66.2 71.5

Rotor speed [Hz] 40 30 40

Mesh size of the sieve [pm] 200 200 150

. , , , , Grain protein product

Yield and protein content

A B C

Protein product from spent grains [%TS] 37.0 17.7 27.4

Protein from the spent grains in the protein product [%TS] 69.1 39.0 50.0

Protein content of the protein product [%TS] 46.4 51.7 46.9

Many attempts have already been made to produce batters or the like with a high wheat gluten content, but there is a problem, particularly when it comes to products based on vital wheat gluten, that processed molded products made of such material when the dough rises or bloat during cooking and thus neither the Outer shape nor the inner structure of corresponding prefabricated products during the cooking process, such as baking or deep-frying, can be retained.

The object of the invention is to provide a method of the generic type in which, even when vital wheat gluten is used to prepare a wheat gluten dough for the production of plastically formable vegetable protein end products, the corresponding dough pieces can be produced effortlessly and in a shape-retaining manner by plastic deformation of the corresponding pieces of dough can be prepared appropriately and the shape and internal structure of the dough pieces are retained during cooking, even when using vital wheat gluten to produce wheat gluten dough, and neither water vapor bubbles form nor a rubbery chewing impression of cooked wheat gluten dough in the desired protein end products.

According to the invention, this object is achieved in a further development of the generic method in that vital wheat gluten is used as the dry wheat gluten precursor and a fine fiber product with sharp-edged fine fiber particles is used as the dry roughage precursor product, in which the fine fiber particles, based on the particle size determination used (CILAS grain size measurement, wet) at least 95 vol % are smaller than 200 μm and at least 60% smaller than 100 μm and the corner angle of the essentially rectangular-plate-shaped fine fiber particles is between 90° and 100°, i.e. in the acute to rectangular range and their cell wall fragments have cut edges which having a thickness in the range 1-2 µm, averaging (measured) 1.2 µm.

A particular embodiment of the method according to the invention provides that the fine fiber material contains fine fibers originating from a side stream of wheat starch production, the diameter of which is at least 60% below 100 μm and at most 8% above 20 μm. It can be provided that the proportion of fine fibers originating from a side stream of wheat starch production in the fine fiber product is 100%.

It can be provided that the fine fiber product comes exclusively from a side stream of wheat starch production.

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spare blade In a further development of the method according to the invention, it can also be provided that the required fine-fiber-containing product comes partly from the described production of fine-fiber-containing draff protein and draff fine-fiber products from brewer’s spent grains and that these products meet the particle structure requirements necessary for carrying out the method according to the invention.

A special embodiment provides that the variability of the separation efficiency and the degree of comminution of the husk portion is used to produce analytically differently composed draff protein and draff fine fiber products, the distinguishing feature of which is the described comminution characteristics of the fibrous material.

A further particular embodiment provides for structuring the particle size reduction of the husk portion by grinding and sieving technology while maintaining the main feature, a particle size <200 μm.

For the production of the protein end products, the procedure according to the invention can be such that the weight ratio of the vital wheat gluten and the fine fiber product(s) (also as spent grain protein product(s)) in the dough is 2:1 to 10:1.

According to one embodiment of the invention, it is particularly preferred that the fine fiber product is used in powder form.

Furthermore, it can be provided that the proportion of spent grains protein product in the mixture with dry wheat gluten precursor is 10-70%, preferably 50%.

The invention also proposes that the possibly several different fine fiber products are first premixed in dry form and only then mixed with water and the vital wheat gluten and processed into a dough.

According to the invention, it can also be provided that the wet gluten produced in the course of the wheat starch production process is first combined directly with one or more of the spent grain protein products by mixing in an intensive mixer and the resulting highly viscous suspension is then pulverized by grinding and drying in an ultra-rotor.

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replacement sheet The invention also proposes, if necessary, that the dough to be produced for the protein preform is prepared with spices, herbs, etc. according to taste in the sense of the recipe design for a boulette.

The invention also relates to a combination dry intermediate product, suitable for use according to the method according to one of the preceding claims, which contains vital wheat gluten as the dried wheat gluten intermediate and a fine fiber product with sharp-edged fine fiber particles as the dry roughage intermediate product, in which at least 95% of the fine fiber particles are smaller in size than 100 μm and 0% have a size of more than 200 μm and the corner angle of the essentially rectangular plate-shaped fine fiber particles is between 90° and 100°, ie in the acute to rectangular range.

The invention also relates to the use of such a combination dry precursor for carrying out the method according to the invention and for the production of bread.

