Method for producing a SOY-free plant-based product

Abstract

It is disclosed a method of producing a soy-free plant-based food product comprising the steps of: providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry weight basis;-providing a protein modifying enzyme; providing cereal flour; providing an aqueous liquid; mixing the soy-free leguminous plant protein material with the protein modifying enzyme, cereal flour and the aqueous liquid to provide a composition; filling the composition in heat-stable package; subjecting the heat-stable package to a heat treatment to provide a soy-free plant-based food product.

Description

[0001] METHOD FOR PRODUCING A SOY-FREE PLANT-BASED PRODUCT

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to a method for producing a soy-free plantbased food product from a leguminous plant material and cereal flour. The invention also relates to a soy-free plant-based food product. The soy-free plant-based food product exhibits a tofu-like structure which is solid, firm and chewy in its texture. The soy-free plant-based food product suitable for frying, grilling, for stir-fried, and baking.

[0004] BACKGROUND OF THE INVENTION

[0005] Plant-based food products are widely available in the market, being soyabased tofu one of the most representatives. There are two main methods of making tofu. Firm tofu is produced by adding a coagulant to soybean milk and pressing it into blocks. Silken tofu is produced by acid gelation with Glucono Delta Lactone (GDL), where the product forms a gel in a container, typically showing a softer consistency than firm tofu. The process for silken tofu does not involve pressing and whey removal steps.

[0006] There are also products that mimic tofu but are made from other plant seeds, such as pumpkin and hemp, or from other legumes, like faba beans. These products, which look like tofu, do not have the same qualities as soy-based tofu; they are less firm, crumblier, and have a stronger taste.

[0007] One major difference between soybean and faba bean is the macronutrient distribution. Soybean has more protein and fat, while legumes has more carbohydrates and fiber, which interfere with the gel formation.

[0008] The conventional methods for making tofu from soybeans are not applicable in the production of tofu-like products from other legumes than soybeans, such as those made from faba bean. The presence of soy naturally forms a better structure, while tofu-like products made from other legumes shows a drier and less cohesive structure.

[0009] WO 2018 / 115595 Al discloses a heat stable plant based protein product suitable for use as a meat substitute, which includes a plant based protein concentrate and a hydrocolloid raw material and maintains its form and does not melt when heated by microwaving, frying or grilling.

[0010] WO 2023 / 076541 A2 discloses a method for obtaining a gelled plant protein composition involving mixing a plant protein raw material and transglutaminase with water. The gelled composition is useful as meat alternatives or meat extenders. There are currently no tofu-like products on the market that do not use soy. There is a need for better soy-free alternatives for those who are allergic to soy. Additionally, creating a tofu-like product without the use of ingredients like carrageenan or xanthan gum has been a challenge both financially and from a consumer perspective.

[0011] There are currently no tofu-like products on the market that contain a mixture of at least one non-soy legume protein ingredient and at least one cereal flour ingredients. There are challenges to prepare tofu-like products that contain a mixture of at least one non-soy legume protein ingredient and at least one cereal flour ingredients because the cereal flour ingredients are mostly substantially insoluble in water.

[0012] BRIEF DESCRIPTION OF THE INVENTION

[0013] An object of the present invention is to provide a method for producing a soy-free plant-based food product from a soy-free leguminous plant protein material and cereal flour having a firm-tofu-like structure and mouthfeel without having press- ing-induced-whey-removal step in the method.

[0014] Another object of the present invention is to provide a soy-free plant-based food product having firm tofu-like mouthfeel comprising a soy-free leguminous plant protein material and cereal flour.

[0015] It was surprisingly found in the present invention that a soy-free plantbased food product having tofu-like structure can be formed from a soy-free leguminous protein containing material and cereal flour.

[0016] Advantageously, heat treatment at a high pressure of the dough of the soy- free leguminous plant material and the protein modifying enzyme provide a protein gel having a strong gel without visible cracks in the gel mass.

[0017] Another object of the present invention is to provide a soy-free plant-based food product. The soy-free plant-based food product of the invention has a pleasant mouthfeel with devoid of gumminess. The product obtained can be stir-fried, cooked to sauce or boiled, and the product keeps its cohesive and a firm tofu-like solid structure. The food product holds its shape well and has a slight chewiness or chewy structure. The food product can be stir-fried, grilled, or baked. In addition, the food product can be cubed, sliced, or crumbled and it is ideal for frying, grilling, or using in hearty dishes where it needs to maintain its shape.

[0018] The soy-free plant-based tofu-like product produced by the method of the invention has a unique and advantageous texture (mouthfeel) related to water binding properties compared to commercial tofu products on the market. When the soy-free tofu-like product of the present invention was moved or cut during food (meal) preparation (handling), it maintained phase stable status, in other words, there is no visible amount of liquid (water, whey) coming out from the tofu matrix. In contrast, when commercial soy tofu products are moved or cut during food (meal) preparation (handling), water escapes from the tofu structure to cut board or hand. The phase stability is desired, because it is clean and easy for food handling. The water escaping from commercial tofu is unfavourable, as it is wet and causes difficulty to clean.

