WO2023201349A1 - Substitut de viande en couches d'origine végétale ou aux champignons et procédés de fabrication d'un tel substitut - Google Patents

Substitut de viande en couches d'origine végétale ou aux champignons et procédés de fabrication d'un tel substitut Download PDF

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Publication number
WO2023201349A1
WO2023201349A1 PCT/US2023/065795 US2023065795W WO2023201349A1 WO 2023201349 A1 WO2023201349 A1 WO 2023201349A1 US 2023065795 W US2023065795 W US 2023065795W WO 2023201349 A1 WO2023201349 A1 WO 2023201349A1
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WO
WIPO (PCT)
Prior art keywords
layers
fungi
plant
fat
layer
Prior art date
Application number
PCT/US2023/065795
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English (en)
Inventor
Julien COIFFIER
Nixon Joshua
Original Assignee
Terramino, Inc.
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 Terramino, Inc. filed Critical Terramino, Inc.
Publication of WO2023201349A1 publication Critical patent/WO2023201349A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
    • A23J3/00—Working-up of proteins for foodstuffs
    • A23J3/14—Vegetable proteins
    • A—HUMAN NECESSITIES
    • A23—FOODS OR FOODSTUFFS; TREATMENT THEREOF, NOT COVERED BY OTHER CLASSES
    • A23J—PROTEIN COMPOSITIONS FOR FOODSTUFFS; WORKING-UP PROTEINS FOR FOODSTUFFS; PHOSPHATIDE COMPOSITIONS FOR FOODSTUFFS
    • A23J3/00—Working-up of proteins for foodstuffs
    • A23J3/20—Proteins from microorganisms or unicellular algae
    • 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
    • A23J3/225—Texturised simulated foods with high protein content
    • A23J3/227—Meat-like textured foods
    • 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
    • A23P—SHAPING OR WORKING OF FOODSTUFFS, NOT FULLY COVERED BY A SINGLE OTHER SUBCLASS
    • A23P20/00—Coating of foodstuffs; Coatings therefor; Making laminated, multi-layered, stuffed or hollow foodstuffs
    • A23P20/20—Making of laminated, multi-layered, stuffed or hollow foodstuffs, e.g. by wrapping in preformed edible dough sheets or in edible food containers
    • 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
    • A23P30/10—Moulding

