Meat-analogue food product and method for manufacturing the same

Abstract

This invention provides a processed meat-like food and its manufacturing method, which uses textured plant material as a substitute for meat. In the processed meat-like food, the yield upon heating is good and it has a meat-like texture when using an oil-in-water emulsion gel containing methylcellulose as the preform. The process involves the following steps: (a) preparing an oil-in-water emulsion containing at least oil, methylcellulose, and water; (b) preparing a preform by mixing textured plant material, insoluble dietary fiber, and citrus fiber into the emulsion in (a); and (c) heating the preform prepared in (b) after molding to produce the processed meat-like food. This allows the manufacture of processed meat-like foods without the use of animal raw materials. The average fiber length of the insoluble dietary fiber is preferably 20 μm to 300 μm, and more preferably bamboo fiber.

Description

Technical Field

[0001] This invention relates to a processed meat-like food and its manufacturing method, in which a tissue-like plant material is used as a substitute for meat. In the processed meat-like food, the embryo containing an oil-in-water emulsion gel containing methylcellulose has a good yield and a meat-like texture when heated. Background Technology

[0002] The plant-based diet market, especially processed meat-like foods such as veggie burgers, has seen significant growth both domestically and internationally. These processed meat-like foods are made from plant-based proteins such as soybeans, processed using extruders to create a textured protein profile resembling meat. However, because many products use dried egg whites, which are animal-based, they are unsuitable for vegans and other strictly vegetarian diets.

[0003] As a substitute for dried egg white, methylcellulose (hereinafter referred to as MC) is mostly used. In Patent Document 1, methylcellulose and gluten are used to produce meat-like processed foods with methylcellulose as the main component. In Patent Document 2, an emulsion curd made by separating soy protein material and methylcellulose is used to produce meat-like processed foods with methylcellulose as the main component. However, it does not achieve a texture that can replace egg white, and there is also dehydration caused by heating due to methylcellulose. Further improvements are expected.

[0004] In Patent Document 3, a meat-like processed food is made by using a lipid gel composed of fats and insoluble fibers. However, the physical properties are different from those of hamburgers sold in Japan, and it is required to suppress the prominent meat grain texture and improve the dryness.

[0005] Citrus fiber is a material that is well used in improving the physical properties of wheat flour products such as baked goods. In Patent Document 4, adding citrus fiber to the marinade of food materials for deep-frying, such as chicken, can improve the crispness of the coating, but there is no disclosure or suggestion regarding its combination with methylcellulose gel.

[0006] Existing technical documents

[0007] Patent documents

[0008] Patent Document 1: Japanese Patent Application Publication No. 2005-21163

[0009] Patent Document 2: Japanese Patent Application Publication No. 2018-29565

[0010] Patent Document 3: Japanese Patent Publication No. 2018-533945

[0011] Patent Document 4: Japanese Patent Application Publication No. 2019-110898 Summary of the Invention

[0012] The problem that the invention aims to solve

[0013] The purpose of this invention is to provide a processed meat-like food product that uses tissue-like plant material as a substitute for meat. In the processed meat-like food product, the embryo material containing an oil-in-water emulsion gel containing methylcellulose has a good yield when heated and a meat-like texture.

[0014] Technical means to solve the problem

[0015] The inventors have conducted repeated and diligent research on the aforementioned subject matter, and as a result, they discovered that by using insoluble dietary fiber and citrus fiber together, the texture, especially the meat-like texture, is improved, as is the yield during heating, thus completing this invention.

[0016] That is, the present invention relates to the following.

[0017] (1) A method for manufacturing a processed meat product, comprising the following steps:

[0018] (a) The process of preparing an oil-in-water emulsion comprising at least oil, methylcellulose and water

[0019] (b) The process of preparing the embryo by mixing textured plant materials, insoluble dietary fiber and citrus fiber into the emulsion of (a).

[0020] (c) The process of heating the embryo prepared in (b) after molding to produce a processed meat-like food.

[0021] (2) The method for manufacturing processed meat products according to (1), wherein the processed meat products do not contain meat or egg white.

[0022] (3) The method for manufacturing processed meat products according to (2), wherein the average fiber length of the insoluble dietary fiber is 20 μm to 300 μm.

[0023] (4) The method for manufacturing processed meat products according to (3), wherein the insoluble dietary fiber is bamboo fiber.

[0024] (5) The method for manufacturing processed meat products according to (1), wherein the average fiber length of the insoluble dietary fiber is 20 μm to 300 μm.

[0025] (6) The method for manufacturing processed meat products according to (5), wherein the insoluble dietary fiber is bamboo fiber.

