Method for producing cookable, grillable or fryable meat- or fish-substitute products from vegetable components, and meat- or fish-substitute product

Abstract

The invention relates to a method for producing cookable, grillable or fryable meat- or fish-substitute products (1) from vegetable components, wherein a fibrous starting mass (2) is produced from a vegetable base material, is dispensed by an extruder (3) by wet extrusion in the form of a continuous strand (4), and after leaving the extruder (3) is cut into individual portions (5). The known methods have the disadvantage that it is not possible to produce three-dimensional products. The invention improves on this in that frozen strand sections for forming individual portions (5) are produced from the strand (4) and, as starting material, are subjected to a moulding process in a pressing device (6) individually or in a combination of two or more individual portions (5).

Description

Title of the invention: Method for manufacturing meat or fish substitute products suitable for boiling, grilling or frying, made from plant-based ingredients, and meat or fish substitute products. Technical Field

[0001] Due to the increasing scarcity of resources, there is a growing need to replace animal-based food products with plant-based alternatives. To protect animals and the environment, many consumers are increasingly calling for a reduction in the consumption of meat or fish products. The invention relates to a method for producing meat or fish substitute products from plant-based components, as well as a meat or fish substitute product produced by such a method.

[0002] Conventional methods are characterised by the production of a starting mass from a plant-based raw material, which is extruded as a continuous extrudate by an extruder using the wet extrusion process and divided into individual portions after exiting the extruder. The desired product can then be produced from these individual portions; however, due to the manufacturing process, these are two-dimensional products. State of the Art

[0003] Proteins for the production of substitute products are known, for example, from WO 23017140 A1 as textured vegetable protein (TVP) containing field bean protein and pea protein, wherein the textured vegetable protein in this case comprises at least 60 per cent by weight of field bean protein and pea protein, based on the dry weight of the TVP.

[0004] A method of the generic type is known from DE 10 2017 223 829 A1 in conjunction with the description of a cooling nozzle for the production of extruded meat substitute products. In this method, an extrudate of material is produced as a continuous extrudate via the die, whereupon the extrudate is cut up for further processing, which can be done, for example, by cutting into strips, cubes or other shapes.

[0005] A system for producing a protein-containing meat analogue is known from WO 23275305 A1, comprising a die and a flow path for the mass, wherein a cooling component is arranged downstream of the die and the flow path passes through the cooling chamber.

[0006] The employment of an extruder for the production of a meat substitute product is known from EP 3 927 176 A1. The extrusion system described therein comprises an extruder and a die, wherein the extruder is connected to the die and is configured to convey a material comprising an animal protein from the extruder to the die and through a fluid path extending through the short die. The die is configured to inject fat or a fat analogue into the material, such that the fat or fat analogue remains embedded but visually distinguishable from the material comprising the animal protein when fat or a fat analogue and protein material leave the die.

[0007] The use of a twin-screw extruder to produce an extrudate is known from EP 4 094 583 A1. Here, plant proteins from legumes, in particular pea protein, are used as the main source for twin-screw extrusion to produce a textured protein piece with a medium moisture content, which can be further processed by controlled hydration and coated with a batter, a breadcrumb coating or a glaze to produce an edible product.

[0008] WO 23 052 130 A1 discloses an extrusion system and a method for producing a meat analogue, comprising an extruder and a die, wherein a die of the extruder comprises a feed section with at least two ports for injecting a protein phase and a fat phase, a feed channel, an extrusion plane with side walls and a die outlet. The protein phase and the fat phase are conveyed from the feed section to an extrusion plane.

