WO2023280392A1

WO2023280392A1 - Production plant and operational method and process product for the production of a dairy-free, in particular vegan, firm feta cheese substitute food product

Info

Publication number: WO2023280392A1
Application number: PCT/EP2021/068743
Authority: WO
Inventors: Fiona KUON; Martin SINNSTEIN; Dirk Michael HERRMANN-BÜRK
Original assignee: Hochland Se
Priority date: 2021-07-07
Filing date: 2021-07-07
Publication date: 2023-01-12
Also published as: EP4366538A1

Abstract

The invention relates to a production plant for producing a dairy-free, in particular vegan, firm feta cheese substitute food product (5), comprising a mixing device (2), a heating device, a forming device (3), a mould and a cooling device. The invention also relates to an operating method for such a production plant.

Description

PRODUCTION EQUIPMENT, OPERATING PROCESS AND PROCESS PRODUCT FOR MANUFACTURING A DAIRY-FREE, ESPECIALLY VEGAN, CUT-RESISTANT FETAKEE FOOD SUPPLY PRODUCT

The invention relates to a production system (device with several functional units) according to claim 1 for producing a milk-free, in particular vegan, firm feta cheese substitute food product with a structure or texture typical of feta (feta-typical), comprising a large number of gas inclusions distributed over the substitute product , especially air or inert gas inclusions.

Furthermore, the invention relates to a method for operating such a production plant according to claim 6 or, to put it another way, a method for producing a dairy-free, in particular vegan, sliceable feta cheese substitute food product with the aforementioned texture typical of feta see.

In addition, the invention relates, preferably as a result of the method, to such a dairy-free, in particular vegan, sliceable feta cheese substitute food product according to claim 14.

Classic feta cheese is a so-called brine cheese in the form of a cheese made from sheep's milk that is usually milked without pressure. Feta cheese is sliceable and is characterized by a structure/texture with a large number of small air pockets. In classic feta production, milk-based curd is dry, ie filled into molds after the milk has been removed and then usually pressed by its own weight. Mechanical crushing does not take place. The salt content and the pH value of the feta cheese are adjusted via the brine or the fermentation. The market is increasingly demanding at least dairy-free or even completely vegan substitutes for classic animal-based cheese products, partly due to intolerance or other health reasons.

For example, a cheese substitute product in brine based on coconut oil is marketed in Germany under the name “bedda hirte”. It is a vegan product that is supposed to be reminiscent of feta cheese - but lacks the structure known from natural feta cheese, which has a large number of small gas pockets.

US Pat. No. 4,185,126 A discloses a method for utilizing cheese offcuts or leftovers. According to the known method, the sliceable cheese sections are ground into small cheese bodies and connected to one another in a mold using pressure and temperature to form a solid block of cheese without air inclusions. A device for comminuting cheese trimmings is known, for example, from US Pat. No. 4,382,969.

US Pat. No. 3,727,308 A describes a device for processing cheese trimmings, which are conveyed through a perforated plate and pressed through an extruder nozzle in order to obtain a solid block of cheese.

From the Database GNPD [online - www.gnpd.com] MINTEL; July 13, 2017, anonymous: "feta style fermented tofu product", xp055730992 a feta cheese substitute product based on tofu is known. It is a product fermented with vegan yoghurt cultures. Neither the texture nor the production equipment or production process required for manufacture are described in the document. A method for producing a cheese substitute product is known from WO 2020/089384 A1. The known product has no feta-typical texture.

EP 3 620 059 A1, which deals with the production of a vegan food particle, is also known as further prior art. The reference does not describe a feta cheese substitute having a texture typical of feta cheese.

Based on the aforementioned prior art, the invention is based on the object of specifying a production plant for producing a milk-free, in particular vegan, sliceable feta cheese substitute product and a corresponding operating method, i.e. a method for its production, in which the feta cheese substitute product is characterized by a feta-typical , i.e. a large number of gas inclusions distributed over the product, preferably randomly, more preferably essentially uniformly, is characterized. The object is also to specify such a feta cheese substitute product, in particular as a result of the operating or manufacturing process, very particularly preferably using a production plant according to the invention.

This object is achieved with the features of claim 1 with regard to the production plant and with the features of claim 6 with regard to the method. The feta cheese substitute food product according to the invention is characterized by the combination of features of claim 14.

Advantageous developments of the invention are specified in the dependent claims. In order to avoid repetition, features disclosed according to the method should also apply and be claimable as disclosed according to the device or production system as well as according to the product. Just- device- and product-specific features should be considered as disclosed and claimable according to the method.