The subject matter of the invention is also a protein end product, such as a meatball or the like, which can be produced by cooking, such as baking, deep-frying, roasting or the like, of a vegetable protein preform produced by the process according to the invention.

The subject matter of the invention is also a bread end product that can be produced by baking a bread dough that has been produced using a combination intermediate product according to the invention.

The invention thus also relates to a process for producing a plastically formable, vegetable protein product by mixing water with vital wheat gluten and fine-fiber-containing by-products from the production of wheat starch or the production of beer with barley malt, with the resulting dough-like mass of the gluten containing its viscoelastic Properties developed, but it largely loses its ability to enclose gases in the form of bubbles in the two-dimensionally stretchable adhesive protein films. The idea of the invention is essentially based on this, with which the prerequisite is created for dividing the dough-like mass into pieces and being able to shape it plastically. Thereafter

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spare blade the shaped pieces can be cooked into end products by frying, roasting, baking or other thermal cooking methods while retaining their shape and internal structural features. After cooking, there is an end product, for example in the form of a boulette, which is a high-quality food with appealing sensory properties due to its high protein content.

The vegetable protein pellet obtainable according to the invention can be processed into a desired edible, tasty food by cooking, such as baking, frying, roasting or the like, much like a minced meat boulette. The simplicity of producing the protein shaped product or product and its ready-to-eat preparation compared to other comparable end products from other vegetable protein products, which primarily require complex mechanical-thermal processes for texturing the proteins, including extrusion processes in particular, are characteristic of the invention.

With regard to the invention, it should also be pointed out that the native glue, when mixed and kneaded with water, develops viscoelastic properties which are unique among all other vegetable proteins. These properties of the native gluten in the flour are particularly advantageous when baking bread. It is the viscoelasticity and the gas holding capacity of the wheat gluten on which the volume expansion of doughs based on wheat flour is based and from which the final formation of the bread volume after the fixing of the dough ingredients, mainly the gluten proteins and the starch, emerges. In the case of bread baking, the viscoelasticity and gas formation limit the volume expansion in a free play of forces between the internal gas pressure in the pores and the tensile stress in the gas-impermeable pore walls, which emanates from the viscoelasticity of the glue.

The invention is based on the surprising finding that it is possible to influence the free play of forces between the internal gas pressure in the pores of the dough and the tensile stress in the gas-impermeable pore walls, which emanates from the viscoelasticity of the glue, in such a way that the glue basically still contains gas remains, but the inclusion of water vapor bubbles in the adhesive films during cooking is specifically limited. This is achieved by the fact that the sharp-edged fine fiber particles that are mixed with the vital wheat gluten according to the invention, so to speak “cut open” the pores of the wheat gluten if they are closed, so that no or only small amounts of

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spare blade Gas or water vapor can be trapped. This reliably avoids any kind of chewing gum-like chewing impression, which otherwise occurs with cooked wheat gluten dough, so that the boulettes, meatballs or the like produced by cooking the molded products according to the invention have the consistency and chewing properties that the consumer expects from meat-containing equivalents to such products, for example from boulettes or meatballs made from minced meat, and also expects this with plant-based products.

In the method according to the invention, the piece of dough (dough) is plastically deformable, but the gas holding capacity of the shaped piece of dough during cooking is limited to an allowable minimum. This prevents the dough piece from bloating due to the water evaporation occurring during cooking, as a result of which the outer shape and also the inner structure of the end product could otherwise not be brought into the desired edible form. The invention is based on the inventive use of the fact that vital wheat gluten can be used as a solid component, although this has a much greater water-binding capacity than wheat flour as a basic material in breadmaking. In this context it should be noted that 100 g vital wheat gluten binds approx. 200 g water, while 100 g wheat flour only absorbs approx. 60 g water when baking bread. If dough balls are made from such shaped pieces by mixing, kneading and shaping, then the sticky dough ball weighs 300 g and the flour dough ball 160 g. If these balls of dough are loosened by fermentation with yeast through the formation of carbon dioxide, the wheat dough ball takes on a volume of about 600 ml, while the volume of the sticky dough ball becomes about twice as large.

The unloosened sticky dough ball is highly elastic but only slightly plastic. It can therefore not be plastically deformed to the extent required for the application. In contrast, the flour dough ball discussed above is far less elastic, but plastic, so that it can be easily plastically deformed. In this way, the piece of dough can be given a stable shape that is only broken up by the formation of gas bubbles in it that accompanies fermentation. As a result, the piece of dough becomes porous and the elastic properties, which depend on its gluten content, emerge.

