A high-moisture plant protein extrudate and methods of making the same

Abstract

The present application relates to a kind of high moisture content plant protein extrudate and its preparation method.The preparation method of high moisture content plant protein extrudate is specifically extruding material containing soybean protein isolate, the moisture content of material containing soybean protein isolate is 55-75wt%, the soybean protein isolate content is 25-45wt%, and the extrusion temperature is 130-170 DEG C.The present application is based on molecular engineering principle, with soybean protein as raw material, using double screw high moisture extrusion technology, by adjusting the extrusion parameter in high moisture extrusion process, the addition amount of soybean protein in material and moisture content, based on the material characteristics of plant protein and the interaction in extrusion process, the extrusion texture characteristics are regulated, with single soybean protein extrudate as raw material, a plurality of plant-based products are developed, the manufacturing process is simple, the simulation of meat and egg white is realized, the product texture is improved, the product taste is enriched, and a new idea is provided for the simulation of meat product and egg product.

Description

Technical Field

[0001] This invention belongs to the field of plant-based product preparation technology, and in particular relates to a plant protein extrudate with high moisture content and its preparation method. Background Technology

[0002] Global meat production faces the serious challenge of failing to meet ever-increasing human demand. It is projected that by 2050, the global population will gradually stabilize at 9 billion, at which point meat production and demand are expected to increase by approximately 50-73%. However, this growth is accompanied by a series of worrying problems. Livestock farming will not only consume vast amounts of arable land, food, and water resources, but will also further exacerbate the environmental burden. The overuse of animal antibiotics and hormones, the spread of diseases such as avian influenza and swine flu, and pathogenic microbial contamination also seriously threaten public food safety. Furthermore, people's dietary habits of consuming large amounts of meat have led to dietary imbalances, resulting in an increase in chronic diseases such as obesity and cardiovascular disease. Therefore, plant-based artificial meat products are increasingly becoming a focus of consumer attention.

[0003] High-moisture extrusion technology is a method for preparing textured plant-based meat that achieves a dense fibrous texture or elastic structure by controlling the input moisture content. In the high-moisture extrusion process, the raw material is first fed into a twin-screw extruder. Under the mechanical action of the screws, the mixture is subjected to shearing and softening. Subsequently, a cooling module at the tail of the extruder causes the proteins in the material to rearrange and layer, making them more stable and forming a fibrous structure, ultimately yielding high-quality plant-based meat products.

[0004] Plant-based meat products are widely recognized as an ideal alternative to animal meat due to their advantages, including low saturated fat, no cholesterol, high protein content, rich in essential amino acids, and good digestibility. Therefore, this method is considered one of the best options for developing plant-based products. Soy protein is considered one of the most common raw materials in the production of artificial meat due to its high water-holding capacity and strong gelling ability. By adjusting the moisture content, extrudates with different textures and mouthfeel can be obtained, providing possibilities for producing a wider variety of plant-based meat products.

[0005] CN101473966A discloses a method for preparing texturized soybean protein imitation meat products. The effects of soybean protein isolate content, material moisture content, extrusion temperature, and screw speed on the degree of texturization were investigated, and the optimal parameters for processing the product were determined: material moisture content of 48–56%, four-zone extrusion temperature of 150.8℃–153.5℃, screw speed of 202–209 rpm, and soybean protein isolate content of 34.5–37.7%. Under these conditions, the product has a good texture and obvious fiber fibers, meeting quality requirements. The process parameters for marinating, braising, coloring, and roasting the prepared soybean protein texturized meat imitation product were further optimized. These processing methods effectively mask the beany smell of fibrous soybean protein, producing an aroma similar to roasted chicken, with a taste and flavor similar to roasted chicken currently on the market. The raw materials for this patent consist of soy protein isolate, defatted soy flour, and wheat gluten, with soy protein isolate accounting for 34.5–37.7 wt% of the total dry weight of the raw materials. The moisture content of the materials is 48–56%. Its focus is on solving the problem of low texturization in plant-based meat.