[0019] BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 shows the composition obtained in the method of the invention during packing.

[0021] Figure 2 is a photograph of the soy-free plant-based food products produced by the method of the invention. The upper sample in the photograph shows the product after heat treatment. The lower sample shows the product cut into pieces and frying on a pan with oil.

[0022] DETAILED DESCRIPTION OF THE INVENTION

[0023] In an aspect, the present invention provides a method for producing a soy- free plant-based product comprising the steps of:

[0024] - providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry weight basis,

[0025] - providing a protein modifying enzyme,

[0026] - providing cereal flour,

[0027] - providing an aqueous liquid,

[0028] - mixing the soy-free leguminous plant protein material with the protein modifying enzyme, cereal flour and the aqueous liquid to provide a composition,

[0029] - filling the composition in heat-stable package,

[0030] - subjecting the heat-stable package to a heat treatment to provide a soy- free plant-based food product.

[0031] All percentages in the present application are given on weight basis.

[0032] In the present invention, the soy-free leguminous plant material can be any edible leguminous plant material except soybean. In an embodiment, the soy-free leguminous plant material is at least one of pea, faba bean, chickpea, mung bean and lentil. In an embodiment, the soy-free leguminous plant material is faba bean. In an embodiment, the faba bean is a faba bean isolate having a protein content of at least 80 wt.% based on weight of the faba bean isolate. In another embodiment, the faba bean is a faba bean concentrate having a protein content of at least 60% based on weight of the faba bean concentrate. In an embodiment, the content of the soy-free leguminous plant material in the composition is about 1 wt.% to about 30 wt.%. In another embodiment, the content is about 10 wt.% to about 25 wt.%. In a further embodiment, the content is about 13 wt.% to about 20 wt.%.

[0033] In an embodiment, the protein modifying enzyme suitable for the method of the invention is a protein crosslinking enzyme. The protein crosslinking enzyme shows cross-linking activities between proteins, creating more rigid and cohesive protein networks, which can enhance the final texture helping the structure to keep its form during cooking. In an embodiment, the protein modifying enzyme used is at least one of transglutaminase, tyrosinase and laccase. Said enzymes can be used alone or in any combinations with each other. In an embodiment, the protein modifying enzyme is used in an amount of about 1 U / g protein to about 9 U / g protein. In another embodiment, the amount is about 1.5 U / g protein to about 7 U / g protein. In a further embodiment, the amount is about 2.0 U / g protein to about 5.0 U / g protein.

[0034] The protein modifying enzyme typically used is transglutaminase (EC 2.3.2.13). Transglutaminase catalyses the formation of covalent bonds between glutamine and lysine residues in protein molecules. There are several commercially available transglutaminase enzyme preparations that are suitable for use in the process of the invention. These include Activa®YG (Ajinomoto, Japan], Activa®MP (Ajinomoto, Japan], and Yiming-TG (Yiming Fine Chemicals Co., Ltd., China]. The liquid transglutaminase enzyme preparation, manufactured by Valio Oy, Finland, has crosslinking activity of about 100 U / g.

[0035] Cereal flour is introduced to the composition. Inclusion of the cereal flour improves the mouthfeel of the product. The cereal flour is at least one flour of oat, wheat, rye, barley, maize, rice and millet. In an embodiment, the cereal flour is oat flour. Cereal flour further improves the mouthfeel of the product while gumminess texture of a protein gel is avoided. In an embodiment, the content of the cereal flour in the composition is about 1 wt.% to about 20 wt.% based on total weight of the composition. In another embodiment, the content is about 3 wt.% to about 10 wt.%. In a further embodiment, the content is about 4 wt.% to about 8 wt.%.

[0036] The aqueous liquid used in the method is selected from water, a plantbased liquid, and any mixture thereof. The plant-based liquid comprises a legume drink, a vegetable drink, a fruit drink, or any mixture thereof. In an embodiment, the aqueous liquid is water.

[0037] In an embodiment, the aqueous liquid is added in an amount of about 60 wt.% to about 85 wt.% based on total weight of the composition. In another embodiment, the added amount is about 65 wt.% to about 75 wt.% based on total weight of the composition.

[0038] In an embodiment, the composition after mixing the soy-free leguminous plant-based protein material with the protein modifying enzyme, cereal flour, and the aqueous liquid the composition is flowable. The flowable composition is possible to transport with through process piping by aid or pump from a production unit to another unit in an industrial scale production plant. The composition may also have an appearance of a thick emulsion type slurry.

[0039] In an embodiment, at least one of salt and plant-based fat is added to the composition. The plant-based fat comprises rapeseed oil, sunflower oil, olive oil, peanut oil, avocado oil, coconut fat, palm oil, cocoa butter, and palm oil or any mixture thereof.

[0040] Optionally, the product is seasoned using methods and equipment known to a person skilled in the art. The product can be brined or salted with dry salt. Salt can be NaCI, KCI, sodium carbonate, sodium hydrogen phosphate or AlV-mix. The product can be seasoned with spices, herbs, fruits and / or vegetables.