The starch content in the flour acts as an inert solid component, making the dough easily malleable as long as it is not saturated by the formation of carbon dioxide

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spare blade fermentation is bloated. The fixing of this freely forming form by baking is a very complex process for which the previously inert starch is of crucial importance. The starch is thermally plasticized by water absorption during baking. The resulting plastic mass contributes significantly to the consolidation of the inner porous structure of the bread. The result of these processes depends largely on the ratio of wet gluten mass to the dry matter fraction of the starch in the flour. This ratio is about 0.3 - 0.4. In other words, the dry mass of starch in the dough is about three times greater than the wet gluten mass.

If the unloosened ball of gluten is merely boiled or baked, the gluten will denature into a resilient, gummy mass that can be cut into pieces that impart a chewing gum-like mouthfeel when eaten. When baking, the mass also puffs up irregularly in large, thick-walled bubbles. The denaturation of the gluten proteins that occurs during baking with the release of water from the gluten dough can be observed well in such an experiment. A corresponding release of water also occurs when baking bread. However, the water is not completely released as a result of the evaporation that occurs, but is absorbed by the starch to plasticize it. A corresponding water binding cannot take place in a dough consisting only of vegetable protein during cooking.

This exemplary consideration of the basics of the task was the starting point for its inventive solution, which makes it possible to produce a protein product from vital wheat gluten with its well-known physical and chemical properties, which, together with a ready-to-eat formulation of its composition, can be prepared by a thermal cooking process to form a ready-to-eat food can. In terms of its sensory properties, the product not only corresponds to products made from comparable other vegetable proteins, but the protein end product also has a "meat character" that is similar to that of, for example, minced meatballs or the like.

For this task, the bread crumb provided an example of how the gluten first thins out in the dough due to the increase in volume and the resulting film formation in the pore walls due to the surface area and then

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spare blade is denatured by baking. The water released by the adhesive is absorbed by the plasticizing starch. In this diluted form, the glue with its elastic properties is an ideal binding agent for the structure of the bread crumb, which together with the plasticized starch makes up the plastic-elastic strength of the crumb and its typical chewiness.

With the protein product that can be produced according to the invention, it is thus possible to achieve a comparable non-rubbery chewability of the cooked vital wheat gluten without being able to resort to starch as a medium for the formation of a gluten film with volume expansion. This problem, which was previously regarded as technically unsolvable, is achieved according to the invention by mixing vital wheat gluten either with a special fine-fiber product from wheat starch production or with a fine-fiber spent grains product made from spent grains or a fine-fiber-containing spent grains protein product.

Dry mixing of vital wheat gluten with the specified fine-fiber-containing products in measured proportions and the subsequent addition of water to this mixture, also in measured amounts, produces a dough from this mixture by mixing and kneading, in which the particles of the fine-fiber product are distributed homogeneously in the continuous dough formed from the gluten Phase, the wet glue, as water-wetted and slightly swollen solids. The surface water of the fine fiber particles and the moist surface of the wet adhesive form a separating boundary whose area corresponds to the size of the surface of the particles. Due to their distribution in the dough as well as their size and sharp-edged shape as well as their property of being able to bind water, the fine fiber particles can apparently fulfill the important functions for the formation of the protein end product if the correct mass ratios for dough production are observed.

It is a surprising finding that, if the above conditions are observed, the dough formed can be divided into plastically formable dough pieces ("bricks"), from which the protein end product with the desired stable, non-puffy shape and internal structure and the resulting non-bulky form can be obtained by frying gummy chewiness develops.

The transfer of this knowledge to the fine-fiber product made from brewer's grains, which is comparable to the fine-fiber product used, and how it is dried technically

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spare blade gentle way according to DE-PS 30 39 430 not only provides proof of the function of the fibers in the protein end product, but also leads to the advantageous teaching of the invention to use the function of the vital wheat gluten itself in the protein end product in order to protein product consisting of two different vegetable proteins.

In a preferred embodiment of the invention, it has proven to be advantageous to use the protein product also produced from spent grains (barley malt as the basis) according to DE-PS 30 39 430, because this has a high protein content and a large proportion of fine fibers due to the process. A mixing ratio of 1:1 for the mixture of the dry products, i.e. the native wheat gluten and the spent grain protein product, has proven to be a particularly preferred application. When mixing and kneading this protein product mixture with a measured amount of water, a dough is formed in which the glue forms a continuous phase as wet glue, in which the protein content of the spent grain protein product is integrated in such a way that a quasi-continuous phase is created in which the fiber particles are homogeneous distributed as wetted, slightly swollen solid bodies. The dough made from the mixed protein product can, like the dough made from the vital wheat gluten, be prepared by cooking to give the protein end product with the desired sensory properties.