The invention is based on the idea of a production plant for producing a milk-free, i. H. no animal milk obtained by milking, preferably but not necessarily vegan, cut-resistant food product, which is characterized by various functional units or devices. The production plant comprises a mixing device, in particular a kneading device, for producing a malleable dough mass based on at least one, preferably vegetable, filler and water-comprising ingredients. In other words, the mixing device can be used to form or mix ingredients into a moldable dough mass, preferably by kneading, with the ingredients comprising at least one filler, preferably a vegetable filler, in addition to water. Furthermore, the production plant comprises a heating device, preferably assigned to the mixing device, very particularly preferably at least partially integrated into it, for setting a processing temperature of the dough mass between 50° C. and <100° C. The heating can be realized by direct evaporation and/or indirectly. Antimicrobial processes can already be observed from 50°C, which ensure a longer shelf life of the end product. In addition, a temperature between 50° C. and <100° C. improves a sintering behavior, which will be explained below, of dough bodies to be produced from the dough mass, i. H. a material-locking connection with each other in sections at their original interfaces.

The core component of the production system according to the invention is a shaping device by means of which dough bodies can be obtained from the malleable dough mass produced with the mixing device by shaping, in particular crushing, preferably at the aforementioned processing temperature set by means of the heating device. The dough bodies are collected in one form of the production plant, with the dough bodies preferably falling into this due to the force of gravity, with sections of the dough bodies joining together materially at their original interfaces in such a way that gas bubbles, in particular air or inert gas bubbles, are trapped between adjacent dough bodies. The inclusion of inert gas bubbles can be achieved by filling the mold with the dough bodies in an inert gas atmosphere. This procedure is comparable to a kind of sintering process, which is characterized in that the dough bodies heated to the processing temperature connect materially in sections and form a body filled with gas bubbles. The temperature of the dough mass (processing temperature) and the viscosity of the dough mass is selected in such a way or set by an appropriate specialist in such a way that adjacent dough bodies not only adhere to one another on the surface, but also bond intimately with one another in sections and enclose or limit gas volumes in surface sections that are not connected to one another. In other words, the viscosity of the dough mass in conjunction with the processing temperature should be selected or set in such a way that adjacent dough bodies not only adhere to one another on the surface but only connect intimately with one another in sections and enclose or limit gas volumes in surface sections that are not connected to one another. Subsequent cooling solidifies the entrapping block or body into the desired feta cheese substitute food product.

It is important that the large number of dough bodies are not collected in water or another liquid, as in the case of spaetzle production, in order to avoid sticking together, but rather deliberately placed in a preferably empty form, ie a form that limits a gas volume, in particular fall in there due to gravity, so that neighboring ones Connect the dough bodies intimately in sections, enclosing gas volumes.

The production plant also includes a cooling device for cooling the connected dough bodies, preferably in the mold, to a cooling temperature of less than 20°C, preferably less than 10°C, to obtain a firm body or feta cheese, preferably in the form of a gel block - Substitute food product. In the simplest case, the cooling device is a cold room. It is particularly preferred if the dough bodies are cooled directly in the mold to the cooling temperature. If a foil bag is used in a preferably rigid mold or directly as a mold, the cooling can also take place in the preferably flexible foil bag. For the preferred, but not absolutely necessary, case of adding a gelling agent as an ingredient in the production of the dough mass, it is preferred if, during the cooling of the dough bodies that are connected to one another in sections, a sol-gel transition of the gelling agent, for example agar Agar or Gellan takes place. The use of non-vegan gelling agents such as gelatine is conceivable, but not preferred in principle.

With regard to the specific design of the heating device, which is preferably assigned to the mixing device, there are different possibilities. For example, it can be designed in such a way that the ingredient water can be heated separately from other ingredients before it is mixed with the filler. Additionally or alternatively, several or all of the ingredients of the dough mass can be heated with the heating device during mixing and/or the heating device is designed in such a way that the dough mass can be heated with it during and/or after the mixing of the ingredients. It is also conceivable for the heating device to be designed in such a way that the dough mass can be kept warm at the processing temperature until it is formed into dough bodies, before in the forming device, very particularly preferably in a funnel of the forming device. The heating device can therefore, for example, be divided between the mixing and forming device or separately from one or both of these two functional units of the production plant. In any case, the heating device is designed in such a way that it can be used to set a processing temperature between at least 50°C and <100°C, very particularly preferably a processing temperature between 60°C and 80°C, even more preferably between 65°C and 75°C . Mixing and heating devices are very particularly preferably combined, for example in the form of a cooking mixer.

As mentioned, the hot dough or dough at processing temperature is shaped into a large number of dough bodies by means of a shaping device at processing temperature. As a rule, the dough mass has to be transported to the forming device. In order to minimize the heat loss, it is preferable to keep the transport routes as short as possible. The transport can take place, for example, by means of a vacuum conveyor or a screw conveyor. The temperature to be adjusted by means of the heating device is to be selected such that the dough mass has the desired processing temperature during processing or shaping in the shaping device, taking into account any heat losses, particularly minor ones, during transport.