[0006] CN114403284A discloses a method for regulating the structural properties and fiber structure of plant proteins during a high-moisture extrusion process. Using plant protein as raw material, the method employs twin-screw high-moisture extrusion technology and introduces polysaccharide food colloidal structure-regulating agents (carrageenan, glucon, potato starch) to regulate the structural properties and fiber structure of plant proteins based on the interaction between the protein and polysaccharide binary components. Compared to high-moisture extrudates made solely from pea protein, the polysaccharide complex increases its texture, hardness, elasticity, and chewiness. Plant-based meat dumplings developed using high-moisture protein-polysaccharide complex extrudates exhibit a significantly superior texture compared to commercially available dry-processed protein-based products. This patent regulates the structural properties and fiber structure of plant proteins by introducing polysaccharide food colloidal structure-regulating agents based on the interaction between the protein and polysaccharide binary components.

[0007] CN115281334A discloses a method for simulating connective tissue using gluconol. Using gluconol as a raw material, it employs twin-screw high-moisture extrusion technology. By adjusting the screw speed, extrusion temperature, feeding speed, and moisture content during the high-moisture extrusion process, the structural properties of the extruded material are controlled based on the material characteristics of polysaccharides and their interactions during extrusion. Suitable extrusion parameters can improve the hardness, elasticity, and chewiness of the gluconol extruded material and effectively simulate connective tissue. This method can be applied to the development of non-muscular connective tissue products such as pigskin, beef trachea, and beef tendon. Specifically, the method for simulating connective tissue using gluconol involves extruding a material containing gluconol, with a moisture content of 70-80 wt% and a gluconol content of 20-30 wt%, at an extrusion temperature of 150℃-180℃.

[0008] Currently, the highest moisture content of common pea protein high-moisture extrudates is 60%, resulting in a soft texture and poor chewiness. Further increasing the moisture content prevents the extrudate from forming properly. Therefore, how to regulate the extrusion of a single soybean protein to produce a variety of plant-based products to fill market gaps is a pressing issue. Solving this problem will play a crucial role in the future research and application of plant-based meat, possessing enormous market potential. Summary of the Invention

[0009] Currently, there are many technologies for simulating meat using plant protein extrusions, but no existing technology has found a way to manufacture multiple plant-based products using the same plant protein. Therefore, this invention provides a high-moisture-content plant protein extrusion and its preparation method.

[0010] The objective of this invention can be achieved through the following technical solutions:

[0011] The present invention first provides a method for preparing a plant protein extruder with high moisture content, specifically by extruding a material containing soy protein isolate, wherein the moisture content of the material containing soy protein isolate is 55-75 wt%, the soy protein isolate content is 25-45 wt%, and the extrusion temperature is 130℃-170℃.

[0012] In one embodiment of the present invention, the material containing soy protein isolate has a moisture content of 75 wt% and a soy protein isolate content of 25 wt%.

[0013] In one embodiment of the present invention, the material containing soy protein isolate is extruded using a twin-screw extruder.

[0014] In one embodiment of the present invention, the twin screw speed is 140 rpm to 180 rpm.

[0015] In one embodiment of the present invention, the feeding speed of the twin-screw extruder is 4 g / min-8 g / min.

[0016] In one embodiment of the present invention, the temperature of the cooling section of the twin-screw extruder is 75°C.

[0017] In one embodiment of the present invention, the moisture content of the material containing soy protein isolate is 65 wt%, the soy protein isolate content is 35 wt%, and when the material containing soy protein isolate is extruded by a twin-screw extruder, the extrusion temperature is 150°C, the screw speed is 180 rpm, and the feeding speed is 7 g / min.

[0018] In one embodiment of the present invention, the material containing soy protein isolate has a moisture content of 75 wt% and a soy protein isolate content of 25 wt%. When the material containing soy protein isolate is extruded by a twin-screw extruder, the extrusion temperature is 140°C, the screw speed is 140 rpm, and the feeding speed is 7 g / min.

[0019] The present invention further provides a plant protein extrudate with high moisture content prepared by the above method.

[0020] In one embodiment of the present invention, the high-moisture-content plant protein extrudate is used to prepare simulated products, including plant-based beef and plant-based dried egg.

[0021] In one embodiment of the present invention, the plant-based beef is produced based on a material containing soy protein isolate and under twin-screw extrusion conditions:

[0022] Materials containing soy protein isolate: moisture content 65%, soy protein content 35%;

[0023] The conditions for twin-screw extrusion are as follows: the screw speed is fixed at 180 rpm, the feed rate of the feeder is 7 g / min, and the barrel temperature is set at 40℃, 60℃, 90℃, 150℃, 150℃, 150℃, 150℃ and 150℃ in 8 zones from the feed section to the die section. The long cooling die is kept at 75℃ by water circulation.