[0041] In an embodiment, the method for producing a soy-free plant-based food product comprises the steps of:

[0042] - providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry basis,

[0043] - providing a protein modifying enzyme,

[0044] - providing cereal flour,

[0045] - providing an aqueous liquid and plant-based fat,

[0046] - mixing the soy-free leguminous plant protein material with the protein modifying enzyme, cereal flour, aqueous liquid and plant-based fat to provide a composition,

[0047] - filling the composition in a heat-stable package,

[0048] - subjecting the heat-stable package to a heat treatment to provide a soy- free plant-based food product.

[0049] In another embodiment, the method for producing a soy-free plant-based food product comprises the steps of:

[0050] - providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry basis,

[0051] - providing a protein modifying enzyme,

[0052] - providing cereal flour,

[0053] - providing an aqueous liquid and plant-based fat, - mixing the soy-free leguminous plant protein material with the protein modifying enzyme, cereal flour, aqueous liquid and plant-based fat to provide a composition,

[0054] - filling the composition in a heat-stable package,

[0055] - subjecting the heat-stable package to a heat treatment under an elevated pressure no higher than 4 bars to provide a soy-free plant-based food product.

[0056] In a further embodiment, the method for producing a soy-free plant-based food product comprises the steps of:

[0057] - providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry basis,

[0058] - providing a protein modifying enzyme,

[0059] - providing cereal flour,

[0060] - providing an aqueous liquid and plant-based fat,

[0061] - mixing the soy-free leguminous plant protein material with the protein modifying enzyme, the cereal flour, the aqueous liquid, and the plant-based fat to provide a flowable, thick emulsion type composition,

[0062] - filling the flowable, thick emulsion type composition in a heat-stable package,

[0063] - subjecting the heat-stable package to a heat treatment to provide a soy- free plant-based food product.

[0064] In a still further embodiment, the method for producing a soy-free plantbased food product comprises the steps of:

[0065] - providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry basis,

[0066] - providing a protein modifying enzyme,

[0067] - providing cereal flour,

[0068] - providing an aqueous liquid and plant-based fat,

[0069] - mixing the soy-free leguminous plant protein material with the protein modifying enzyme, the cereal flour, the aqueous liquid, and the plant-based fat to provide a flowable, thick emulsion type composition,

[0070] - filling the flowable, thick emulsion type composition in a heat-stable package,

[0071] - subjecting the heat-stable package to a heat treatment under an elevated pressure no higher than 4 bars to provide a soy-free plant-based food product.

[0072] In the present invention, the plant-based fat comprises rapeseed oil, sunflower oil, olive oil, peanut oil, avocado oil, coconut fat, palm oil, cocoa butter, and palm oil or any mixture thereof.

[0073] In an embodiment, the composition is packed in a sealed package.

[0074] In an embodiment, the plant-based fat is added in an amount of about 5 wt.% to about 20 wt.% based on total weight of the composition. In another embodiment, the added amount is about 8 wt.% to about 15 wt.% based on total weight of the composition.

[0075] The method of the invention may further contain additional optional method steps, such as adding further plant-based ingredients, emulsifiers, other protein and / or amino acid sources, and / or a further method step, for instance recovering the product in a manner characteristic to it. These optional steps are performed in an appropriate stage of the method known by a person skilled in the art. The selection of suitable optional steps and conditions belongs to knowledge of a person skilled in the art.

[0076] In an embodiment, the heat treatment of the heat-stable packages is performed under elevated pressure, where the pressure is higher than atmospheric pressure. In an embodiment, the pressure is in the range of about 1.1 bar to about 4 bar. In another embodiment, the pressure is about 2 bar to about 3.5 bar. The heat treatment in elevated pressure is steam cooking. The heat treatment in elevated pressure may be performed in an autoclave.

[0077] A product dough is formed by mixing the soy-free leguminous plant material with the protein modifying enzyme, the cereal flour and the aqueous liquid. Mixing may be performed for example by a high shear mixer. In an embodiment, the mixing is conducted for about 3 min to about 120 min. In another embodiment, mixing is conducted for about 10 min to about 120 min. In another embodiment, mixing is conducted about 15 min to about 60 min. In another embodiment, the mixing is performed for about 20 min to about 60 min. In a further embodiment, the mixing is performed for about 25 min to about 50 min.

[0078] In an embodiment, after the mixing, the composition has a storage modulus of about 50 Pa to about 1500 Pa. In another embodiment, the storage modulus is about 75 Pa to about 1000 Pa. In a further embodiment, the storage modulus is about 100 Pa to about 500 Pa.

[0079] In an embodiment, after the mixing, the composition has a loss modulus of about 5 Pa to about 500 Pa. In another embodiment, the loss modulus is about 10 Pa to about 250 Pa. In a further embodiment, the loss modulus is about 20 Pa to about 100 Pa.