As mentioned, the dough bodies are collected in a mold downstream of the shaping device, it being preferred if the dough bodies fall out of the shaping device into the mould. In the mold, adjacent dough bodies connect intimately with one another in sections and enclose gas volumes or gas bubbles that are closed on all sides. In order to make it easier to empty the mold later, it is preferable to line it with a film bag that accommodates the dough bodies and that can be closed after filling. In principle, it is preferred to use the form after the Filling and preferably closing, for example by means of a lid, turning through 180°, so that a smooth surface is also created on the mold side that is initially open or upper during filling. In principle, it is preferred if the weight or the weight of the dough body is sufficient to connect them intimately in sections at a given temperature - if necessary, a pressing force, in particular a stamping force, can be applied in order to achieve or accelerate an intimate connection in sections, however, this is preferably dispensed with.

With regard to the specific configuration of the shaping device, there are different possibilities - what is essential is that the hot dough mass or one that is at the processing temperature is divided or shaped into a large number of small dough bodies. In a further development of the invention, a very particularly preferred possibility consists in conveying, preferably pressing, the hot dough mass through a perforated mask, preferably in the form of a perforated plate, whereby provision can be made for cutting the strings of dough emerging from the perforated mask to length, i.e. for adjusting the length the dough body, preferably the perforated mask is to be followed by stripping means, for example in the form of a rotating, more preferably knife-shaped stripper or a translationally moved stripper. Depending on the consistency of the dough, this can be omitted.

It is very particularly preferred if the viscosity of the dough mass at the processing temperature is adjusted in such a way, for example by selecting a correspondingly high dry matter content and/or adding at least one hydrocolloid, in particular a gelling agent, that the dough mass does not drip through the perforated mask automatically, i.e. not solely due to the force of gravity or even flows. Experiments have shown that the viscosity of the dough mass is adjusted for this purpose in such a way that it is temperature has a value of at least 2000 cP, more preferably at least a value between 2000 cP and 2500 cP, in particular in the case of the hole designs and/or sizes of a perforated mask that is preferably used, which are explained below.

The viscosity of the dough mass at the processing temperature can be measured, for example, with a rotational viscometer at the processing temperature, in particular at a shear rate of 160 rpm over 5 minutes. A rotational viscometer with the designation RVA 4500 from PerkinElmer with the following measuring geometry is preferred: measuring cylinder radius 37.56 mm , length 68.16mm, agitator blade radius 2.83mm, length 36.16mm and the software TCW 3 from Perten. The measuring cylinder preferably used for the viscosity measurement and the agitator blade preferably used for the viscosity measurement are shown in different views in FIGS. 6a and 6b.

The dough mass is preferably actively conveyed through the perforated mask, in particular pressed through the perforated mask, for which purpose the shaping device has appropriate pressurizing or conveying means. It is conceivable for this purpose to provide the forming device with a screw conveyor and/or a pressure ram, preferably in front of the shadow mask in the conveying direction. Additionally or alternatively, the forming device can be characterized by a rotatable pressure application element, preferably helical or ramp-shaped in sections, which approaches against a rotation device along an axis of rotation in the direction of the shadow mask and presses the dough mass through the shadow mask during rotation. It is therefore essential that the dough mass is subjected to conveying pressure. As mentioned, it is preferred to associate stripping means with the shadow mask in order to adjust the length of the dough bodies. These wiper means are preferably arranged downstream of the shadow mask in a conveying direction and can be moved relative to the shadow mask, preferably rotationally or alternatively translationally.

The perforated mask, in particular a perforated plate, is characterized in a further development of the invention by channels or passages arranged uniformly distributed over its surface, very particularly preferably with a circular contour, it being preferred if the diameter of the passages or openings is selected from a value range between 4 mm and 10 mm, preferably between 5 mm and 9 mm, even more preferably between 6 mm and 8 mm, or is particularly preferably 7 mm. The openings in the perforated mask (preferably perforated disk) can also have other shapes, for example squares or rectangles, oval or free shapes, it being particularly preferred if the free cross-sectional area of the openings, regardless of the specific peripheral shape, has a value range between 12.6 mm ² and 78.5 mm ² , more preferably between 19.6 mm ² and 63 mm ² , or more preferably 38.5 mm ² . If the passages vary, the viscosity of the dough must be adjusted. Larger apertures require higher viscosity to prevent the batter from dripping or flowing through the apertures.

The method of the present invention utilizes a manufacturing facility of the present invention to produce the feta cheese analog food product having the texture typical of feta. It is essential that the dough mass is produced on the basis of water and at least one, preferably vegetable, filler, in particular kernels and/or nuts. The dough mass brought to its processing temperature between at least 50°C and <100°C, preferably between 60°C and 80°C, more preferably between 65°C and 75°C, is converted into a plurality of by means of the forming device formed into small dough bodies, which are then collected in a mold, in particular collected, and are intimately connected to one another in sections. The viscosity of the dough mass is adjusted in such a way that the dough bodies do not run completely into one another but have such independence or strength that they only form an intimate connection in the manner of a sintering process and limit gas inclusions in the remaining area. It is essential not to collect the dough bodies in a liquid bath, for example in a water bath, but rather to take up the gas volume limited in a film bag arranged in the mould. After a preferred turning of the mold, the intimately connected dough bodies are cooled to a cooling temperature of less than 20° C., for example in a cold store. In a further development of the invention, the production plant can be equipped with a corresponding turning device for turning the mold.