[0026] (7) The method for manufacturing processed meat products according to (1), wherein the pre-emulsion contains an oil-in-water emulsion gel containing methylcellulose.

[0027] (8) The method for manufacturing processed meat products according to (7), wherein the processed meat products do not contain meat or egg whites.

[0028] (9) The method for manufacturing processed meat products according to (8), wherein the average fiber length of the insoluble dietary fiber is 20 μm to 300 μm.

[0029] (10) The method for manufacturing processed meat products according to (9), wherein the insoluble dietary fiber is bamboo fiber.

[0030] (11) The method for manufacturing processed meat products according to (7), wherein the average fiber length of the insoluble dietary fiber is 20 μm to 300 μm.

[0031] (12) The method for manufacturing processed meat products according to (11), wherein the insoluble dietary fiber is bamboo fiber.

[0032] (13) A processed meat-like food containing textured plant material, methylcellulose, insoluble dietary fiber and citrus fiber, wherein the processed meat-like food contains an oil-in-water emulsion gel containing methylcellulose in the germ.

[0033] (14) The processed meat products according to (13) do not contain meat or egg white.

[0034] (15) The processed meat product according to (14) wherein the average fiber length of the insoluble dietary fiber is 20 μm to 300 μm.

[0035] (16) The processed meat product according to (15), wherein the insoluble dietary fiber is bamboo fiber.

[0036] The effects of the invention

[0037] This invention provides a meat-like processed food product that improves the yield during heating while reducing or eliminating the use of egg white. Detailed Implementation

[0038] (Processed meat products)

[0039] The processed meat-like foods of this invention refer to those processed primarily using tissue-like plant materials to resemble meat. Examples of processed meat-like foods include: hamburgers, pies, meatballs, fried meat chunks, roasted meatballs, ham, sausages, salami, Frankfurt sausages, American dogs, dumplings, shumai, spring rolls, steamed buns, mini steamed buns, fried meat patties, meat pies, ravioli, lasagna, toast-shaped meat strips, stuffed cabbage rolls, stuffed bell peppers, or other general foods that typically use various meat fillings.

[0040] (oil-in-water emulsion)

[0041] In this invention, there is a need for an oil-in-water emulsion comprising methylcellulose and water.

[0042] The methylcellulose used in this invention is produced by methoxylating naturally distributed cellulose. It is typically manufactured by treating cellulose with caustic soda followed by reaction with methyl chloride and an etherifying agent. Furthermore, it possesses the property of reversibly increasing gelling power upon heating. In this invention, methylcellulose can be used either as elemental methylcellulose or in combination with other gelling agents. Other gelling agents include: egg white, gellan gum, carrageenan, alginate, agar, curdlan, konjac flour, and starch.

[0043] Various oils and fats can be used in the emulsions of this invention. Specifically, examples include soybean oil, rapeseed oil, rice bran oil, corn oil, palm oil, tallow, lard, and their separated oils, hardened oils, and transesterified oils, which may be suitably selected for use. However, since the purpose of this invention is to produce meat-like processed foods, it is ideal to use oils and fats that are in a melted state at edible temperature or even mouth temperature.

[0044] (Insoluble dietary fiber)

[0045] The insoluble dietary fiber used in this invention is a plant-derived fiber that is insoluble in water or warm water. Specifically, examples include bamboo fiber, oat fiber, and wheat fiber. Bamboo fiber, which imparts a moderate firmness without drying out, is particularly preferred. Furthermore, its average fiber length is preferably 20 μm to 300 μm, and more preferably 30 μm to 200 μm. Moreover, the average fiber length can be determined by measuring the fiber length of the dietary fiber using a scanning electron microscope. That is, the average fiber length is obtained by randomly selecting 30 fibers in the field of view and taking their average value.

[0046] Adding insoluble dietary fiber can improve the gel-like texture caused by methylcellulose, thereby achieving a meaty fibrous texture similar to that of typical processed meat products. If the fiber length is within an appropriate range, the fibrous texture is reduced and the chewiness becomes better; however, if it is shorter than 20 μm, the meaty texture is slightly weakened; and if the fiber length exceeds 300 μm, the gel-like texture is not significantly reduced, and there is a tendency for the texture to become tough.