[0080] After the mixing, the composition is transferred to a package, such as containers, casings or other forms of airtight enclosures. In an embodiment, after the mixing, the composition is transferred to a sealed package, such as containers, casings or other forms of airtight enclosures. The sealing process allows to maintain the desired structure of the composition. The package is then subjected to a heat treatment for gel formation, and to ensure microbiological quality. In the method of the invention, the heat-treatment is performed using methods known per se. In an embodiment, the heat treatment of the sealed package is carried out at about 70°C to about 150°C. In an embodiment, the heat treatment is at about 80°C to about 130°C. In a further embodiment, the heat treatment is at about 90°C to about 120°C.

[0081] In the heat-treatment step of the method, a gel is formed which is necessary for forming the desired structure of the soy-free food product. In an embodiment, the heat treatment of the heat stable package is carried out for about 10 min to about 60 min. In another embodiment, the heat treatment is carried out for about 10 min to about 30 min. In another embodiment, the heat treatment is carried out for about 15 min to about 20 min.

[0082] In an embodiment, after or before the heat treatment step, the composition is incubated at 35-55°C for 5 to 90 minutes. In another embodiment, the composition is incubated at 40-50°C for 5 to 90 minutes, or at < 8°C for 6 to 12 hours.

[0083] In an embodiment, the heat treatment of the sealed package can be performed under an elevated pressure in a closed pressure vessel such as a pressure cooker or autoclave to improve the gel structure. In an embodiment, the method further comprises a pressure treatment in a closed pressure vessel in a pressure above atmospheric pressure. In an embodiment, the pressure is about 1.1 bar to about 4 bar. In another embodiment, the pressure treatment is at about 2 bar to about 3.5 bar.

[0084] In an embodiment, the moisture content of the soy-free plant-based food product produced by the method of the invention is about 65% to about 85%. In another embodiment, the moisture content is about 70% to about 80%.

[0085] In an embodiment, the soy-free plant-based food product produced by the method of the invention has at least one of the following features:

[0086] - a protein content of about 9 wt.% to about 20 wt.%, specifically about 10 wt.% to about 15 wt.%,

[0087] - a carbohydrate content about 0.5 wt.% to about 7.5 wt.%, specifically about 2.5 wt.% to about 5 wt.%,

[0088] - a fat content of about 2.5 wt.% to about 15 wt.%, specifically about 8 wt.% to about 12 wt.%. The soy-free plant-based food product produced by the method of the invention can be used as a meat substitute or a meat analogue, showing the form of a block, a cube, a mince, a grain, a slice, a stripe or block or filet pressed or processed from the cubes, minces, stripes, grains and / or slices.

[0089] In another aspect, the present invention provides a soy-free plant-based food product comprising a soy-free leguminous plant material and cereal flour having at least one of the features:

[0090] - chewiness from about 880 to about 6000 measured at TPA 40% strain,

[0091] - hardness from about 1500 g and 6000 g measured at TPA 40% strain.

[0092] In an embodiment, the chewiness is in the range from about 1000 to about 5500 measured at TPA 40% strain. In another embodiment, the chewiness is from about 1800 to about 5000 measured at TPA 40% strain. In a further embodiment, the chewiness is from about 2000 to about 3500 measured at TPA 40% strain.

[0093] In an embodiment, the hardness is from about 1800 g to about 5500 g measured at TPA 40% strain. In another embodiment, the hardness is from about 1900 g to about 5200 g at TPA 40% strain. In a further embodiment, the hardness is from about 2000 g to about 5000 g measured at TPA 40% strain.

[0094] In an embodiment, the soy-free plant-based food product of the invention comprises about 10 wt.% to about 30 wt.% of the soy-free leguminous plant material. In another embodiment, the soy-free plant-based food product of the invention comprises about 13 wt.% to about 20 wt.% of the soy-free leguminous plant material.

[0095] In an embodiment, the soy-free plant-based food product of the invention comprises about 3 wt.% to about 20 wt.% of the cereal flour. In another embodiment, the content of the cereal flour is about 4 wt.% to about 10 wt.%. In a further embodiment, the content of the cereal flour is about 5 wt.% to about 8 wt.%.

[0096] The soy-free leguminous plant material of the soy-free plant-based food material of the invention is selected at least one of pea, faba bean, chickpea, mung bean and lentil. In an embodiment, the free leguminous plant material is faba bean.

[0097] The cereal flour of the soy-free plant-based food material of the invention is selected at least one of oat, wheat, rye, barley, maize, rice and millet. In an embodiment, the cereal flour is oat flour.

[0098] In an embodiment, the soy-free plant-based food product of the invention has at least one of the following features:

[0099] - a protein content of about 9 wt.% to about 20 wt.%, specifically about 10 wt.% to about 15 wt.%,

[0100] - a carbohydrate content about 0.5 wt.% to about 7.5 wt.%, specifically about 2.5 wt.% to about 5 wt.%,

[0101] - a fat content of about 2.5 wt.% to about 15 wt.%, specifically about 8 wt.% to about 12 wt.%,

[0102] - a moisture content of about 60% to about 85%, specifically about 70% to about 80%.

[0103] The soy-free plant-based food product of the invention, or that produced by the method of the invention has an energy content of about 80 kcal / lOOg to about 200 kcal / lOOg. In an embodiment, the energy content is about 130 kcal / lOOg to about 160 kcal / lOOg.