Adjusting the appropriate viscosity or firmness of the dough mass is the responsibility of a person skilled in the art and is not a problem for him. As mentioned, it is particularly preferred if the person skilled in the art adjusts the viscosity of the dough mass so that it does not automatically drip through the perforated mask of the forming device purely due to the force of gravity at the processing temperature, but rather that the application of conveying pressure is necessary. This ensures a certain dimensional stability of the dough bodies to be produced by pressing the dough mass through the perforated mask, which therefore do not run completely together, but only connect to one another in sections, as desired. The viscosity of the dough mass is preferably adjusted by the production plant operator so that it is at least 2000 cP, even more preferably at least between 2000 cP and 2500 cP, at the processing temperature, for which purpose a previously described measuring device and a previously described measuring method are preferably used. The viscosity of the dough can be influenced by the choice of dry matter, as well as by adding at least one hydrocolloid, for example a gelling agent. The addition of native starches as a hydrocolloid is very particularly preferably avoided. In principle, it is preferable to dispense with hydrocolloids containing starch or hydrocolloids consisting of starch.

Possible or preferred hydrocolloids will be discussed later.

It is very particularly preferred if the ingredients used to produce the dough mass are grain-free or at least grain-flour-free. If grain and/or grain flour is added, it is preferred if the maximum amount, based on the dough mass, does not exceed 5% by weight and is very particularly preferably at most 1% by weight.

The invention is not limited to a specific dough body shape of the dough body to be produced from the dough mass by means of the shaping device. It is essential that a large number of dough bodies are formed from the dough mass and collected in the mold in order to obtain many, in particular small, gas, preferably air pockets, which are preferably distributed randomly, particularly preferably at least approximately evenly over the finished food product . It is preferred if the dough bodies have a worm shape, i.e. extend straight or curved along a (straight or curved) longitudinal axis and two broad axes that intersect at right angles and also extend at right angles to the longitudinal axis, and a higher, in particular at least twice as high, lengthwise and average width extension along the width axes (thus the width extension along both width axes divided by two). The longitudinal extension is preferably at most 10 times, preferably at most 5 times, the mean width extension. Of course, the aforementioned values are in each case an average longitudinal and average, ie averaged, width extension. The longitudinal extent can be influenced by a movement speed, in particular a rotational speed, of stripping means preferably arranged downstream of the shadow mask and the feed speed of the dough mass through the shadow mask. To determine the dimensions of the dough bodies, they are preferably collected in water (contrary to the procedure used in the production of the feta cheese substitute product) and then measured, for example using calipers.

As an alternative to a sausage shape, the dough bodies can also have other shapes, in particular a teardrop, cylinder or cartridge shape, depending on the design of the shadow mask.

It is particularly preferred if at least 50%, more preferably at least 70%, very particularly preferably at least 90% of the dough bodies each have a weight from a value range between 0.3 g and 2 g, particularly preferably between 0.5 g and 1 g.

The method is particularly preferably designed in such a way, in particular the size/shape as well as the viscosity and processing temperature of the dough mass or dough body, that the volume fraction of the gas inclusions in the total volume of the finished food substitute product, in particular a gel block, is between 5 vol. -% and 30% by volume, more preferably between 10% by volume and 25% by volume. -% amounts to.

It is very particularly preferred if the average number of gas inclusions per 10 cm ² of cut surface is between 1 and 20, preferably between 1 and 11, very particularly preferably between 3 and 8. To determine the number of gas pockets per cut surface, the gas pockets visible to the naked eye per cut surface are counted.

It is particularly useful if the ingredients are selected and coordinated in such a way that the dry matter content of the dough mass is between 15% by weight and 45% by weight, more preferably between 25% by weight and 45% by weight, even more preferably between 30% by weight % and 40% by weight.

It is particularly expedient to set the fat content of the dough mass to a value from a value range between 10% by weight and 35% by weight, even more preferably between 20% by weight and 29% by weight.

The protein content of the dough mass is expediently adjusted to a value from a value range between 3% by weight and 10% by weight, even more preferably between 3% by weight and 9% by weight, very particularly preferably between 4% by weight and 8% by weight .

As already indicated, there are different options with regard to the choice of the preferred vegetable filler for dough production. It is very particularly preferred if comminuted kernels and/or nuts are used as the filler. The use of seed flour and/or nut flour, particularly expediently almond flour, is very particularly preferred. This can be non-oil-free flour or partially oil-free flour, with the latter case possibly having to add a larger amount of oil and/or fat to set a desired fat content in the finished food product. In addition or as an alternative to the use of kernel and/or nut flour, kernel and/or nut paste can also be used, very particularly preferably as an alternative to a combination of kernel and/or nut flour and fat. In addition or as an alternative to using comminuted kernels and/or nuts, it is conceivable to use other oilseeds and/or roughage and/or fibers as a filler. Grain products are preferably not used. However, this is not mandatory. It is also conceivable to use aqueous, in particular starch-reduced or, very particularly preferably, starch-free grain or pseudo-grain extracts, which are also colloquially referred to as grain milk, such as oat milk, for example. In this case, the fillers may already contain all or at least part of the total amount of water required. However, it is preferable to avoid grain or pseudo-grain extracts.