[0047] (Citrus fiber)

[0048] The citrus fiber used in this invention is produced by pressing citrus fruits such as oranges, removing the juice from the juice, and subjecting the powdered cell walls to high-impact treatment. Therefore, in this citrus fiber, the micelle structure of the cells is disrupted, resulting in a porous structure, significantly increasing water absorption and water binding capacity, thus enhancing water retention. Specifically, this means that the water absorption per unit weight of fiber is 15 times or more, preferably 18 times or more. Furthermore, the water absorption is determined by adding 50g of water to 1g of each sample of fiber, stirring in a 50ml container, allowing it to stand for 24 hours, and then confirming the boundary between the supernatant and the precipitate. Additionally, the insoluble dietary fiber refers to fiber with a formal water absorption of less than 15 times, preferably less than 10 times.

[0049] By adding citrus fiber, dehydration during the heating and molding process, which is a problem when using methylcellulose, can be suppressed, thereby maintaining a meat-like texture and improving yield.

[0050] (tissue-like plant material)

[0051] The tissue-like plant material used in this invention is a material containing directional, water-insoluble tissue, mainly divided into tissue-like plant protein material and tissue-like plant polysaccharide material.

[0052] Textured plant-based protein materials can be categorized as those made from plant-based raw materials such as soybeans, defatted soybeans, soy protein isolate, soy protein concentrate, wheat, wheat protein, peas, pea protein, chickpeas, and mycoprotein, processed into textured forms. For example, in the case of soybeans, materials such as defatted soybeans and soy protein isolate can be combined with other raw materials as needed and textured under high temperature and pressure using a single-shaft or bi-shaft extruder (extruder) to produce granules, flakes, sliced ​​meat, or other similar shapes. Peas, mung beans, and chickpeas can also be processed using round beans or their graded products to obtain textured materials.

[0053] This invention is suitable for textured soybean protein materials made primarily from soybeans, and products of any shape or size can be selected according to the desired commercial form. Furthermore, although products that have been rehydrated and then distributed exist, dried products (moisture content below 10% by weight) are ideally used in this invention. Additionally, soybean materials textured through pressing into tofu are also suitable for this invention.

[0054] As a tissue-like plant protein material, so-called gluten flakes prepared by processing wheat protein can also be used in this invention.

[0055] On the other hand, tissue-like plant polysaccharide materials can be used as polysaccharide materials by freezing polysaccharides, especially konjac gel, in which some polysaccharides are insoluble.

[0056] In this invention, the tissue-like plant materials can also be used in combination with various shapes such as flat or granular. Furthermore, various tissue-like plant materials can also be used in combination.

[0057] The emulsion containing textured plant polysaccharides, insoluble dietary fiber, and citrus fiber is used as a pre-gel. By heating the pre-gel, the textured plant polysaccharides are agglomerated using a gelling agent primarily composed of methylcellulose, thus producing meat-like processed foods. These meat-like processed foods have a similar texture to meat processed foods using egg whites.

[0058] (Process a) (Emulsion Preparation)

[0059] Oil-in-water emulsions are prepared by mixing oils, methylcellulose, and water. When shearing is applied using a mixer, food processor, silent cutter, manual mixer, or Stephan mixer, the emulsion particles become finer, which is preferable. Even better emulsions can be obtained by pre-mixing and thoroughly dispersing the oils and methylcellulose before adding water.

[0060] The amount of oil is preferably 10% to 40% by weight, and more preferably 15% to 30% by weight. The amount of methylcellulose needed to form a gel can be, for example, 2% to 8% by weight.

[0061] The amount of water varies depending on the amount of other additives, but is preferably 55% to 88% by weight, and more preferably 55% to 83% by weight. Furthermore, the solubility of methylcellulose increases at low temperatures, so the water used is preferably cold, and ice water is even more preferred. Freezing after emulsion preparation is also effective.

[0062] Other ingredients, such as sweeteners, spices, salt, flavoring materials, and seasonings, may be added to the emulsion to a extent that does not impair the effects of the present invention. These additions may be made before or after the emulsification process.

[0063] (Process b) (Preparation of raw material)

[0064] In the emulsion prepared in step a, insoluble dietary fiber, citrus fiber, and textured plant material are mixed to form a pre-emulsion. Mixing can be performed using a mixer, food processor, or silent cutter. When the textured plant material is textured plant protein material, it is usually a dried form. Therefore, in this case, mixing is first performed on a "rehydration" process to soften the tissue through water absorption. However, adding dried textured plant protein material and water is acceptable, as is adding a portion of rehydrated textured plant protein material and water. Alternatively, a portion of the water can be incorporated into the oil-in-water emulsion.

[0065] To alter the flavor or physical properties, various seasonings, vegetables, starches, gelling agents, egg whites, powdered soy protein, and other plant-based protein materials can be added. Furthermore, the addition of meat is also permitted.