In the industrial application of the invention, the wet gluten is obtained from a wheat flour dough according to the industrially customary centrifugal separation technique and, insofar as it is expedient for the various options for carrying out the method according to the invention for the production of the protein end products, to vital wheat gluten according to a flash-drying process (ring-flow drying) dried and powdered. The fine wheat fiber product is isolated from the fiber fraction that occurs when the A-starch milk is cleaned using jet sieves. For this purpose, the starch contained in this fiber fraction is enzymatically hydrolyzed to glucose. In addition, the pentosans also contained in it are partially enzymatically hydrolyzed to soluble products. This creates a decantable suspension from which the fiber fraction can be separated as a heavy phase using a decanter. The separated fiber cake is gently dried with an ultra-rotor and pulverized into a fine wheat fiber product.

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spare blade The two draff products, ie the draff fine fiber product and the draff protein product, are produced according to DE-PS 30 39 430 as co-products from brewer's draff and in accordance with the state of the art described therein.

The method according to the invention can be carried out according to the procedures described below, which are mainly aimed at exemplifying the principle according to the invention, since this alone is decisive for the aim sought. The aim is to modify the visco-elastic properties of dough made from vital wheat gluten by adding vegetable fine fiber particles in such a way that the dough becomes malleable and can be divided into pieces of a defined shape, with thermal denaturation of the native protein content directly by roasting, deep-frying or baking as well as other comparable cooking methods can be cooked to protein end products that do not leave a rubbery chewing impression when eaten and whose consistency is similar to that of meatballs made from animal proteins.

The two examples selected for this, namely once according to Figure 1 and also according to Figures 2 and 3, refer to the production of meatballs, which are of great importance in contemporary nutrition. This is evidenced by the many burger products that are mainly made on the basis of meat.

The first example provides that 75 parts of vital wheat gluten are mixed with 25 parts of fine wheat fiber to form a basic mass. Depending on taste preference, this basic mixture is mixed with various spices and other dry ingredients. The mixture can be stored before further processing. To prepare a boulette from the seasoned base, add 150 parts water to 100 parts base. From this, a dough is formed by mixing and kneading, in which the glue forms a continuous phase in which the fiber particles are embedded. The dough is divided into pieces that are formed into raw boulettes. The raw meatballs are cooked by frying. Frying can be done in two consecutive steps. In the first step, the raw boulette is pre-fried for 5-7 minutes at 150 degrees Celsius to form an intermediate product. After cooling and deep-freezing, the pre-fried boulette can be stored until the second step is carried out. In the second step, the deep-frozen meatballs are placed directly in the fryer and fried in another 5 minutes. - Freshly made

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spare blade raw meatballs are cooked in 10-12 minutes to the purely plant-based protein end products.

Figure 1 shows a ready-to-eat boulette, which has been cooked from a pre-fried, deep-frozen boulette, as a whole boulette and in a sectional view, to illustrate example 1 in Figure 2

Example 2 relates to the combined functionalization of wheat gluten with the fine-fiber-containing spent grains protein product. In this regard, the example draws attention to the process and product-related advantage, which consists in the production of a preliminary product with properties that are particularly advantageous for the production of the end product.

The preliminary product is made from the wet gluten produced in the course of the wheat starch production process, which is combined in batches in an intensive mixer with moistened spent grain protein product with simultaneous mixing and kneading to form a homogeneous dough. In the example, 20 kg of wet glue were used with 8 kg of spent grain protein product moistened with water, from which a highly viscous dough (Fig. 2) was created, which was dried and ground directly with an Ultra-Rotor to the powdered precursor without product recycling. The preliminary product contains all three products used for its production in a non-segregable solid compound in a homogeneous combination. Therefore, each individual particle has the functional properties of the entire mass. This is particularly advantageous for developing the functional properties of the protein end product, including its water-binding properties.

In Example 2, the boulette shown in Figure 3 as a whole and in Figure 4 in section was prepared from this preliminary product. For this purpose, a dough was produced from the preliminary product, as described above for the first example. 100 parts of water were added to 100 parts of precursor. The finished dough was portioned and formed into boulettes. The raw meatball was then fried in oil in a pan until done.

For the background of the procedure modified or designed according to the invention, reference is also made to the following references:

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spare blade 1. Jirmann, F., Meuser, F., Niefind, H.: Process for obtaining fiber-rich and protein-rich fractions from spent grains. DE-PS 3039430.

2. Roick, T.: Obtaining a water-soluble dietary fiber concentrate from the process water of a wheat starch factory and considering the economics of the process. Dissertation, TUB, 2009.