The fat content of the dough mass is preferably adjusted by adding oil. Additionally or alternatively, fat that is solid at room temperature (20° C.) can also be used to adjust the fat content of the dough mass, in which case it is preferable to add the fat in the melted state and mix it with the remaining ingredients.

It is particularly expedient to adjust the desired salt content of the finished food product by optionally adding salt during the preparation of the dough mass, in particular to a percentage by weight of between 0.1 and 6% by weight, particularly preferably between 1 and 3% by weight. -%. This procedure has the advantage that, in contrast to classic feta production, no brine storage is required to adjust the salt content—such a brine storage is preferably dispensed with within the scope of the invention. It is also preferred to adjust the pH of the finished food product by appropriate acidification of the dough mass. The pH is preferably adjusted to a value between 3.0 and 6.0, in particular between 4.5 and 5.0, by adding acid, for example adding lactic acid. If required, additives such as herbs can be added during the production of the dough mass, in particular vegan additives, preferably in a cooking mixer.

As mentioned, it is preferable to use at least one, preferably vegan, hydrocolloid to set a desired or suitable viscosity of the dough mass at the processing temperature. The reaction or action mechanism of the at least one hydrocolloid is initially of secondary importance. The type and quantity of the hydrocolloid is to be selected in any case so that the dough mass can be shaped into the desired dough bodies, which then connect intimately with one another in sections. It is particularly preferred if one or more, preferably exactly two or more, hydrocolloids from the following group of hydrocolloids are used: agar-agar; alginates; Propylene Glycol Alginate (PGA) ; kappa carrageenan; lambda carrageenan; iota carrageenan ; carboxymethyl cellulose (CMC); gelatin ; gellan ; ghatti gum; guar; gum arabic ; hydroxypropyl cellulose (HPC) ; locust bean gum (JBKM) ; karaya gum ; konjac glucomannan; colloidal MCC ; methyl cellulose (MC) ; Hydroxypropyl Methyl Cellulose (HPMC) ; modified starches; native starches ; pullulan; tamarind gum ; tara gum; astragalus; xanthan.

The above list of hydrocolloids also includes gelatin, modified starches and native starches, these substances preferably being omitted. Although these can be used to produce a feta cheese substitute product according to the invention with a feta-typical texture, it is preferably not used.

With regard to the aforementioned, preferred hydrocolloids, it is preferred that each with a wt. Percentage of the To use dough mass, combinations of different hydrocolloids, in particular with a respective proportion, are also possible. In principle, if the viscosity should be too low in the case of a specified preferred minimum amount, the proportion should preferably be increased in the specified range and/or another (another) hydrocolloid should also be added, preferably with a percentage by weight from the range given in Table 1 below. It is also possible in individual cases, depending on the choice of one or more specific hydrocolloids, to exceed the specified maximum amount in order to set a desired viscosity.

Table 1: Preferred proportions by weight of preferred hydrocolloids for adjusting the viscosity/strength.

The invention also leads to a milk-free, in particular vegan, sliceable feta cheese substitute food product that can be produced or produced preferably by using the method described above and/or the use of a production plant described above. The food product is characterized by a structure/texture comprising a large number of gas inclusions, in particular air or inert gas inclusions, the feta cheese substitute food product containing at least one, preferably vegetable, filler and water. It is preferred if a hydrocolloid is included as at least one ingredient to set a desired firmness. If the hydrocolloid is a gelling agent, the feta cheese substitute food product according to the invention can be configured as a gel block. The food product according to the invention is preferably characterized by a strength, measured at a temperature between 7° C. and 10° C., preferably at least approximately at 8° C., of between 12 N and 25 N, preferably between 14 N and 22 N, more preferably between 16 N and 20 N. The measurement is preferably carried out using a texture testing machine, more preferably using a Zwick/Roell texture testing machine, type BT1-FR0.5TN-T14. A test ball with a diameter of 25.33 mm penetrates the sample at a speed of 2 mm/s over a distance or depth of 7 mm, with the temperature of the sample preferably being kept constant during the measurement. The measure of the firmness of the finished feta cheese substitute product (food product) is the maximum force absorption of the sensor of the texture testing machine, measured in N.

The following parameters should preferably be set:

Software: testXpert 2 V3.6

Table 2: Preferred measuring device parameters for the strength measurement of the finished food product with the texture testing machine used.