[0104] The soy-free plant-based food product of the invention exhibits low tendency for syneresis. In this context, syneresis is the separation of liquid from the solid food matrix. The final product, which is the product after the heat treatment, shows a very low amount of separated liquid. In an embodiment, the amount of a liquid separated from the soy-free plant-based product is less than 5 g per 100 g of the product. In another embodiment, the amount of a liquid separated from the soy-free plantbased product is less than 2 g per 100 g of the product.

[0105] The soy-free plant-based food product can be used as a meat substitute or a meat analogue, showing the form of a block, a cube, a mince, a grain, a slice, a stripe or block or filet pressed or processed from the cubes, minces, stripes, grains and / or slices.

[0106] Texture profile analysis (TPA)

[0107] The samples were measured with TA.XTplus texture analyser, Stable Micro Systems, England by using compression platen P75, Stable Micro Systems, England. Samples were tempered to 8 °C before measurement. The pieces of non-soya tofu to be analyzed were cut into 2 cm diameter and 2 cm long cylinders. The measurement program was adopted from a standard TPA measurement protocol. The manual of the measurement equipment "Texture profile analysis (TPA) is an objective method of sensory analysis. TPA is based on the recognition of texture as a multi-parameter attribute. For research purposes, a texture profile in terms of several parameters determined on a small homogeneous sample may be desirable. The test consists of compressing a bitesize piece of food two times in a reciprocating motion that imitates the action of the jaw and extracting from the resulting force-time curve a number of textural parameters that correlate well with sensory evaluation of those parameters. The mechanical textural characteristics of foods that govern, to a large extent, the selection of a rheological procedure and instrument can be divided into the primary parameters of hardness, cohesiveness, springiness, and adhesiveness, and into the secondary (or derived) parameters of fracturability (brittleness), chewiness and gumminess."

[0108] The downward speed before the probe touching the sample was 1 mm / s (pre-test speed). The speed of compression when the blade touched the sample was 5 mm / second (test speed) and compression went to a compression depth until 40% of the height of the sample was reached. Then the probe withdraw (move upward) with speed (post-test speed) 5 mm / second. There was a "trigger force" setting, which was set as 10 g in this study. The waiting time between the first and the second compression was 5 s. The Hardness, cohesiveness, springiness, adhesiveness, chewiness, gumminess and resilience values are calculated by the software of the measurement equipment.

[0109] In the present invention, hardness is expressed as the maximum force of the 1st compression. The Hardness value is the peak force that occurs during the first compression. The hardness need not occur at the point of deepest compression, although it typically does for most products. Cohesiveness was the area of work during the second compression divided by the area of work during the first compression. Cohesiveness is how well the product withstands a second deformation relative to its resistance under the first deformation. Springiness was expressed as a ratio or percentage of a product's original height. Springiness was how well a product physically springs back after it has been deformed during the first compression and has been allowed to wait for the target wait time between strokes. The springback is measured at the downstroke of the second compression. Chewiness was calculated as Hardness * Cohesiveness * Springiness. Chewiness was only applied to solid products and is calculated as Gumminess * Springiness. Resilience was calculated by dividing the upstroke energy of the first compression by the downstroke energy of the first compression. Resilience was how well a product "fights to regain its original height". Resilience was measured on the withdrawal of the first penetration, before the waiting period is started. Resilience can be measured with a single compression; however, the withdrawal speed must be the same as the compression speed.

[0110] Having hardness between 1500 g and 3435 g, preferably between 2000 g and 3000 g, even more preferably between 2200 g and 2500 g. When compared to silken tofu, non-soy tofu has 10 times higher hardness values. When compared to firm tofu, non-soy tofu is comparable with Commercial SoyaTofu 1, but has less hardness than others.

[0111] Rheological measurement

[0112] Rheological measurements were performed with Anton Paar Physica MCR 301 rotational rheometer for different recipes to estimate the changes in the mass after mixing. C-PTD200 measuring cell was used with CC27 measuring system with CC27 / P6 geometry. Shear strain of 0.1% and frequency of 1 Hz were used. Measurement was carried out at +4 °C and at +15 °C.

[0113] Mass was produced by mixing enzyme with cool water followed by addition of faba bean isolate and oat flour. Mixing was performed with a Bamix hand blender for 2 minutes and rapeseed oil was added while mixing. Mixing was performed with a Bamix hand blender for total of 3.5 minutes. A solution of water, enzyme, faba bean protein isolate and oat flour was mixed for 2 minutes, after which rapeseed oil was added. Mixing was then continued for 1.5 minutes. The resultant mixture was poured to the CC27 measuring system 5 minutes after the mixing started. Mixed mass was measured with shear strain of 0.1% and by frequency of 1 Hz for 360 minutes.

[0114] Values of storage modulus (G') and loss modulus (G") in pascals (Pa) were acquired for a mixed dough after 2 minutes to 360 minutes. These values were compared with the consistency of mixed mass in the same time points to evaluate the composition of the mass.