[0009] The substitute products manufactured using the known method have the disadvantage that their shape is generally a strict geometric basic form with smooth edges and surfaces, which consumers often perceive as artificial and unappealing. Furthermore, they have a structure that is more reminiscent of tofu or other substitute products, but cannot create the impression of a real piece of meat or fish. This is significantly improved by the present invention. Object of the invention

[0010] It is an object of the invention to provide a method for producing a meat or fish substitute from plant-based components, in which the greatest possible variety of shapes of the final product is achievable and which, whilst ensuring sufficient firmness of the product, offers the consumer a consistency that is as pleasant as possible—particularly one reminiscent of the grain or structure of pieces of meat or fish—both during preparation and consumption. Technical solution

[0011] According to the invention, this object is achieved by first cutting individual sections from the extrudate, as is currently known, then freezing these sections, and finally dividing the frozen sections into individual portions. Subsequently, the individual portions, which are still frozen, are subjected to a moulding process either individually or in a composite of two or more individual portions. The shaping process is carried out using a pressing device which comprises at least one pressing plunger and at least one counter-face against which the pressing plunger can be positioned, and which is designed such that, when the pressing plunger is positioned against the counter-face, at least one cavity remains between a pressing surface of the pressing plunger and the counter-face for the shaping reception of the input material.

[0012] By the shaping process, the frozen individual portions or the composite of several individual portions are reshaped via the press die and the counterface into a meat or fish substitute product suitable for boiling, grilling or frying, with the desired contour and the desired orientation of the fibres of the fibrous input material. Preferred embodiments of the invention

[0013] The invention now enables the production of virtually any shape. Moulding processes for producing foodstuffs that resemble, for example, a piece of natural muscle meat are known from EP 3 128 847 B1 or WO 2009 052 865 A1.

[0014] In these known pressing processes, pieces of natural muscle meat, either a single piece or several pieces as an assembly of individual parts, are placed in a mould and then pressed under pressure. Depending on the contour of the mould, this produces a coherent piece bound by proteins that is very similar to a piece cut from a piece of muscle meat; however, prior weight optimisation and uniform shaping during the pressing process make it possible to produce pieces of the same weight under the same preparation conditions. In addition to avoiding weight fluctuations, this also prevents overcooking of pieces that are too thin or undercooking of thick pieces, for example when the pieces are prepared together in a commercial kitchen.

[0015] In the manufacture of meat or fish substitute products from plant-based components, it was previously assumed that it was inevitable to accept a uniform basic structure of the product, dictated by the mass emerging from the extruder. The invention now makes it possible to preserve the fibre orientation of a fibrous plant-based raw material and to take this into account during the forming process in the manufacture of the final product. This allows a similar impression to be created to that produced by the fibres of a meat product. In this way, the final product, namely the meat or fish substitute, takes on a significantly more appealing appearance during preparation and consumption.

[0016] In the case of red meat and fish, pressing using a pressing device, as described above, is feasible for a for the skilled person because binding forces result from or are already present due to escaping proteins and the existing fibre structure of the meat, this is not immediately the case with plant-based, protein-containing substitute products. Consequently, the skilled person initially assumes that reshaping a deep-frozen product followed by cooking after thawing is not possible, as the product will subsequently disintegrate. The invention now changes this by ensuring that the fibre structure is initially preserved and, in particular, taken into account during the shaping process.

[0017] By using a moulding machine that applies pressure instead of the cutting machines previously used, it is now possible to produce any desired contours, in addition to the smooth, often unnatural-looking edges and shapes.

[0018] First, a mass emerging continuously from the extruder nozzle is produced from the plant-based raw material as the input product in a wet extrusion process, forming an extrudate. In this respect, this first step does not yet differ from the previously known processes mentioned above. The extrudate is then divided into shorter pieces, i.e. individual portions. In doing so, the fibre structure is preserved and taken into account. Through the use of an extruder, the fibres of the plant-based raw material automatically align radially to the screw axis of the extruder, so that a circular fibre pattern results in the front region of the screw due to the mass being conveyed forwards in a helical and circular flow direction and the associated flow direction.

[0019] The extruder is preferably designed such that the aforementioned alignment of the plant fibres in the space in front of the screw and upon exiting the die remains unchanged. In the extrudate drawn from the extruder, the circular alignment of the fibres parallel to the plane perpendicular to the direction of exit is thereby maintained. Due to the specific nature of the extrusion process, the fibres are arranged along a circular path within the extrudate.