Particularly preferably, the dry matter content, especially when using powdered fillers, of the feta cheese substitute food product is between 15% by weight and 45% by weight, preferably between 25% by weight and 45% by weight, even more preferably between 30 wt.% and 40 wt.% and/or the fat content of the feta cheese substitute food product between 10 wt.% and 35 wt.%, preferably between 20 wt.% and 29 wt.% and/or the protein content of the feta cheese substitute food product is between 3% and 10% by weight, more preferably between 3 wt% and 9 wt%, more preferably between 4 wt% and 8 wt%. In the case of liquid fillers, such as aqueous cereals or pseudo-cereal extracts, lower protein contents may be achieved.

Preferably the volume of gas pockets is between 35% by volume, preferably between 10% by volume and 25% by volume of the total volume of the feta cheese substitute food product.

Preferably between 1 and 20, preferably between 1 and 11 and very particularly preferably between 3 and 8 gas inclusions visible to the human eye are provided per 10 cm ² cut surface.

Advantageous refinements of the invention result from the following description of preferred exemplary embodiments and from the drawings.

These show in:

1: a flow chart for visualizing different functional units of the production plant according to the invention or for visualizing a preferred process sequence,

Fig. 2a: and

2b: different, schematic views of a possible embodiment of a forming device,

3: an illustration of a possible dough body shape,

Fig. 4 is an illustration of a feta cheese substitute food product made according to the inventive concept;

5: a preferred embodiment of a forming device of a production plant according to the invention, and

6a and

Fig. 6b: Different views of an agitator blade preferably used for viscosity measurement (left) and a measuring cylinder preferably used for this purpose (right).

In the figures, the same elements and elements with the same function are identified by the same reference symbols.

In FIG. 1, reference number 1 shows an optional dissolving device, which is advantageous in particular when methylcellulose is used as the hydrocolloid, in order to dissolve the methylcellulose in water. To this end, the preferred powdered methylcellulose is added to water at a temperature of 65° C. and mixed, with cooling then taking place the methylcellulose-water mixture by adding ice to a temperature below 13°C, in this case to about 8°C, so that the methylcellulose dissolves completely. The methylcellulose-water solution is then placed in a mixing device identified by the reference number 2 with an integrated heating device of the production plant that is not identified separately by a reference number. In the specific exemplary embodiment, the mixing device with an integrated heating device is a cooking mixer. In principle, the dissolving of the methyl cellulose can also take place directly in this. The other ingredients are added in the mixing device 2, for example using the following recipe according to Table 3.

Table 3 - example recipe Alternatively, of course, other formulations can also be implemented, in the following example without methyl cellulose:

Table 4 - further sample formulation

A more general formulation can be formulated as follows:

Table 5 - Alternative recipe (more general)

As can be seen from the example of the formulation according to Table 3, the hydrocolloid agar-agar is used as the gelling agent in order to obtain a cut-resistant gel block at the end by cooling. The sol-gel transition takes place when the temperature falls below 45°C.

The amount of condensate from Table 3 together with the amount of water results in the total water content.

The coconut fat, which is solid at 20°C, is added in the melted state. The almond product, which is used as a filler in the present example, is preferably parts of the almond flour mixed with vegetable oil, preferably almond oil. Alternatively, non-oil-free almond flour can be used, preferably without further addition of vegetable oil. Alternative to a mixture of flour and fat an almond paste can also be used. In principle, the use of flour and pastes from other oilseeds is additionally or alternatively possible. In principle, other fats, such as palm fat, shea fat, cocoa fat and/or hydrogenated oils, can also be used instead of the coconut fat used.

The ingredients are mixed in the mixing device 2 and, in the present case, heated to a processing temperature of 86° C. by means of the heating device, for example by direct steam injection. For this purpose, the resulting dough mass receives its desired viscosity of more than 2000 cP. The dough mass is then transported, for example by means of a vacuum conveyor, to a shaping device 3, which can be designed, for example, as shown in FIGS. 2a and 2b or also as shown in FIG. A large number of small dough bodies are produced by means of the shaping device 3 and collected or caught in a mold 4, where they connect intimately with one another in sections and form gas inclusions or enclose gas bubbles between them. It is particularly preferred to arrange a foil bag in the mold 4, which holds the dough body and which is particularly preferably closed after it has been taken up. After filling, the mold 4 is turned through 180°, preferably together with an optional foil bag, and then cooled to a cooling temperature of preferably less than 20° C. in a cooling device (not shown). In the present exemplary embodiment, the dough bodies, which are intimately connected to one another in sections and located in the mold 4, are cooled down to a cooling temperature of between 0.degree. C. and 20.degree. A temperature below 0° C. is generally also conceivable, but not preferred. It is important that the mould, preferably a foil bag located therein, is empty before filling with the dough bodies, i.e. in particular no liquid bath, in particular no water bath, but only limits a gas volume, for example an air or inert gas volume, in which the dough bodies are then accommodated . The result is a feta cheese substitute food product 5 shown in FIG. 4, which is characterized by a large number of small, feta-typical gas pockets which are distributed relatively evenly in the product. In other words, the feta cheese food substitute 5 of the present invention has a texture similar to feta.