[0115] The soy-free plant-based tofu-like product produced by the method of the invention has a unique and advantageous texture (mouthfeel) related to water binding properties compared to commercial tofu products on the market. When the soy-free tofu-like product of the present invention was moved or cut during food (meal) preparation (handling), it maintained phase stable status, in other words, there is no visible amount of liquid (water, whey) coming out from the tofu matrix. In contrast, when commercial soy tofu products are moved or cut during food (meal) preparation (handling), water escapes from the tofu structure to cut board or hand. The phase stability is advantageously preferred, as it is clean and easy for food handling. Syneresis from commercial tofu is unfavourable, as it is wet and causes difficulty to clean.

[0116] The following examples are presented for further illustration of the invention without limiting the invention thereto.

[0117] Example 1

[0118] A doughy composition of the invention was prepared as follows: An aqueous solution was produced by adding transglutaminase (TG) having a crosslinking activity of 100 U / g to water. Faba bean isolate (84% of protein), oat flour and rapeseed oil were added to the aqueous solution. The aqueous solution was mixed for 4 minutes with Thermomix whereby a doughy composition showing a gel structure was obtained.

[0119] In addition, an aqueous solution from TG, faba bean and rapeseed oil was product in a similar manner as describe above but without using oat flour (#1).

[0120] Four samples (#1, #2, #3, #4) produced by the method described above were manufactured. Reference sample (#RS1) without faba bean was also produced. Ingredients and their amounts in the manufacture of the samples are given in Table 1.

[0121] TABLE 1

[0122] The samples were then packed to a vacuumed, sealed plastic container, the filled container was kept for overnight (about 10 hours) at +4°C, and then heat-treated at a temperature of 121°C (i.e., sterilizing program, a) or 105°C (i.e., pasteurizing program, b) in autoclave at a pressure of about 2-4 bar to improve the gel structure of the samples. Soy-free plant-based product was produced.

[0123] The TPA test was conducted for the samples described in Table 1.

[0124] TABLE 2

[0125] The results of Table 2 shows that #RSlb was too soft to be cut and measured with pasteurization, but this was possible with sterilization. In other words, sterilization in high pressure makes the samples with oat flour less adhesive.

[0126] In dry matter, stickiness and gumminess of the product can be adjusted by ratio of faba bean isolate to oat flour in a way shown in Table 2. When 20% faba isolate is used (#1), the product is hardest, but also has highest gumminess, which is not as pleasant to eat. It was observed that in the product S3, the ratio between faba and oat was liked the most of five samples. #2 was in between of #1 and #3 but had more pleasant bite than with #1. However, #4 had high adhesiveness and was not as pleasant to eat. #RS1 sample was very soft and sticky, and its softness made it difficult to be cut.

[0127] Example 2

[0128] Cold water was mixed with transglutaminase enzyme. Faba bean isolate and oat flour were mixed with the mixture of water and enzyme for 10 minutes. Oil was added, and mixing was continued for 10 min to provide a mass. The mass was kept at +3°C for 25 minutes and packed.

[0129] Ingredients and amounts thereof used in the manufacture of the mass are given in Table 3.

[0130] TABLE 3

[0131] The product had the following composition: Carbohydrate content: 2.8 g / 100 g product (of which sugars: 0.2 g / 100 g product); Fibre content: 0.6 g / 100 g product; protein content: 12.1 g / 100 g product; fat content: 9.7 g / 100 g product (of which saturated: 0.6 g / 100 g product).

[0132] Example 3

[0133] Cold water was mixed with oil. Faba bean isolate and oat flour were mixed with the mixture of water and oil for 10 minutes. Transglutaminase enzyme was added, and mixing was continued for 10 min to provide a mass. The mass was kept at +3°C for 25 minutes and packed. The packed mass was then heat treated with pasteurization program or sterilization program shown in the Table 7 and Table 8, respectively

[0134] Ingredients and amount thereof used in the manufacture of the mass are given in Table 4. TABLE 4

[0135] Faba bean

[0136] Faba bean concentrate

[0137] Raw material isolate (%) (%)

[0138] Water 70.50 70.14

[0139] Rapeseed oil 10.73 9.36

[0140] Enzyme 0.50 0.5

[0141] Faba bean protein isolate 14.82 0

[0142] Gluten free oat flour 3.45 0

[0143] Faba bean protein concentrate 0 20

[0144] DM% 29.50 29.86

[0145] Of which Of which

[0146] _ Carb sugars _ Fibre Protein _ Fat saturated _ Isolate 2.8 _ 0.2 _ 0.7 13.0 11.0 _ 0.7 Concentrate 5.0 0.3 2.47 12.3 10.1 0.7

[0147] Faba protein isolate had 84% protein. Faba protein concentrate had 60% protein. Oat flour had 12% protein.

[0148] Program step °C min pressure

[0149] Heating 45 5 1 bar

[0150] Holding 45 60 1 bar

[0151] Heating 95 5 2 bar

[0152] Holding 95 60 2 bar

[0153] Cooling to < +6 °C

[0154] Table 5 shows the TPA analysis with 40% strain at 8°C of four soy-free plant-based products of the invention, i.e., the first four products in Table 5 designated as "non-soy tofu" (faba bean isolate, pasteurized and sterilized, and faba beam concentrate, pasteurized and sterilized), and commercial products.