Definitions

  • meat analog food products can be formulated using plant-or fungi-based proteins. These plant- or fungi-based proteins are aggregated to form a meat analog that is capable of mimicking the taste, texture, appearance, and overall sensory experience of cooking and eating meat from an animal source.
  • Vegetable and fungi proteins are commonly used to make plant- or fungi- based meat analogs.
  • An extrusion process uses shear force to realign the plant or fungi proteins into a linear fibrous structure that results in a final product that more closely resembles the physical properties of muscle tissue found in animal meat.
  • a drawback to extrusion processing is that it is relatively expensive. This has prevented currently available plant- or fungi-based meat analogs to be sold to consumers at a competitive price when compared to “whole muscle” cuts of animal meat. Extrusion is also time consuming and can act as a bottleneck to the manufacture of plant- or fungi-based meat analogs. Additionally, while extruded vegetable or fungi protein can reasonably simulate the texture and sensory properties experienced by a consumer of ground meat, it currently is not capable of duplicating the actual texture or appearance of the highly elongated fibers in “whole muscle” cuts of animal meat. [0005] Vegetable oils are commonly used in plant- or fungi-based meat analogs to replace the fats found in animal foods.
  • oils due to their different physical and chemical properties, tend to liquify at lower temperatures and often leak out of plant- or fungi-based meat analogs when they are cooked. This leakage is visible to the consumer when cooking plant-or fungi-based meat, is usually perceived as unpleasant, and is a noticeable difference from cooking animal meat. Furthermore, oils and fats play an essential role in the taste and sensory attributes of meat and meat-like food products, since the molecules responsible for flavor are often attached to lipids. The rapid loss of oils and fats during the cooking process can result in a plant- or fungi- based meat analog reducing or completely losing its flavor during cooking.
  • a common solution to this problem is to contain the oil within the food product using chemically modified ingredients such as methylcellulose, which consumers looking for “natural” or “clean label” ingredients seek to avoid.
  • chemically modified ingredients such as methylcellulose
  • methylcellulose which consumers looking for “natural” or “clean label” ingredients seek to avoid.
  • the inclusion of methylcellulose and other chemically modified ingredients on a food package label can make the product less desirable and negatively affect sales.
  • chemically modified ingredients can make consumers less willing to switch from animal meats to plant-based meats.
  • the present disclosure provides various methods to create a plant- or fungi-based, bacon analog product having layers of protein and fat, with a complete control over the pattern of layers created.
  • individual layers are created, stacked over each other and joined, such as pressed together in a mold, in order to create a cohesive final product.
  • this disclosure provides a method of forming a plant- or fungi-based meat analog, such as a bacon analog.
  • the method includes providing at least one plant- or fungi-based protein layer, providing at least one fat layer, and arranging the at least one plant- or fungi-based protein layer and the at least one fat layer to form a stack. After forming the stack, the method includes applying pressure to the stack to compress together the at least one plant-based protein layer and the at least one fat layer.
  • FIG. l is a top plan view of a plant-based layered bacon strip.
  • FIG. 2A is a schematic side view of a batch process showing plurality of layers
  • FIG. 2B is a schematic top view of the plurality of layers of FIG. 2A.
  • FIG. 3 is a schematic side view of the plurality of layers from FIG. 2A and FIG. 2B compressed together.
  • FIG. 4 is a step-wise method of a batch process for forming a plant-based layered bacon strip.
  • FIG. 5 A is a schematic side view of a continuous process of joining a plurality of layers
  • FIG. 5B is a schematic top view of the plurality of layers of FIG. 5 A.
  • FIG. 6 is a step-wise method of a continuous process for forming a plant-based layered bacon strip.
  • the present disclosure is directed to various methods for making a plant- or fungi-based layered or striated food product, such as a bacon analog, having at least one protein layer and at least one fat layer.
  • the methods include a discrete batch process and a continuous process.
  • one or more protein layers and one or more fat layers are used to prepare a meat analog, such as a bacon analog.
  • these layers can be created in advance using any suitable methods.
  • the layers are created using an extrusion process
  • the die of the extruder will generally dictate the width, thickness, and cross-sectional shape of the layer, and, assuming the extrusion is relatively continuous, the length of each layer is dictated by cutting the extrudate at various intervals as it exits the extruder.
  • the extruder can be run in a batch-like fashion, in which case the length of the layer leaving the extruder is dictated by all of the material being fed into the extruder leaving the extruder.
  • a lamination process may involve stacking one or more layers of the fat or one or more layers of protein and running the stack of uniform material under a lamination mechanism, such as a roller applying downward pressure on the stack. This will set the thickness of the resulting layer, but post processing steps may be required to set the desired length and/or width of the layer.
  • a lamination mechanism such as a roller applying downward pressure on the stack.
  • FIG. 1 shows a strip of plant- or fungi -based bacon analog 100 from a top view.
  • the bacon analog 100 has a body 101 having a generally strip form, with a first side edge 102, an opposite side edge 104, a first end 106 and an opposite end 108. Not seen, the bacon analog strip 100 has a thickness that extends into the page.
  • the bacon strip analog 100 has regions 110 of protein (illustrated in FIG. 1 using dark vertical lines) and regions 120 of fat (illustrated in FIG. 1 using generally white space).
  • the fat regions 120 surround the protein regions 110, creating semi-discrete regions of protein in a contiguous fat region.
  • the protein regions 110 can surround the fat regions 120, forming semi-discrete regions of fat in a contiguous protein region.
  • neither the protein regions 110 nor the fat regions 120 are contiguous.