In Fig. 2 and 2b, a Umformeinrich device 3 is shown in different views, which has a shadow mask 7 at the end with a plurality of through-openings 8. The dough mass 9 produced is pressed through this. In the present case, the through openings 8 have a circular cross section with a diameter of 7 mm. On the rear side or downstream of the perforated mask 7 in the conveying direction are scraper means 10, in the present case in the form of a rotatably drivable scraper, the rotational speed of which determines the length of the dough bodies 11. The dough bodies 11 are collected in a mold 4 indicated in FIG. 2a, in the present case open at the top, and connect intimately in sections, with adjacent dough bodies 11 delimiting gas inclusions. Before being filled with the dough bodies 11, the mold 4 only limits a gas volume and does not contain a water bath. It is preferred to line the mold before filling it with a foil bag (not shown) by collecting the dough bodies 11 .

3 shows a possible embodiment of dough bodies 11 shaped by means of a shaping device. You can see their worm-like shape with a greater length than width. In the present exemplary embodiment, the dough bodies 11 have a weight between 0.55 g and 0.98 g. The longitudinal extent along its longitudinal axis varies from dough body 11 to dough body 11 between 1.9 mm and 3.5 mm. A width measured along a first width axis varies between 0.3mm and 0.9mm, while a width extending perpendicularly thereto the second width varies between 0.6 mm and 0.2 mm. The shadow mask 7 used has circular openings each with a diameter of 7 mm.

5 shows an alternatively designed forming device 3 of a possible embodiment of a production plant according to the invention. The forming device 3 comprises a perforated mask 7. Below the perforated mask 7 there is a mold 4 which is open in the illustration below but is in practice closed, which limits a gas volume and which preferably accommodates a foil bag. The dough bodies 11 produced by means of the shaping device 3 can fall into the mold 4 , preferably guided via a funnel (not shown) which can be arranged between the mold 4 and the perforated mask 7 . Above the perforated mask 7 there is a storage volume 12 (container) for intermediate storage of the dough mass 9 produced by means of the mixing device. If necessary, this storage volume 12 can be temperature-controlled or heated. Above the perforated mask 7 there is a partially helical pressurizing element 13 which is rotatably arranged and approaches the perforated mask 7 against a direction of rotation along an axis of rotation in order to thereby press dough mass 9 through the perforated mask 7 during rotation. A possible wiper was omitted in the exemplary embodiment shown.

The selected drive is here, for example, a hand crank drive, which can of course be replaced by a motor drive, for example an electric motor drive. LIST OF REFERENCE NUMERALS 1 release device

2 mixing device

3 forming device

4 shape

5 Feta Cheese Substitute Food Product 7 Shadow Mask

8 through holes

9 batter

10 stripping means 11 dough body 12 storage volume

13 pressurizing element

Claims

patent claims

1. Production plant for producing a dairy-free, in particular vegan, firm feta cheese substitute food product, (5) having a structure having a large number of gas pockets, in particular air or inert gas pockets, comprising: a) a mixing device (2), in particular a kneading device for producing a malleable dough mass (9) based on at least one ingredient, preferably vegetable, comprising filler and water, b) a heating device preferably assigned to the mixing device (2) for setting a processing temperature of the dough mass (9) between at least 50°C and <100°C, c) a shaping device for shaping the dough mass (9) into a large number of dough bodies (11) at the processing temperature, d) a device preferably lined with a film bag and/or closable with a lid , Form (4) with gas volume, in particular air volume for dry collection of the dough body (11) in the gas volume, so that benac intimately connect the exposed dough bodies (11) to one another in sections and enclose gas volumes between them, e) a cooling device for cooling the connected dough bodies (11), preferably in the mold (4), to a cooling temperature of less than 20°C, preferably less than 10°C to obtain a sliceable feta cheese substitute food product, preferably in the form of a gel block (5).

2. Production plant according to claim 1, characterized in that that the forming device (3) comprises a perforated mask (7), preferably in the form of a perforated plate, through which the dough mass (9) can be conveyed to form the dough bodies (11).

3. Production plant according to claim 3, characterized in that the forming device (3) for conveying the dough mass (9) through the perforated mask (7) has a screw conveyor and/or a pressure stamp and/or a rotatable, counter to a direction of rotation along an axis of rotation of the perforated mask (7) comprises an approximately pressure-loading element (13), preferably helical or ramp-shaped in sections.

4. Production plant according to one of claims 2 or 3, characterized in that the perforated mask (7), preferably in a conveying direction of the dough mass (9) downstream of the perforated mask (7), movable, preferably rotatable, relative to the perforated mask (7). (10) are assigned.

5. Production system according to one of Claims 2 to 4, characterized in that the perforated mask (7) comprises openings, preferably arranged evenly distributed over its surface, the openings being characterized by an average and/or respective diameter from a value range between 4 mm and 10 mm, preferably between 5 mm and 9 mm, even more preferably between 6 mm and 8 mm, very preferably 7 mm and/or that the passages are characterized by an average and/or respective free cross-sectional area from a value range between 12, 6mm ² and 78.5 mm ² , more preferably between 19.6 mm ² and 63.6 mm ² , very particularly preferably 38.5 mm ² .