[0155] The tested commercial tofu products were as follows:

[0156] Faba Tofu 1: Herkka Tofunkaltainen (Herkka Snacks Oy)

[0157] Soya Tofu 1: Sofine Tofu (SoFine Foods)

[0158] Soya Tofu 2: Jalotofu (Oy Soya Ab)

[0159] Soya Tofu 3: Extra firm tofu (Yipin)

[0160] Silken Tofu 1: TofuMoon (Tofusta Oy)

[0161] Silken Tofu 2: Jalotofu Pehmea (Oy Soya Ab)

[0162] Processed sausage: Lauantaimakkara (Atria)

[0163] "Sterilized" means sterilization at 95°C. "Pasteurized" means a pasteurization at 65°C. Processed sausage is used as a reference to what is not tofu-like.

[0164] The results of Table 5 shows that Silken tofu has chewiness ranging from 72 to 220. Commercial faba bean tofu has chewiness of 305. Also, firm tofu has lower chewiness ranging from 1913 to 2415. This non-soy tofu preferably has chewiness above Silken tofu and other commercial faba based tofu when measured by texture profile analysis. Based on Table 1, Non-soya tofu preferably has the chewiness between 1000 and 5231, more preferably between 1800 and 3500, and even more preferably between 2100 and 2900.

[0165] Gumminess is included in the Table 5 for semi-solid products like silken tofu. In comparison to silken tofu, gumminess of non-soy tofu is at least 9 times greater.

[0166] Resilience, springiness and cohesiveness are greater in non-soy tofu than with commercial FabaTofu 1 or with silken tofu. The difference is biggest in resilience.

[0167] Processed sausage has highest hardness and chewiness and is not regarded as tofu like structure.

[0168] Faba protein isolate creates better tofu-like structure than faba bean concentrate.

[0169] It will be obvious to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.

Claims

CLAIMS1. A method of producing a soy-free plant-based food product comprising the steps of:- providing a soy-free leguminous plant protein material having a protein content of at least 35 wt.% on dry weight basis,- providing a protein modifying enzyme,- providing cereal flour,- providing an aqueous liquid,- mixing the soy-free leguminous plant protein material with the protein modifying enzyme, cereal flour and the aqueous liquid to provide a composition,- filling the composition in heat-stable package,- subjecting the heat-stable package to a heat treatment to provide a soy- free plant-based food product.

2. The method of claim 1, wherein the aqueous liquid is at least one of water and a plant-based liquid comprising a legume drink, a vegetable drink, a fruit drink, or any mixture thereof, specifically water.

3. The method of claim 1 or 2, wherein the soy-free leguminous plant material is at least one of pea, faba bean, chickpea, mung bean and lentil, specifically faba bean, more specifically a faba bean isolate having a protein content of at least 80 wt.% based on weight of the faba bean isolate, or a faba bean concentrate having a protein content of at least 60 wt.% based on weight of the faba bean concentrate.

4. The method of any one of the preceding claims, wherein the content of the soy-free leguminous plant material in the composition is about 1 wt.% to about 30 wt.%, specifically about 10 wt.% to about 25 wt.%, more specifically about 13 wt.% to about 20 wt.%.

5. The method of any one of the preceding claims, wherein the cereal flour is at least one of oat, wheat, rye, barley, maize, rice and millet, specifically oat flour.

6. The method of any one of the preceding claims, wherein the cereal flour is added and the content thereof in the composition is about 1 wt.% to about 20 wt.%, specifically about 3 wt.% to about 10 wt.%, more specifically about 4 wt.% to about 8 wt.%.

7. The method of any one of the preceding claims, wherein the protein modifying enzyme is a protein crosslinking enzyme.

8. The method of claim 7, wherein the protein crosslinking enzyme is at least one of transglutaminase, tyrosinase and laccase, specifically transglutaminase.

9. The method of any one of the preceding claims, wherein the protein modifying enzyme is used in an amount of about 1 U / g protein to about 9 U / g protein, specifically about 1.5 U / g protein to about 7 U / g protein, more specifically about 2.0 U / g protein to about 5.0 U / g protein.

10. The method of any one of the preceding claims, wherein the composition is incubated at 35-55°C for 5 to 90 minutes, specifically at 40-50°C for 5 to 90 minutes, or at < 8°C overnight.

11. The method of any one of the preceding claims, wherein the aqueous liquid is added in an amount of about 60 wt.% to about 85 wt.%, specifically about 65 wt.% to about 75 wt.%, based on total weight of the composition.

12. The method of any one of the preceding claims, wherein at least one of salt and plant-based fat comprising rapeseed oil, sunflower oil, olive oil, peanut oil, avocado oil, coconut fat, palm oil, cocoa butter, and palm oil or any mixture thereof is added to the composition.

13. The method of claim 12, wherein the plant-based fat is added in an amount of about 5 wt.% to about 20 wt.%, specifically about 8 wt.% to about 15 wt.%, based on total weight of the composition.