  • the protein regions 110 and the fat regions 120 are formed from distinct layers; that is, each protein region 110 is formed from at least one protein layer and each fat region 120 is formed from at least one fat layer. In some instances, multiple protein regions 110 are formed from a single protein layer. Alternately, one protein region 110 is formed form multiple protein layers. Additional details regarding formation of the bacon strip analog 100 and the regions 110, 120 are provided below.
  • FIG. 2A, FIG. 2B and FIG. 3 illustrate a batch process for forming a bacon strip analog.
  • a plurality of protein layers 210 are alternatingly stacked with a plurality of fat layers 220. While FIGs. 2A, 2B and 3 show the stacks being formed in a mold 201, it should be appreciated that mold 201 is not required when preparing stacks.
  • the layers 210, 220 are arranged in a generally striated manner.
  • two like layers, e.g., two protein layers 210 or two fat layers 220 may be adjacent to each other, in a lateral direction vertical direction, or both.
  • Each of the layers 210, 220 may be created by any appropriate mechanism, including by extrusion, by lamination, or other known mechanism.
  • the layers 210, 220 may be formed to the desired dimensions (length, width, thickness) when formed or may be subsequently converted (e.g., cut, sliced, etc.) to the desired size.
  • Different layers 210, 220 may have different thickness, length, and/or width.
  • each of the layers 210, 220 may be dimensioned so as to not extend to or beyond the entire length and/or width of the mold 201.
  • protein layer 210a does not extend the full length of the mold 201, leaving the tops of the end portions of the vertically adjacent fat layer 220a exposed.
  • protein layer 210a does not extend to or beyond the entire width of the mold 201, as seen in FIG. 2B (a top down view of the view shown in FIG. 2A).
  • two protein layers 210b, 210c are positioned at the same elevation, both between fat layer 220a and fat layer 220b. In such a manner, a bacon-like appearance, as shown in FIG. 1, is achieved.
  • the protein layers 210 may include any suitable non-animal -based protein, including plant-based or fungi-based protein.
  • Plant-based protein can be derived from, for example, vegetables and legumes
  • the plant-based or fungi-based protein may be crushed, ground, flaked, or pulverized and optionally bound with liquid binder to form a paste.
  • the paste can then be manipulated to form a solid or semi-solid material that can serve as the plant-based or fungi- based protein layer.
  • Exemplary though non-limiting examples of fungi that can be used in the fungi- based protein layer include those from the Rhizopus, Aspergillus, or Pleurotus genus of fungi.
  • species of fungi that can be used include, but are not limited to Rhiszopus oligosporus, Rhizopus oryzae and Aspergillus oryzae. Other filamentous microorganisms and fungi may also be used.
  • Exemplary though non-limiting examples of vegetable and legume that can be used in the plant-based protein layer include soy, lentils, chickpeas or garbanzo beans, tempeh, oats and oatmeal, quinoa, instantan, broccoli, peas, kale, potatoes, and hemp.
  • seeds such as sesame and chia
  • eggs may be used as the protein source in the non-meat-based protein layers, as well as nuts such as almonds, peanuts, walnuts, and hazelnuts.
  • Spirulina algae may also be used.
  • the fat layer 220 may include any suitable non-animal-based fat, including plantbased or fungi-based fats.
  • plants from which the plant-based fats can be derived include corn, maze, masa, canola and rapeseed, soybeans, soy hulls, soybean protein derivatives, wheat, wheat middling, wheat straw, millet, alfalfa, sorghum, milo, sugar cane, sugar beets, corn stalks, com cobs, popcorn husks, sweet bran, silage, oats, oat straw, barley, barley straw, sunflower seeds and hulls, cottonseed, coconut, cocoa beans, olives, palm, grapeseed, nuts (e.g., peanut, almond) and other oil or fat sources.
  • Modifiers such as methylcellulose or other hydrocolloids or gel may be added to the fat layer.
  • some embodiments may employ a binder layer provided between the protein layer(s) 210 and the fat layers(s) 220.
  • the material for the binder layer include hydrocolloids and gels.
  • hydrocolloids include alginate, carrageenan, starch, xanthan, guar gum, locust bean gum, gum karaya, gum tragacanth, gum arabic and cellulose derivatives. Not all hydrocolloids can form gels. Only a subset of hydrocolloids can form gels that are insoluble in water. Gels form when polymers arrange to form a three-dimensional structure characterized by connection points at junction zones, allowing solvent to be contained in the interstices. Hydrocolloids commonly used to make gels include alginate, pectin, carrageenan, gelatin, gellan and agar.
  • pressure is applied to the layers 210, 220, as seen in FIG. 3.
  • the pressure compacts the layers 210, 220 and increases the density of the layers 210, 220 and of the resulting product (as compared to the initial layers 210, 220).
  • the application of pressure may be accompanied by the application of heat. The heat used should not be so high and/or sustained as to result in cooking or baking of the protein or fat layers.
  • each of the layers 210, 220 may not extend the entire length and width of the mold, the elevational position of one or more of the layers 210, 220 may shift or distort. For example, as shown in FIG. 3, one end of protein layer 210c is bent downward upon compaction due to the underlaying protein layer 210d not extending completely under the layer 210c.
  • the white space generally represents the fat material.
  • the fat layers 210 shown in FIG. 2A may combine as a result of the compression step such that there are no longer distinguishable boundaries between the previous fat layers.
  • FIG. 3 no longer shows boundary layers between fat layers, but instead shows one unitary fat structure in which the protein layers 210a-d are interspersed. This combination of fat layers is not required, and the compression step may be carried out in a manner that, while compressing together the protein and fat layers, does not eliminate the boundary layers between fat layers.
  • the resulting product is removed from the mold 201 (in embodiments where mold 201 is used).
  • the resulting product may have the desired final dimensions (length, width) or the product may be converted to a desired size, such as via cutting, slicing, etc.
  • a general batch process for making a bacon analog is shown in FIG. 4 as method 300.
  • step 302 at least one protein layer and at least one fat layer are stacked and optionally placed in a mold.
  • the layers may be created by, e.g., an extrusion step or a lamination step.
  • the extrusion or lamination step may involve suitable dimensioning of the layers for subsequent use in the formation of a bacon analog as described herein.