6. Method for operating a production plant according to one of the preceding claims for producing a milk-free, in particular vegan, firm feta cheese substitute food product (5), having a structure comprising a large number of gas inclusions, in particular air or inert gas inclusions, with the steps : a) Mixing ingredients comprising a preferably grain-free and/or grain-flour-free, more preferably vegetable filler, in particular kernels and/or nuts, and water by means of the mixing device and producing a moldable dough mass

(9), b) setting a processing temperature of the dough mass, (9) between at least 50° C. and <100° C., preferably between 60° C. and 80° C., even more preferably between 65° C. and 75° C., by means of the heating device c) shaping the dough mass (9) with the shaping device into a large number of dough bodies (11) at the processing temperature, d) collecting the dough bodies (11) in the gas volume of the mold, (4) in particular in one in the mold (4) arranged and the gas volume absorbing foil bag, wherein adjacent dough bodies (11) connect intimately with each other in sections and enclose gas volumes between them, e) Obtaining a sliceable, preferably designed as a gel block, feta cheese substitute food product (5) by cooling the connected dough bodies (11) with the gas pockets in between to the cooling temperature of less than 20°C, preferably at most 10°C or less, by means of the cooling device.

7. The method according to claim 6, characterized in that the viscosity of the dough mass (9) is adjusted, preferably at the processing temperature to a value to be determined using a rotational viscometer at a shear rate of 160 rpm of at least 2000 cP, more preferably between at least 2000cP and 2500cP that the dough mass (9) does not automatically drip through a perforated mask (7) of the forming device purely due to the force of gravity.

8. The method according to any one of claims 6 or 7, characterized in that the dough bodies (11) are produced in such a way that they extend along a longitudinal axis and two width axes which intersect at right angles and also extend at right angles to the longitudinal axis have a higher, in particular at least twice as high, average longitudinal and average width, averaged with respect to the respective width axes, and/or that the dough bodies (11) are produced in such a way that at least 50%, preferably at least 70%, even more preferably at least 90% of the dough bodies (11) each have a weight from a value range between 0.3 g and 2.0 g, preferably between 0.5 g and 1.0 g.

9. The method according to any one of claims 6 to 8, characterized in that the volume fraction of the gas inclusions in the total volume of the feta cheese substitute food product (5) is reduced to a value between 5% by volume and 30% by volume, preferably between 10% and 25%. is set.

10. The method according to any one of claims 6 to 10, characterized in that the dry matter content of the dough mass (9) is reduced to a value from a value range between 15% by weight and 45% by weight, preferably between 25% by weight and 45% by weight, even more preferably between 30% by weight and 40% by weight, and/or that the fat content of the dough mass (9) is set to a value from a value range between 10% by weight and 35% by weight. %, preferably between 20% by weight and 29% by weight, and/or that the protein content of the dough mass (9) is set to a value from a value range between 3% by weight and 10

% by weight, more preferably between 3% by weight and 9% by weight, even more preferably between 4% by weight and 8% by weight.

11. The method according to any one of claims 6 to 10, characterized in that one or more substance / s from the following group is used as a filler and / or consists of: crushed kernels and / or nuts, preferably in flour form and / or paste form; dietary fibers; fibers; Oilseed, preferably in flour form and/or paste form; aqueous, preferably starch-free, grain or pseudo-grain extracts.

12. The method according to any one of claims 6 to 11, characterized in that the ingredients include at least one, preferably vegan, hydrocolloid, particularly preferably selected from the group: agar-agar; alginates; Propylene Glycol Alginate (PGA); kappa carrageenan; lambda carrageenan; iota carrageenan; carboxymethyl cellulose (CMC); Gelatin; gellan; ghatti gum guar; gum arabic; hydroxypropyl cellulose (HPC); locust bean gum (JBKM); karaya rubber; konjac glucomannan; colloidal MCC; methyl cellulose (MC); Hydroxypropyl Methyl Cellulose (HPMC); modified starches; native starches; pullulan; tamarind gum; tara gum; astragalus; xanthan.

13. The method according to any one of claims 6 to 12, characterized in that the fat content of the dough mass (9) is adjusted by adding oil and/or fat that is solid at room temperature (20°C), the fat preferably being added in the molten state and is mixed.

14. A milk-free, in particular vegan, sliceable feta cheese substitute food product that can be produced preferably by means of a production system according to one of claims 1 to 6 and/or by carrying out an operating method according to one of claims 7 to 13, (5) produced from a dough mass (9) , having a structure comprising a plurality of gas inclusions, in particular air or inert gas inclusions, wherein the feta cheese substitute food product (5) has at least one, preferably vegetable, filler, in particular kernels and/or nuts, water and preferably at least one contains vegan, hydrocolloid.