[0020] The alignment of the fibres can be optimised by temperature control within the extruder or during the withdrawal of the extrudate from the extruder. For example, it is possible to heat the extruder to improve the flowability of the fibrous material, so that this improved flowability results in a targeted and improved alignment of the fibres in the direction of flow (wound around the screw axis of the extruder).

[0021] To prevent the fibres in the pressure chamber adjacent to the screw, upstream of the extruder die, from being realigned parallel to one another by the forward flow through the die—which is directed along the draw direction—this area can, for example, be cooled. It is also possible to cool the extrudate to improve the dimensional stability of the extrudate prior to solidification. At the same time, this also further fixes the fibre structure within the material.

[0022] Preventing a reversal in the flow direction of the plant-based raw material processed by the extruder, both within the extruder and during extrusion from the die, thus ensures that the input material is extruded straight out of the die from the pressure chamber of the extruder, between the tip of the extruder screw and the front housing or die, without reorientation of the fibres in the direction of draw.

[0023] A further preferred variant of the method uses a twin-screw extruder, whereby fibre orientation in the aforementioned plane, perpendicular to the direction of exit of the extrudate, is also achieved here. The fibre orientation in the extrudate can be optimised by means of the pressure and the space in front of the screw, as well as the choice of the geometry of the exit die.

[0024] The nozzle is preferably designed as a cooling nozzle, whereby the product channel of the cooling nozzle may, for example, have a height of between 35 mm, preferably between 10 mm and 25 mm. Compared to cooling nozzles known to date, it is advantageous to use a nozzle in which the product channel has an increased outlet gap. This increases design freedom during the subsequent pressing moulding process. Due to the compressive stress in the pressing process, the individual fibres of the material separate slightly from one another during forming, resulting in a particularly pleasant texture in the sense of a light, fluffy product. After forming, the product can be cooked traditionally in a pan or on a grill, or processed in other ways.

[0025] The consideration and targeted alignment of the fibre orientation during the manufacture of the individual portions intended for further processing, as well as the use of fibrous base material instead of a uniform, more finely ground or shredded input material, is an aspect of the present invention. In this context, the circular orientation of the fibres described above is preferred, although there are also applications in which a preferred orientation of the fibres parallel to the direction of withdrawal should be set. Ultimately, this depends on the subsequent processing.

[0026] A parallel alignment can be achieved by appropriately modifying the exit area of the mass from the extruder and, if necessary, also by means of a movable screw within the extruder, as is known from injection moulding in plastics technology. For example, the area in front of the extruder may be large and, if necessary, additionally heated, so that a preferential flow of a flowable material through the die results, parallel to the axis of rotation of the screw and the direction of withdrawal, whereby this flow and the flow path are then shaped in such a way that the fibres, which were originally arranged in a circular pattern, can orient themselves in the direction of flow. Inserted combing devices or intermediate dies, or other flow-guiding profiles or means, can optimise this.

[0027] The extrudate drawn or extruded from the extruder in this manner is now, according to the invention, fed for further processing. There are various possibilities for this.

[0028] In the simplest case, the extrudate is divided into individual portions. These portions are then frozen, preferably deep-frozen. Freezing has the advantage that, on the one hand, the individual frozen portions can be handled more easily by a handling system and, on the other hand, the fibre orientation in the individual portions is fixed. The frozen individual portions are then fed into the moulding process, i.e. pressed into shape in a mould cavity or on a flat support surface using the smooth or contoured surface of a press die. This allows the desired contour to be produced. As with the known methods, shapes of typical steaks, cutlets, but also sausages or pieces of fish, particularly in fillet form, can be produced here.

[0029] The individual portions can be frozen after the extruded material has been cut and subsequently fed into further processing. Preferably, they are deep-frozen to a temperature of -16 °C or lower. Alternatively, the extrudate can, of course, also be frozen before being cut into individual portions and subsequently cut. This can be done, as is the case with fish fingers, using band saws or appropriate knives or bending devices.