14. The method of any one of the preceding claims, wherein the mixing is conducted for about 3 min to about 120 min, specifically about 10 min to 120 min, more specifically about 15 min to about 60 min, even more specifically about 20 min to about 60 min, still more specifically about 25 min to about 50 min.

15. The method of any one of the preceding claims, wherein after the mixing, the composition has a storage modulus of about 50 Pa to about 1500 Pa, specifically about 75 Pa to about 1000 Pa, more specifically about 100 to about 500 Pa.

16. The method of any one of the preceding claims, wherein after the mixing, the composition has a loss modulus of about 5 Pa to about 500 Pa, specifically about 10 Pa to about 250 Pa, more specifically about 20 Pa to about 100 Pa.

17. The method of any one of the preceding claims, wherein the heat treatment of the heat-stable package is carried out at about 70°C to about 150°C, specifically about 80°C to about 130°C, more specifically about 90°C to about 120°C.

18. The method of any one of the preceding claims, wherein the heat treatment of the heat-stable package is carried out for about 10 min to about 30 min, specifically about 15 min to about 20 min.

19. The method of any one of the preceding claims, wherein the heat treatment of the heat-stable package is carried out in a closed pressure vessel at a pressure of about 1.1 bar to about 4 bar, specifically about 2 bar to about 3.5 bar.

20. The method of any one of the preceding claims, wherein the moisture content of the soy-free plant-based food product is about 65% to about 85%, specifically about 70% to about 80%.

21. The method of any one of the preceding claims, wherein the soy-free plant-based food product has at least one of the following features:- a protein content of about 9 wt.% to about 20 wt.%, specifically about 10 wt.% to about 15 wt.%,- a carbohydrate content about 0.5 wt.% to about 7.5 wt.%, specifically about 2.5 wt.% to about 5 wt.%,- a fat content of about 2.5 wt.% to about 15 wt.%, specifically about 8 wt.% to about 12 wt.%.

22. The method of any one of the preceding claims, wherein the soy-free plant-based food product displays a syneresis less than 5 g per 100 g of the product, preferably less than 2 g per 100 g of the product.

23. The method of any one of the preceding claims, wherein the soy-free plant-based food product has an energy content of about 80 kcal / lOOg to about 200 kcal / lOOg, specifically about 90 kcal / lOOg to about 180 kcal / lOOg, more specifically about 120 / 100g to about 170 kcal / lOOg24. A soy-free plant-based food product comprising a soy-free leguminous plant material and cereal flour having at least one of the features:- chewiness from about 880 to about 6000, specifically about 1000 to about 5500, more specifically about 1800 to about 5000, even more specifically about 2000 to about 3500, measured at TPA 40% strain,- hardness from about 1500 g and 6000 g, specifically about 1800 g to about 5500 g, more specifically about 1900 g to about 5200 g, even more specifically about 2000 g to about 5000 g, measured at TPA 40% strain.

25. The soy-free plant-based food product of claim 24 comprising about 10 wt.% to about 30 wt.%, specifically 13 wt.% to about 20 wt.%, of the soy-free leguminous plant material and about 3 wt.% to about 20 wt.%, specifically about 4 wt.% to about 10 wt.%, more specifically about 5 wt.% to about 8 wt.%, of the cereal flour.

26. The soy-free plant-based food product of claim 24 or 25, wherein the soy-free leguminous plant material is at least one of pea, faba bean, chickpea, mung bean and lentil, specifically faba bean.

27. The soy-free plant-based food product of any one of claims 24-25, wherein the cereal flour is at least one of oat, wheat, rye, barley, maize, rice and millet, specifically oat flour.

28. The soy-free plant-based food product of any one of claims 26 and 27, wherein the soy-free leguminous plant material is at least one of pea, faba bean, chickpea, mung bean and lentil, specifically faba bean, and the cereal flour is at least one of oat, wheat, rye, barley, maize, rice and millet, specifically oat flour.

29. The soy-free plant-based food product of any one of claims 24-28, wherein the soy-free plant-based food product has at least one of the following features:- a protein content of about 9 wt.% to about 20 wt.%, specifically about 10 wt.% to about 15 wt.%,- a carbohydrate content about 0.5 wt.% to about 7.5 wt.%, specifically about 2.5 wt.% to about 5 wt.%,- a fat content of about 2.5 wt.% to about 15 wt.%, specifically about 8 wt.% to about 12 wt.%,- a moisture content of about 60% to about 85%, specifically about 70% to about 80%.

30. The soy-free plant-based food product of any one of claims 24-29, wherein the soy-free plant-based food product has an energy content of about 80 kcal / lOOg to about 200 kcal / lOOg, specifically about 90 kcal / lOOg to about 180 kcal / lOOg, more specifically about 120 / 100g to about 170 kcal / lOOg.

31. The soy-free plant-based food product of any one of claims 24-30, wherein the soy-free plant-based food product displays a syneresis less than 5 g per 100 g of the product, preferably less than 2 g per 100 g of the product.

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