[0024] In one embodiment of the present invention, the plant-based dried egg is produced based on a material containing soy protein isolate and under twin-screw extrusion conditions:

[0025] Materials containing soy protein isolate: moisture content 75%, soy protein content 25%;

[0026] The conditions for twin-screw extrusion are as follows: the screw speed is fixed at 140 rpm, the feed rate of the feeder is 7 g / min, and the barrel temperature is set at 40℃, 60℃, 90℃, 140℃, 140℃, 140℃, 140℃ and 140℃ in 8 zones from the feed section to the die section. The long cooling die is kept at 75℃ by water circulation.

[0027] The study found that soybean protein extrudates with low moisture content have a dense and chewy fiber structure, making them suitable for developing plant-based beef products; while those with high moisture content have a smooth surface and a springy texture, making them suitable for developing plant-based egg products.

[0028] This invention discloses a method for preparing plant protein extrudates with high moisture content, reaching up to 75%. By comparing soybean proteins with high, medium, and low gel strength, this invention discovers that using weakly gelled soybean protein as raw material and employing twin-screw high-moisture extrusion technology, high-moisture textured plant protein extrudates with a moisture content of up to 75% can be prepared. Furthermore, by adjusting process parameters (moisture content, extrusion temperature, screw speed, and feeding speed), the textural properties of the extrudate, such as hardness, elasticity, and chewiness, can be directionally controlled. Among these, moisture content (50%-80%) has the greatest impact on the texture of the soybean protein extrudate; extrudates with a moisture content of 55%-65% have stronger chewiness and can be developed into plant-based meat products similar to beef; extrudates with a moisture content of 70%-75% have greater elasticity and a softer texture and can be developed into plant-based products similar to dried egg.

[0029] Compared with commercially available plant protein extrudates that are typically used to simulate plant-based meat, the soybean protein extrudate prepared by this invention has a higher moisture content. By controlling the moisture content, it can simulate plant-based products such as plant-based meat and plant-based eggs, which not only significantly reduces production costs but also expands the application of plant protein extrudates in plant-based products, laying a technical and theoretical foundation for the comprehensive development and utilization of plant proteins.

[0030] This invention employs twin-screw high-moisture extrusion technology, based on molecular engineering principles, to prepare high-moisture protein extrudates by controlling extrusion parameters, the amount of protein base added, and the moisture content of the material.

[0031] In-depth research has revealed that plant-based artificial meat uses plant protein as its raw material and employs twin-screw extrusion technology to regulate the textural properties and structural characteristics of plant proteins during high-moisture extrusion. When the moisture content is low, the soy protein extrudate can form a significant fibrous structure, mimicking muscle tissue products; when the moisture content is low, the soy protein extrudate is gel-like with no obvious fibrous structure, and its texture is similar to egg white, making it suitable for the development of egg products.

[0032] Compared with the prior art, the advantages and beneficial effects of the present invention are as follows:

[0033] This invention, based on molecular engineering principles, uses soy protein as raw material and employs twin-screw high-moisture extrusion technology. By adjusting the extrusion parameters, the amount of soy protein added, and the moisture content during the high-moisture extrusion process, the structural properties of the extruded material are controlled based on the material characteristics of plant proteins and their interactions during the extrusion process. Multiple plant-based products have been developed using soy protein extrudate as raw material. The manufacturing process is simple, achieving the simulation of meat and egg whites, improving product texture, enriching product taste, and providing new ideas for the simulation of meat and egg products. Attached Figure Description

[0034] Figure 1The effect of different moisture contents on the appearance morphology of high-moisture soybean protein extrudate;

[0035] Figure 2 The effect of different moisture contents on the hardness of high-moisture soybean protein extrudate;

[0036] Figure 3 The effect of different moisture contents on the elasticity of high-moisture soybean protein extrudate;

[0037] Figure 4 The effect of different moisture contents on the chewiness of high-moisture soybean protein extrudate;

[0038] Figure 5 Comparison of moisture distribution in soybean protein extrudates with different moisture contents;

[0039] Figure 6 The inversion spectra of transverse relaxation time (T2) of soybean protein extrudates with different moisture contents;

[0040] Figure 7 Packing diagram of moisture peak area for soybean protein extrudates with different moisture contents;

[0041] Figure 8 Two plant-based products developed based on high-moisture soybean protein extrusion;

[0042] Figure 9 Sensory evaluation radar charts for two plant-based products developed based on high-moisture soybean protein extrusions;

[0043] Figure 10 A schematic diagram illustrating the process of regulating the structural properties of soybean proteins and developing plant-based products during high-moisture extrusion. Detailed Implementation

[0044] A schematic diagram illustrating the process of regulating soybean protein structure and properties and developing plant-based products through high-moisture extrusion is shown below. Figure 10 As shown.