[0030] The only important aspect of the method according to the invention is that individual portions can be fed into further processing whilst frozen and that these portions have been produced whilst maintaining the fibre orientation. How the orientation of the fibres is then utilised ultimately depends on the desired final product.

[0031] A further advantage of the orientation of the fibres is that, during the pressing process, the fibres’ ability to hold the composite together can be utilised. Thus, it is less likely that an individual portion, whose fibres extend laterally outwards - even if this were only to occur during forming due to the flow of material in the mould - will break apart as a result of the forming process. If the fibres are aligned parallel to the pressing force, the product is much more likely to fall apart.

[0032] One aspect of the invention is therefore the use of the fibre structure to both optimise the cohesion of the product during forming and improve the visual and tactile impression of the finished product.

[0033] In a further possible application of the method, the plant-based materials are first extruded from the extruder as described above in such a way that the fibres are arranged in a circular orientation. This extrudate is then also cut lengthwise into individual portions, whereby these individual portions also exhibit the circular fibre structure in cross-section, i.e. when viewed from the cut surface.

[0034] However, in this version of the process, the individual portions can then be divided lengthwise once again, so that the resulting sections exhibit a semi-circular fibre structure, which, after being placed in the mould, lies with the cut edge of the circle facing either downwards or upwards. When the press ram is lowered, the fibres are then aligned laterally outwards and in the direction of the straight-line orientation. This means, however, that they can retain their cohesive function, as they are not compressed or torn by the press.

[0035] In addition to processing the protein-containing feedstock, further substances may be added to the feedstock either in the extruder or prior to feeding into the extruder. As already described in the prior art mentioned above, these may be fats or fat-like substances. These substances may serve to improve the texture and flavour of the final product or may also be used to modify the flow properties of the material in the extruder and during subsequent drawing. Depending on the application, animal-derived material, frozen water, egg white, marinades or spices may also be added.

[0036] The addition can take place directly into the extruder, for example via lateral inlet channels into the space between the screw and the extruder housing. Furthermore, it is possible to feed the additives into the space in front of the screw or, particularly where it is desired to coat the extruded material with a material (as is known in the manufacture of electrical cables), to add them within the cooling die during the drawing of the extruded material.

[0037] Finally, multiple extruders may also be used to prepare different materials, which are then combined via a duct system into a common outlet die to produce an extrudate that exhibits a material mix distributed across the cross-section. Here, for example, different flavours can be achieved. It is also possible to produce an outer layer which, for example, by adding nonstick agents, prevents the product from sticking to or burning on the hot surface when it is subsequently fried or grilled. Brief description of the drawings

[0038] Further aspects of the invention are apparent from the following description of preferred embodiments, with reference to the drawings. The figures show:

[0039] Fig.1: a schematic illustration of a device for carrying out the method according to the invention and

[0040] Fig.2 a flowchart showing the main steps of the process. Description of the various embodiments

[0041] Figure 1 shows a schematic view of a possible device with which the method according to the invention can be implemented.

[0042] In the embodiment shown, the processing line generally comprises three to four components. Firstly, a fibrous input material 2 is fed into an extruder 3 via an inlet hopper. In this context, ‘fibrous’ means that the plant fibres have been retained, at least in part, preferably to a large extent and most preferably in their entirety, during the production of the input material 2. The input material 2 may, of course, also be a mixture of several products, at least one of which has a retained fibre structure.

[0043] The extruder 3 extrudes the input material 2 towards an outlet nozzle, from which an extrudate 4 is drawn off by drawing means. The extruder 3 may comprise zones that are heated or zones that are cooled. The outlet die may be a cooling die which cools the extrudate as it exits the extruder 3 in order to improve dimensional stability and fix the fibre orientation.