[0066] Regarding the respective amounts used, in the germ, the emulsion is preferably 10% to 40% by weight, more preferably 20% to 30% by weight. The insoluble dietary fiber is preferably 0.1% to 5% by weight, more preferably 0.5% to 3% by weight. The citrus fiber is preferably 0.1% to 5% by weight, more preferably 0.5% to 3% by weight. The tissue-like plant material, on a dry weight basis, is preferably 5% to 30% by weight, more preferably 8% to 20% by weight.

[0067] Meat can also be used to replace textured plant protein materials, but the amount of meat is preferably 25% by weight or less, more preferably not used. Egg white can also be added, but the amount of egg white is preferably 5% by weight or less, more preferably not used.

[0068] (Process c) (Molding heating)

[0069] The blank produced in step b is shaped into the required size and shape using a forming machine. It is then fed into a heating process. The heating method in this invention can be appropriately combined with calcination heating, steam heating, boiling heating, frying heating, electromagnetic wave heating, etc. Alternatively, dry distillation heating can also be used. The resulting blank solidifies upon heating, stabilizing its shape.

[0070] Temperature and time also depend on shape or weight and heating method, but calcination heating can be exemplified by 180℃~300℃ for 5 minutes to 15 minutes, dry distillation heating can be exemplified by 115℃~130℃ for 10 minutes to 60 minutes, and cooking heating can be exemplified by 75℃~100℃ for 5 minutes to 50 minutes.

[0071] This invention enables the production of meat-like processed foods with the same taste as conventional meat-based processed foods without reducing or eliminating the use of animal-derived raw materials such as meat or egg whites, and without lowering the yield during heating.

[0072] Example

[0073] The present invention will be described below by way of examples. The following parts are defined as parts by weight.

[0074] Example 1

[0075] 1.3 parts of methylcellulose (Shin-Etsu Chemical, MCE100TS) were added to 4.2 parts of rapeseed oil. After stirring in a robot coupe, 16.6 parts of ice water were added and stirred further to obtain oil-in-water emulsion A. Relative to the total amount of emulsion A, 2.0 parts of bamboo fiber (Rettenmaier, BAF90, average fiber length 80μm, water absorption 4.5 times) and citrus fiber (DSP Gokyo, Herbacel AQ Plus CF-D) were added. 2.0 parts of CF-D (100 / 40 times water absorption) were added after mixing with a mixer. Then, 2.5 parts of textured soy protein material B (manufactured by Fuji Oil, Apex 650 / granule shape) reconstituted with 10 parts water were added; 7.5 parts of textured soy protein material C (manufactured by Fuji Oil, Apex 350 / granule shape) reconstituted with 18.8 parts water were added; 3.0 parts of textured soy protein material D (manufactured by Fuji Oil, Apex 950 / flat shape) reconstituted with 7.5 parts water were added; 5.0 parts of vegetable oil that is solid at room temperature (manufactured by Fuji Oil, Unishort MJ) were added; 8.6 parts of seasonings and spices were added; 10.0 parts of onion cut into 5mm cubes were added; and α-starch (manufactured by Matsutani Chemical, Matsutani) was added. Mix 2.0 parts of pinesoft (B) with a Kenwood mixer for 3 minutes to form a dough.

[0076] The dough was punched and shaped using an automatic forming machine (GM-D) manufactured by Japan Career Co., Ltd., to produce 70g pieces. These pieces were then heated in a convection oven (manufactured by Rational Japan Co., Ltd., SCC WE 101) at 300°C for 6 minutes to obtain hamburger-like food.

[0077] Example 2

[0078] The citrus fiber in the formulation of Example 1 was replaced with orange fiber (manufactured by Torigoe Flour, Citri-Fi 100FG / 20 times water absorption), and prepared in the same manner as in Example 1.

[0079] Comparative Example 1

[0080] Remove the citrus fiber and bamboo fiber from the formulation of Example 1, and prepare it in the same manner as in Example 1.

[0081] Comparative Example 2

[0082] Remove the citrus fiber from the formulation of Example 1 and prepare it in the same manner as in Example 1.

[0083] Regarding Examples 1, 2, and Comparative Example 1 above, each molded part was heated at 90°C for 12 minutes using a convection oven (manufactured by Rational Japan, SCC WE 101). Additionally, each molded part was heated in a frying pan for approximately 6 minutes until the core temperature reached 80°C. Furthermore, each molded part was subjected to dry distillation heating at 121°C for 30 minutes using an RCS-40RTG manufactured by Nichisaka.

[0084] Comparative Example 3

[0085] The citrus fiber in the formulation of Example 1 was replaced with pea fiber (manufactured by Rettenmaier, Pea EF150 / 14 times water absorption) and prepared in the same manner as in Example 1.