[0045] First, a single-factor extrusion experiment of soybean protein was designed, as shown in Table 1.

[0046] Table 1. Single-factor experimental design of high-moisture soybean protein extrudate

[0047]

[0048] Note: The underlined factor level is the fixed level of this experimental factor when examining other experimental factors.

[0049] Based on the single-factor experiments, an orthogonal experiment was designed, as shown in Table 2, to explore the optimal extrusion conditions.

[0050] Table 2. Orthogonal experimental design of high-moisture soybean protein extrudate

[0051]

[0052] The results of the orthogonal experiment are shown in Table 3.

[0053] Table 3. Orthogonal experimental characteristics data of high-moisture soybean protein extrudate

[0054]

[0055] Further data transformations were performed on some data in Table 3, and compared with the data of beef slices and dried egg, to ensure that the extruded product is closer to the real product. After rounding, the beef slices had a hardness of 15000g, an elasticity of 0.82, and a chewiness of 8800g; the dried egg had a hardness of 5100g, an elasticity of 0.92, and a chewiness of 3800g. These were used as the target values ​​for the final optimization of the extruded product, and the transformation formula is as follows:

[0056]

[0057] The converted data are shown in Tables 4 and 5.

[0058] Table 4. Results of orthogonal experimental data transformation of high-moisture soybean protein extrudate to beef slices.

[0059]

[0060] Table 5. Results of orthogonal experimental data transformation between high-moisture soybean protein extrudate and standard dried egg.

[0061]

[0062]

[0063] For beef slices: Principal component analysis is shown in Table 6.

[0064] Table 6. Statistical analysis of principal component scores and overall scores in the orthogonal experiment comparing high-moisture soybean protein extrudate with beef slices.

[0065]

[0066] The scoring equation for the first principal component is as follows, where Z represents the standardized value of the index: Principal Component F1 = 0.534 × Z Hardness + 0.280 × Z Elasticity + 0.457 × Z Chewiness. Through score calculation, the optimal combination was found to be A1B3C3D3, namely, a moisture content of 65%, a temperature of 150℃, a screw speed of 180 rpm, and a feeding rate of 7 g / min.

[0067] For dried egg: Principal component analysis is shown in Table 7.

[0068] Table 7. Statistical analysis of principal component scores and overall scores in the orthogonal experiment comparing high-moisture soybean protein extrudate with dried egg.

[0069]

[0070] The scoring equation for the first principal component is as follows, where Z represents the standardized value of the index: Principal Component F1 = 0.476 × Z Hardness – 0.162 × Z Elasticity + 0.483 × Z Chewiness. Through score calculation, the optimal combination was found to be A3B2C1D3, i.e., 75% moisture content, 140℃ temperature, 140rpm screw speed, and 7g / min feeding rate.

[0071] The present invention will be further illustrated below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. After reading the present invention, any modifications of the present invention in various equivalent forms by those skilled in the art will fall within the scope defined by the appended claims.

[0072] Example 1

[0073] The application of a high-moisture protein-based extrudate in simulated beef includes the following steps:

[0074] A twin-screw extruder is used for high-moisture extrusion of soy protein isolate. The material contains 65% moisture and 35% soy protein. The twin-screw extrusion conditions are: a fixed screw speed of 180 rpm, a feed rate of 7 g / min, and barrel temperatures set at 40℃, 60℃, 90℃, 150℃, 150℃, 150℃, 150℃, and 150℃ in eight zones from the feed section to the die section. The long cooling die is maintained at 75℃ through water circulation.