[0044] The extrudate 4 is then fed to a cutting station, which divides the extrudate 4 into individual portions 5. This can be achieved using knives, band saws, laser cutting systems or shearing devices. Further measures may also be provided in this area; in particular, the extrudate 4 may, for example, be coated in an intermediate step, for instance with fat, a breadcrumb coating or other ingredients specified by the recipe.

[0045] In the embodiment shown, the cutting station is followed by a plate freezer, which deep-freezes the individual portions 5. The individual portions 5 are then fed to a pressing device 6, where they are placed into a mould cavity as a counter-support 8 via a handling system not shown in detail here, and subsequently shaped into the desired, application-specific form by a pressing ram 7. The final product of the process is then the meat or fish substitute product 1 made from a protein-containing plant material. This meat or fish substitute product 1 can then be further processed using conventional cooking methods.

[0046] Figure 2 depicts the essential steps of the method according to the invention, which can be carried out, for example, using the apparatus shown in Figure 1, in the form of a flowchart. First, the fibrous plant-based raw material is produced as a fibrous input mass 2. This is fed into an extruder 3, in this case a twin-screw extruder, either as a single variety or as a mixture with similar or other products. The extruder 3 produces a extrudate 4 with a circular fibre orientation in cross-section. This extrudate 4 is then cut into individual thread sections of the extrudate, with the fibres lying at least partly, and preferably predominantly, in the plane of the cut or in a plane parallel thereto.

[0047] In this way, individual portions 5 are produced, which are subsequently deep-frozen, possibly after optional pre-forming. The deep-frozen individual portions 5 are then formed into a three-dimensional final product of the desired shape in a pressing device 6 by means of a press ram 7 and an abutment 8, against which the press ram 7 is adjustable. Examples

[0048] Using the method according to the invention, it is possible, for example, to produce meat substitutes, minced meat products (meatballs, patties, cevapcici, etc.) and fish-like products in any shape. These may, for example, take the classic forms familiar from meat processing, or they may be small pieces, such as those used in goulash, for immediate preparation or as part of a skewer. Thanks to the improved cohesion of the individual pieces via the fibres, it is possible, on the one hand, to produce a greater variety of three-dimensional shapes and, on the other hand, to create more complex shapes—for example, in the form of a skewer to be grilled later—without the preparation by the end customer or in a commercial kitchen posing the problem of the product falling apart. Industrial applicability

[0049] The invention relates to the commercial production of meat or fish substitutes in the food industry. It is used to manufacture products for the end consumer or for further processing within the food industry. List of reference signs

[0050] 1 Meat or fish substitutes

[0051] 2 Fibrous feedstock

[0052] 3 Extruder

[0053] 4 Extrudate

[0054] 5 Individual portions

[0055] 6 Pressing device

[0056] 7 Pressing punch

[0057] 8 Anchor Citations

[0058] patcit1: WO 23 017 140 A1

[0059] patcit2: DE 10 2017 223 829 A1

[0060] patcit3: WO 23 275 305 A1

[0061] patcit4: EP 3 927 176 A1

[0062] patcit5: EP 4 094 583 A1

[0063] patcit6: WO 23 052 130 A1

[0064] patcit7: EP 3 128 847 B1

[0065] patcit8: WO 2009 052 865 A1

Claims

Patent Claims1. A method for producing meat or fish substitute products (1) suitable for boiling, grilling or frying from plant-based components, wherein a fibrous input mass (2) is produced from a plant-based base material, which is fed into an extruder (3) as a continuous extrudate (4) using the wet extrusion process and, after emerging from the extruder (3), is divided into individual portions (5) which are processed into the meat or fish substitute product (1), characterised in that individual sections of the extrudate (4) are first cut to form individual portions (5), then the individual portions (5) are frozen, or the extrudate (4) is first frozen and then sawn or cut into individual sections to form frozen individual portions (5), and then the frozen portions (5) produced in this way are subjected to a moulding process as input material, either individually or in a combination of two or more individual portions (5), wherein the moulding process is carried out using a pressing device (6) which comprises at least one pressing plunger (7) and at least one counter-face (8) against which the pressing plunger (7) can be positioned, and which is designed such that, when the press punch (7) is brought into contact with the counter-face (8), at least one cavity remains between a pressing surface of the press punch (7) and the counter-face (8) for the shaping reception of the input material, and wherein, in the forming process, the frozen input material is placed in the press device (6) via the press punch (7) and the abutment (8) into the press device (6) to form a meat or fish substitute product (1) suitable for cooking, grilling or frying with the desired contour, and is then shaped in such a way that the resulting meat or fish substitute product (1) exhibits a predetermined, desired fibre structure.