3. Meuser, F., Niefind, H., Köhler, F. Fischer, G.: Utilization of draff for fiber-enriched bread. Cereals, Flour and Bread 36(1982)92-97.

4. Feldheim, W., Wisker, E.: Fiber enrichment in baked goods: use of draff bread as a source of fiber in human food. Nutrition Review 30(1983)405-406.

5. Meuser, F., van Lengerich, B., Köhler, F.: Technological and nutritional aspects for the production of an extruded flat bread enriched with draff. Food Technology.i6(i983).

6. Pietsch, VI, Emin, AZ, Schuchmann, HP: Process conditions influencing wheat gluten polymerization during high moisture extrusion of meat analogue products. Journal of Food Engineering 198 (2017) 28-35.

7. Klotz, D., Schneeweiß, R., Lämmsche, S.,Stötzer, E. Suckow, P: Possibilities for improving the sensory properties of cereal bran. Mühle + Mischfuttertechnik 137 (2000) 1-5.

The features of the invention disclosed in the above description, in the drawing or the illustrations and in the claims can be essential for the realization of the invention in its various embodiments, both individually and in an appropriate combination.

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replacement sheet

Claims

Method for producing a vegetable product that can be cooked by thermal treatment, such as baking, frying or the like, in which a wheat gluten dry precursor is mixed with water together with a dietary fiber dry precursor as a combination dry precursor and then processed into a plastically deformable dough and shaped into the desired shape , such as boulette, meatball, or the like, characterized in that vital wheat gluten is used as the dry wheat gluten preliminary product and a fine fiber product with sharp-edged fine fiber particles is used as the dry roughage preliminary product, in which the fine fiber particles are based on the particle size determination used (CILAS particle size measurement, wet). at least 95 vol having a thickness in the range 1-2 µm, averaging (measured) 1.2 µm. Process according to claim 1, characterized in that the fine fiber product contains fine fibers originating from a side stream of wheat starch production, the diameter of which is at least 60% below 100 µm and at most 8% above 200 µm. Process according to claim 1 or 2, characterized in that the fine fibers in the fine fiber product originate exclusively from a side stream of wheat starch production. Method according to Claim 1 or 2, characterized in that the required fine-fiber product originates in part from the processing of spent grains into fine-fiber-containing spent grains protein products or spent grains fine-fiber products.

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replacement sheet Method according to claim 4, characterized in that the required fine fiber product (as spent grains protein product) originating from the processing of spent grains into spent grains protein products containing fine fibers or spent grains fine fiber products comes from that spent grains fraction which has the greatest protein content during processing. Method according to one of the preceding claims, characterized in that the weight ratio of the vital wheat gluten and the fine fiber product in the dough is 2:1 to 10:1. Method according to any one of the preceding claims, characterized in that the fine fiber product is used in powder form. Process according to one of Claims 4 to 7, characterized in that the proportion of the protein product originating from the processing of spent grains in the mixture with wheat gluten - dry preliminary product is 10-70%. Method according to one of the preceding claims, characterized in that the possibly several different fine fiber products are first premixed in dry form and only then are they mixed with water and the vital wheat gluten and processed into a dough. Method according to one of Claims 7 to 9, characterized in that the wet gluten obtained in the course of the wheat starch production process is first combined directly with one or more of the spent grain protein products by mixing in an intensive mixer and the resulting highly viscous suspension is then pulverized by grinding and drying in an ultra-rotor. Method according to one of the preceding claims, characterized in that the dough to be produced for the protein preform is flavored with spices, herbs etc. in the sense of the recipe design for a boulette. Combination dry precursor suitable for use according to the method according to any one of the preceding claims, which as a wheat gluten

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spare blade Dry preliminary product containing vital wheat gluten and, as a roughage dry preliminary product, a fine-fibre product with sharp-edged fine-fibre particles, in which at least 95% of the fine-fibre particles have a size of less than 100 μm and 0% have a size of more than 200 μm and the corner angle is essentially rectangular-plate-shaped Fine fiber particles between 90° and 100°, i.e. in the acute to rectangular range. Use of the combination dry precursor according to Claim 12 for carrying out the method according to one of Claims 1 to 11. Use of the combination dry precursor according to Claim 12 for the production of bread. Protein end product, such as a boulette, meatball, bread or the like, which can be produced by cooking, such as baking, deep-frying, roasting or the like, of a vegetable protein preform produced by the method according to any one of claims 1-11. Bread end product which can be produced by baking a bread dough which has been produced using a combination dry intermediate product according to claim 12.