[0075] Collect the extrudate and cool it. Marinate the extrudate with seasoning to obtain a high-moisture extruded protein-based biomimetic beef slice product. The seasoning formula includes the following components: cut 200g of extrudate into 2×2cm pieces and marinate them in 100g of seasoning overnight until the flavor is absorbed, thus obtaining the plant-based "Husband and Wife Lung Slices" product. A picture of the finished plant-based "Husband and Wife Lung Slices" product is shown below. Figure 8 As shown.

[0076] Macroscopic results showed that soybean protein extrudates with different moisture contents had different morphological appearances. At 65% moisture content, the extrudate surface exhibited a layered fibrous structure, more closely resembling the appearance of real beef slices (see [link to study]). Figure 1 , Figure 8 ).

[0077] Texture characteristics of the extrudates were characterized using a texture analyzer. The results showed that there were significant differences in hardness and chewiness of soybean protein extrudates with different moisture contents, with the extrudates at a moisture content of 65% being closest to beef slices. (See also...) Figure 2 , Figure 4 ).

[0078] Sensory evaluation results showed that the protein-based high-moisture extruded biomimetic beef slices were similar to the real product in terms of texture, color, aroma, taste, and mouthfeel, and had a high overall acceptance. Figure 9 ).

[0079] Example 2

[0080] The application of a high-moisture protein-based extrudate in simulated dried egg includes the following steps:

[0081] A twin-screw extruder is used for high-moisture extrusion of soy protein isolate. The material contains 75% moisture and 25% soy protein. The twin-screw extrusion conditions are: a fixed screw speed of 140 rpm, a feed rate of 7 g / min, and barrel temperatures set at 40℃, 60℃, 90℃, 140℃, 140℃, 140℃, 140℃, and 140℃ in eight zones from the feed section to the die section. The long cooling die is maintained at 75℃ through water circulation.

[0082] Collect the extrudate and cool it. Marinate the extrudate with seasoning to obtain a high-moisture extruded protein-based biomimetic egg white product. The seasoning formula includes the following components: cut 200g of extrudate into 5mm wide strips and soak them in 100g of seasoning overnight until well-seasoned. A picture of the finished plant-based egg white product is shown below. Figure 8 As shown.

[0083] Macroscopic results showed that soybean protein extrudates with different moisture contents exhibited different morphological appearances compared to other extrudates. The extrudate with a moisture content of 75% had a smooth surface, compact texture, and no damage, more closely resembling the appearance of real dried egg (see [link to study]). Figure 1 , Figure 8 ).

[0084] Texture properties of the extrudates were characterized using a texture analyzer. The results showed that there were significant differences in hardness and chewiness of soybean protein extrudates with different moisture contents, both reaching their minimum values ​​at a moisture content of 75% (see [link to original text]). Figure 2 , Figure 4 ).

[0085] Low-field nuclear magnetic resonance (NMR) is a classic analytical method used to measure the physical and chemical fluidity of water in samples. It is also used to study the properties of meat matrices, such as water distribution, compartmentalized tissue, water flow, and the interactions of water with other molecules. Results obtained through low-field NMR detection (see...) Figure 5 , Figure 6 , Figure 7 Soybean protein extrudate with a moisture content of 75% contains an even higher proportion of bound water, reaching 91.3%.

[0086] Sensory evaluation results showed that the protein-based, high-moisture extruded biomimetic egg jerky was similar to the real product in terms of texture, color, aroma, taste, and mouthfeel, and had a high overall acceptance. Figure 9 ).

[0087] The above description of the embodiments is provided to enable those skilled in the art to understand and use the invention. It will be apparent to those skilled in the art that various modifications can be made to these embodiments, and the general principles described herein can be applied to other embodiments without inventive effort. Therefore, the present invention is not limited to the above embodiments, and any improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the invention should be within the protection scope of the present invention.

Claims

1. A method for preparing a plant protein extrudate with high moisture content, characterized in that, A twin-screw extruder is used to extrude soy protein isolate at high moisture content. The material contains 75% moisture and 25% soy protein. The conditions for twin-screw extrusion are as follows: the screw speed is fixed at 140 rpm, the feed rate of the feeder is 7 g / min, and the barrel temperature is set at 40°C, 60°C, 90°C, 140°C, 140°C, 140°C, 140°C and 140°C in 8 zones from the feed section to the die section. The long cooling die is kept at 75°C by water circulation. Collect the extrudate, cool it, and marinate it with seasonings to obtain a high-moisture extruded protein-based biomimetic egg white product, which is plant-based dried egg.

Images