  • step 304 pressure is applied to the layers (optionally in the mold), compressing together the one or more layer of fat and protein.
  • the specific manner of applying pressure to the stacked layers is generally not limited, nor is the specific amount of pressure. In some embodiments where a mold is used, all layers are pressed together with a press of length, width and shape equating the mold. As noted previously, the pressure applied may or may not compress the fat to a point of combining fat layers (i.e., eliminating distinguishable boundaries between fat layers).
  • step 306 the resulting product is removed from the mold, in embodiments where a mold is used. The specific manner of removing the product from the mold is not limited.
  • the mold may be inverted to let gravity assist with the removal of the product from the mold.
  • the mold can also be laid with a non-stick protective layer.
  • This protective layer can be a liquid (including but not limited to oil, water, etc.) or a solid (including but not limited to plastic sheet, aluminum foil, parchment paper, etc.).
  • FIG. 5A and FIG. 5B illustrate a continuous process for forming a bacon strip analog. It is to be understood that various features and/or details from the batch method, described above, may be applied to this continuous method unless contrary to the process or the construction. Generally speaking, and as discussed in more detail below, the length of the layers used in the continuous process does not need to be taken into account. Only width and thickness parameters need to be determined to match the desired custom pattern.
  • a plurality of protein layers 410 are alternatingly stacked with a plurality of fat layers 420 in a striated manner.
  • two like layers e.g., two protein layers 410 or two fat layers 420 may be adjacent to each other in the vertical and/or lateral direction.
  • Different layers 410, 420 may have different thickness, length, and/or width.
  • Each of the layers 410, 420 may be dimensioned and/or arranged so as to not extend the entire length and/or width of the stack.
  • protein layer 410a does not extend the full length of the fat layer 420a on which it is stacked, leaving a top side of an end of the fat layer 420a exposed.
  • Fat layer 420b does not extend the length or the width of the protein layer 410a on which it is stacked, nor the width of the fat layer 420a located under the protein layer 410a. Fat layer 420b extends to the second side edge 404 of the strip but does not extend to the first side edge 402 of the strip.
  • the protein layer 410b is actually two parallel layers 410b’ and 410b”, both extending to the appropriate side edge 402, 404 but not to the center of the strip.
  • the fat layer 420c also does not extend the full width, extending from the first side edge 402 short of the second side edge 404.
  • the protein layer 410c also does not extend the full width, extending from the second side edge 404 short of the first side edge 402. In such a manner, a bacon-like appearance, as shown in FIG. 1, is achieved after compression as described in further detail below.
  • FIGS. 5A and 5B For ease of understanding the layout of the layers 410, 420 herein, all of the multiple layers 410, 420 are shown in FIGS. 5A and 5B as not having the same length; however, to achieve a resulting product with a consistent or close to consistent thickness, many if not most of the layers 410, 420 will have the same length and/or will have laterally adjacent layers such as shown in FIG. 2A (see, e.g., layers 210b and 210c).
  • the additional added layers 410, 420 may be arranged in a pattern as the previous layers or may be arranged in a different pattern. Compression may take place either by moving the stacked layers under a stationary but rotating lamination mechanism, or by moving the rotating lamination mechanism over the stationary stacked layers.
  • the resulting product may have the desired final dimensions (length, width, thickness) or the product may be converted to a desired size though post processing, such as cutting, slicing, etc.
  • a general continuous process for making a bacon analog is shown in FIG. 6 as method 500.
  • step 502 at least one protein layer and at least one fat layer are stacked, such as in the manner described previously with respect to FIGs. 5 A and 5B.
  • Each layer may be created by an extrusion step or a lamination step, which may optionally include a cutting and/or sizing step.
  • step 504 pressure is applied to the stacked layers in a continuous or semi- continuous manner, thereby compressing the layers.
  • compression may take place either by moving the stacked layers under a stationary but rotating lamination mechanism, or by moving the rotating lamination mechanism over the stationary stacked layers.
  • the lamination mechanism applies a generally downward force on the stack to thereby compress the layers.
  • the lamination mechanism may also be heated to further aid in compression.
  • step 506 the stack, having moved through the lamination mechanism or having had the lamination mechanism passed thereover, is provided as a final product.
  • further dimensioning of the final product may take place, such as to prepare shorter length strips of the bacon analog.
  • the methods combine at least one plant-based or fungi-based protein layer 210, 410 and at least one fat layer 220, 420 in a stack, and pressure is applied to the stack, in either a batch or continuous fashion, to compress the layers and provide the resultant product.
  • multiple protein layers 210, 410 and multiple fat layers 220, 420 arranged in various patterns designed to replicate the structure of natural bacon, will be used to form the stack.
  • the number of protein layers 210, 410 can be the same as the number of fat layers 220, 420, or one or the other may have more.
  • one elevational position may have multiple layers, e.g., multiple protein layers 210, 410, such as layers 210b and 210c in FIG. 2A or layers 410b’ and 410b” in FIG. 5B.
  • Different layers may have different thicknesses. Any of the layers may be continuous and contiguous. Layers may be porous (e g., a fungi-based protein layer) to facilitate adhesion of adjacent layers.
  • spatially related terms including but not limited to, “bottom,” “lower”, “top”, “upper”, “beneath”, “below”, “above”, “on top”, “on,” etc., if used herein, are utilized for ease of description to describe spatial relationships of an element(s) to another.
  • Such spatially related terms encompass different orientations of the device in addition to the particular orientations depicted in the figures and described herein. For example, if a structure depicted in the figures is turned over or flipped over, portions previously described as below or beneath other elements would then be above or over those other elements.