[0086] Comparative Example 4

[0087] The bamboo fiber was removed from the formulation of Example 1, and the same preparation was carried out as in Example 1.

[0088] Example 3

[0089] The bamboo fiber in the formulation of Example 1 was replaced with an equal amount of sugarcane fiber (manufactured by JRS Corporation, SF601, average fiber length 100 μm / water absorption rate 4.8 times), and prepared in the same manner as in Example 1.

[0090] Example 4

[0091] The bamboo fiber in the formulation of Example 1 was replaced with an equal amount of wheat fiber (manufactured by Rettenmaier, VITACEL WF200 / average fiber length 250μm / water absorption 7.5 times), and prepared in the same manner as in Example 1.

[0092] (Table 1) Composition of each test case

[0093]

[0094] (evaluate)

[0095] The weight of each molded blank was measured before and after heating, and the heating yield was calculated. Based on this, the yield was expressed as a relative value with the yield of Comparative Example 1 set as 100. In addition, the functional evaluation was performed according to the following criteria.

[0096] (Sensory evaluation criteria)

[0097] The sensory evaluation was conducted by a panel of five skilled members who comprehensively assessed the taste of processed meat products, especially hamburgers, and made a decision through consultation.

[0098] A: It's just as good as a meat burger, especially good.

[0099] B: As a hamburger-like food, it's fine and has no problems.

[0100] C: Although slightly worse, it's still within the range of hamburger-like foods.

[0101] D: It feels out of place and inappropriate as a hamburger-like food.

[0102] (Table 2) Yield and functional evaluation of each test case

[0103]

[0104] The formulations and evaluation results are shown in Table 2. While the texture varies depending on the formulation, all examples can be said to have a texture equivalent to processed meat products. On the other hand, the comparative examples are unsuitable due to issues such as a "sticky" texture, insufficient meat-like texture, excessive dehydration, and low yield caused by heating.

[0105] Industrial availability

[0106] Using this invention, processed meat-like foods can be manufactured with almost no animal-derived ingredients.

Claims

1. A method for producing a processed food having a texture of meat, comprising the steps of: (a) a step of preparing an oil-in-water emulsion containing at least 10 to 40% by weight of fat, 2 to 8% by weight of methylcellulose, and 55 to 88% by weight of water; (b) a step of preparing a dough-like material by kneading the oil-in-water emulsion prepared in the step (a) and a water-insoluble food fiber; (c) a step of heating the dough-like material prepared in the step (b) after molding to produce a processed food having a texture of meat. The water-insoluble food fiber is bamboo fiber or sugar cane fiber. (b) a step of mixing the organized plant material, the insoluble dietary fiber, and the citrus fiber in the emulsion of (a) to prepare a precursor, (c) a step of heating the dough-like material prepared in the step (b) after molding to produce a processed food having a texture of meat. The processed food does not contain meat and egg white.

2. The method for producing a livestock-meat-like processed food according to claim 1, wherein The average fiber length of the water-insoluble food fiber is 20 to 300 μm.

3. The method for producing a livestock meat-like processed food according to claim 2, wherein The average fiber length of the water-insoluble food fiber is 20 to 300 μm.

4. The method for producing a livestock meat-like processed food according to claim 1, wherein The dough-like material contains an oil-in-water emulsion gel containing methylcellulose.

5. The method for producing a livestock meat-like processed food according to claim 1, wherein The processed food does not contain meat and egg white.

6. The method for producing a processed food of animal meat according to claim 5, wherein The average fiber length of the water-insoluble food fiber is 20 to 300 μm.

7. The method for producing a processed food of animal meat according to claim 6, wherein The average fiber length of the water-insoluble food fiber is 20 to 300 μm.

8. The method for producing a processed food of animal meat according to claim 5, wherein The water-insoluble food fiber is bamboo fiber or sugar cane fiber.

9. A processed food in the form of a meat-like food product, comprising a plant material in the form of a tissue, methylcellulose, insoluble dietary fiber, and citrus fiber, the processed food in the form of a meat-like food product comprising a gel in which an oil-in-water emulsion containing 10 to 40% by weight of oil, 2 to 8% by weight of methylcellulose, and 55 to 88% by weight of water is contained in a base material, wherein, 10. The processed food having a texture of meat according to claim 9, which does not contain meat and egg white. The average fiber length of the water-insoluble food fiber is 20 to 300 μm.

11. The poultry meat analogue processed food according to claim 10, wherein, The average fiber length of the water-insoluble food fiber is 20 to 300 μm.

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