2. A method for producing meat or fish substitute products (1) from plant-based components of claim 1, characterised in that the individual portions (5) are pre-shaped by cutting, embossing or other means prior to freezing and pressing in the pressing device (6).

3. A method for producing meat or fish substitute products (1) from plant-based ingredients of claim 1 or claim 2, characterised in that the meat or fish substitute product (1), which is suitable for boiling, grilling or frying, is deep-frozen after the shaping process.

4. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that the feedstock (2) contains protein-rich plant products, in particular from pulses, soya, mushrooms or the like, wherein a protein-containing wet extrudate is produced from the components in the extruder (3).

5. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that a rectangular die with a width and a height of at least 10 mm and a maximum of 150 mm each, preferably with a width between 30 mm and 150 mm and a height of at least 50 mm to a maximum of 150 mm, is used as the extruder die.

6. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that the extruded product (4) is cut into extruded sections such that individual portions (5) are produced, which have a length of between 300 mm and 700 mm, preferably between 400 mm and 600 mm, and most preferably between 450 mm and 500 mm.

7. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that the individual portions (5) are deep-frozen at a temperature of -16°C or lower.

8. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that the sections of the extrudate are cut in the longitudinal direction of the extrudate (4) so as to produce longitudinal sections with a longitudinal cut surface in the longitudinal direction, wherein the individual portions (5) are separated from the halves of the extrudate thus produced in the transversedirection, in particular by cutting or notching, so that the portions (5) have cross-sectional surfaces and a longitudinal cut surface.

9. A method for producing meat or fish substitute products (1) from plant-based components according to the preceding claim, characterised in that, during the moulding process, the individual portions (5) are positioned in the pressing device (6) in such a way that the press ram (7) is subsequently moved against the longitudinal cut surface and the pressing force acts directly on the longitudinal cut surface.

10. A method for producing meat or fish substitute products (1) from plant-based components according to claim 7, characterised in that, during the forming process, the individual portions (5) are placed with the longitudinal cut surface on the abutment (8) so that the pressing force acts indirectly as a reaction force on the longitudinal cut surface.

11. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that the frozen portions (5) are shaped in such a way that the meat or fish substitute product (1) has a flat or contoured underside and / or a flat or contoured upper side.

12. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that the meat or fish substitute product (1) is subjected to additional treatment before or after shaping, in particular by marinating, breading or otherwise coating.

13. A method for producing meat or fish substitute products (1) from plant-based components according to one of the preceding claims, characterised in that, during the production of the extrudate (4) via extrusion, the fibres of the input mass (2) in the extrudate (4) are aligned such that they are arranged in a circular pattern in a plane perpendicular to a discharge direction in which the extruded material leaves the extruder (3).

14. A method for producing meat or fish substitute products (1) from plant-based components according to the preceding claim, characterised in that the extrudate sections are inserted into the cavity of the pressing device (6) insuch a way that the fibres are arranged in a plane perpendicular to a pressing force applied by the pressing ram (7).

15. A method for producing meat or fish substitute products (1) from plant-based components according to claim 13, characterised in that the extrudate sections are placed in the cavity of the pressing device (6) in such a way that the fibres are arranged in a flat or curved plane which is parallel to a pressing force applied by the pressing ram (7).

16. A meat or fish substitute product (1) characterised in that it is produced by a method according to one of the preceding claims.

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