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  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Food Science & Technology (AREA)
  • Polymers & Plastics (AREA)
  • Health & Medical Sciences (AREA)
  • Biochemistry (AREA)
  • Nutrition Science (AREA)
  • Biotechnology (AREA)
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  • Molecular Biology (AREA)
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Abstract

Des procédés de fabrication d'un produit alimentaire en couches ou strié, tel que du bacon d'origine végétale ou aux champignons. Pour le bacon, des couches individuelles de protéine et de graisse sont créées, disposées les unes sur les autres en un motif souhaité, et combinées les unes aux autres pour créer un produit final cohésif. Les couches peuvent être formées individuellement, empilées et stratifiées ou pressées ensemble pour former le produit. En variante, de multiples couches peuvent être formées simultanément et peuvent être pressées ensemble pour former le produit. Le matériau stratifié ou pressé peut, ou non, être coupé à la forme et à la taille souhaitées.
PCT/US2023/065795 2022-04-15 2023-04-14 Substitut de viande en couches d'origine végétale ou aux champignons et procédés de fabrication d'un tel substitut WO2023201349A1 (fr)

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200323238A1 (en) * 2019-04-10 2020-10-15 Université De Montpellier Meat analogues and meat analogue extrusion devices and methods
US20210045409A1 (en) * 2019-08-13 2021-02-18 Givaudan S.A. Fat delivery system, fat delivery method and food product containing the fat delivery system
US20210092978A1 (en) * 2019-09-30 2021-04-01 Shanghai Sunlight Innov Trading Co., Ltd. Edible Pet Chew with Meat Analogue Member and Method for Making the Same
US20210392920A1 (en) * 2019-12-31 2021-12-23 Air Protein, Inc. High Protein Food Compositions
KR20220033482A (ko) * 2019-07-12 2022-03-16 소시에떼 데 프로듀이 네슬레 소시에떼아노님 베이컨 유사 제품

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20200323238A1 (en) * 2019-04-10 2020-10-15 Université De Montpellier Meat analogues and meat analogue extrusion devices and methods
KR20220033482A (ko) * 2019-07-12 2022-03-16 소시에떼 데 프로듀이 네슬레 소시에떼아노님 베이컨 유사 제품
US20210045409A1 (en) * 2019-08-13 2021-02-18 Givaudan S.A. Fat delivery system, fat delivery method and food product containing the fat delivery system
US20210092978A1 (en) * 2019-09-30 2021-04-01 Shanghai Sunlight Innov Trading Co., Ltd. Edible Pet Chew with Meat Analogue Member and Method for Making the Same
US20210392920A1 (en) * 2019-12-31 2021-12-23 Air Protein, Inc. High Protein Food Compositions

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