Textured plant proteins

Abstract

The present invention provides a textured plant protein defined as a fibrous plant protein material having a protein content of at least 40 wt.% relative to dry matter wherein the textured plant protein is prepared by extruding a feed composition at a moisture content of 18.1-25.9 wt.%, the feed composition comprises: a) a source of plant protein from seeds, cereals, algae, fruits, leaves or legumes, comprising at least 65 wt.% of plant protein relative to dry matter; and b) a source of tuber protein comprising at least 75 wt.% of tuber protein relative to dry matter, and c) a filler, In addition, the invention provides food products comprising the TVP of the invention, as well as methods for obtaining these products, and the use of TVP in food products to replace meat of animal origin.

Description

Background Technology

[0001] Protein extrusion cooking is an emerging technology in industrial food preparation, evolving towards increasingly sophisticated levels. Extrusion cooking takes place in an extruder. An extruder comprises one or more rotating screws (e.g., single or twin screws, rotating in the same or opposite directions) located in continuous blocks, which together form the barrel. Each block can be heated or cooled independently as needed. The protein material fed into the extruder undergoes plasticization under the influence of heat and shear forces within the barrel, a process typically carried out in the presence of additional water and / or other components.

[0002] The plasticized material formed in the extruder moves through the barrel, propelled by the rotating screw, to the exit orifice in the last section (called the die), which provides a reaction force to the material flow, causing pressure to build up in the barrel. Upon exiting the die, the pressure is released and the plasticized material rapidly reaches equilibrium with the chamber conditions. During this process, proteins and other components undergo various physicochemical modifications, thereby altering the properties of the proteins.

[0003] Through extrusion cooking, protein materials can be endowed with enhanced functional, physicochemical, and sensory properties. For example, protein powder can be transformed through extrusion cooking into protein products of very different size, shape, hardness, or elasticity from the initial product. For instance, "fluffy" (foamy) aerated protein products can be obtained, as well as elastic, crisp, soft, firm, rubbery, or fibrous materials. The type of product obtained depends largely on the different components present during extrusion and the conditions applied. It is currently unclear why a particular feed composition provides specific characteristics of the resulting product under given conditions.

[0004] The presence of fibrous and firm protein material is an important characteristic of meat products. Therefore, the presence of fibrous and firm protein material is also an ideal characteristic when producing vegetarian and vegan meat analogues. For this purpose, non-meat proteins such as plant proteins can be converted into textured vegetable protein (TVP).

[0005] TVP has been defined as a pre-prepared, palatable food ingredient, optionally processed from an edible protein source and with other ingredients, for nutritional or technical purposes. Commonly used protein sources for such applications include soy protein, pea protein, or wheat protein. While TVP can have many physical characteristics, particularly desirable characteristics are fiber and firmness.

[0006] Extrusion cooking for obtaining textured plant proteins is generally divided into two categories of conventional methods: high-moisture extrusion (HME) and low-moisture extrusion (LME). High-moisture conditions (40-80% moisture in the barrel) are known to provide good fiber content (see, for example, Samard, J. Sci. Food. Agric. 2019, 99, 4922-4931) because the high moisture content allows the extrusion process to obtain a layered structure that transforms into a highly fibrous product upon exiting the die.

[0007] However, due to its high moisture content, HME suffers from the disadvantage of low solids yield compared to other HME processes. Furthermore, the resulting product has a limited shelf life due to its high moisture content; it must be used as soon as possible after production to obtain a usable food product. Alternatively, the product can be further processed (e.g., frozen) to allow for storage, which significantly impacts the properties of the HME product. Even so, the high moisture content makes long-distance transportation of the product uneconomical.

[0008] Protein products obtained by extrusion cooking under low moisture conditions (typically less than 35% moisture) do not have these disadvantages. The resulting product is more or less dry, has a high solids content, and remains stable for months even under ambient conditions. Therefore, LME products can be stored and transported without difficulty.

[0009] However, extrusion under low moisture conditions typically does not produce fibrous products. Instead, products extruded under low moisture conditions are mostly amorphous, glassy, ​​or spongy.

[0010] Several attempts have been made to produce fibrous (textured) protein products under low-moisture conditions. WO2020 / 038541 describes high-moisture extruded protein materials composed primarily of oat material. US2021 / 329942 describes protein-carbohydrate composite materials obtained under low-moisture extrusion conditions, and also describes such products as typically sponge-like, paste-like, or rubbery.

[0011] There remains a need for tissue-modified plant protein materials with high fiber content and high firmness, which can be obtained using the LME process. This invention provides such materials. Summary of the Invention

[0012] The present invention is based on the discovery that even when pure tuber protein or pure plant protein from seeds, cereals, algae, fruits, leaves or legumes extruded under the same conditions does not provide a fibrous and / or compact TVP product, low-moisture extrusion of a mixture of tuber protein and plant protein from seeds, cereals, algae, fruits, leaves or legumes can provide a fibrous and / or compact TVP product in the presence of filler.

[0013] Therefore, the present invention provides a textured plant protein, defined as a fibrous plant protein material having a protein content of at least 40 wt.% relative to dry matter, wherein the textured plant protein is prepared by extruding a feed composition at a moisture content of 18.1-25.9 wt.%, the feed composition comprising... a) Sources of plant protein from seeds, cereals, algae, fruits, leaves, or legumes, including at least 65 wt.% plant protein relative to dry matter; and b) Sources of tuber protein, including at least 75 wt.% tuber protein relative to dry matter; and c) Packing material.

[0014] It has been found that the textured plant protein (TVP) of the present invention has high fiber content and high firmness. This TVP has beneficial properties when used in food products such as, for example, vegetarian and vegan meat substitutes.

[0015] Furthermore, the present invention also provides food products including the TVP of the present invention, methods for preparing TVP and food products, and the use of TVP in food products as a substitute for animal-derived meat. Attached Figure Description

[0016] Figure 1 : A fibrosis rating scale used to assess fibrosis. Detailed Implementation

[0017] Surprisingly, the aforementioned problems in obtaining textured plant protein (TVP) under LME conditions have been found to be solved by co-extruding plant proteins and fillers from seeds, cereals, algae, fruits, leaves, or legumes with tuber proteins. The additional presence of tuber proteins leads to increased fibrousness and / or firmness of the resulting TVP. The presence of fillers allows for a reduction in protein content, resulting in a material that requires fewer resources while still possessing sufficient nutritional value. Therefore, the TVP of the present invention exhibits excellent fibrous structure and high firmness.

[0018] This is surprising because, under the same extrusion conditions, plant proteins from seeds, grains, algae, fruits, leaves, or legumes, as well as tuber proteins, do not provide fibrous material. Only when mixed can a fibrous and compact product be obtained.

[0019] Furthermore, the water absorption index (WAI) makes the TVP of the present invention suitable for use, for example, in meat substitutes. As described in Example 4, the water absorption index (WAI) is a measure of the amount of water that a TVP can absorb under standardized conditions. For a TVP to be used in food products, the WAI must be sufficiently high. The TVP of the present invention preferably has a WAI of 100-1000, more preferably 250-750, more preferably 300-650, more preferably 350-650, and even more preferably 390-650.

[0020] Within this scope, WAI can also indicate the fiberity and / or firmness of the TVP product. Therefore, the lower WAI of the TVP of the present invention (containing added tuber protein) relative to the reference material (which does not contain tuber protein) indicates increased firmness and / or fiberity.

[0021] Therefore, the present invention provides a textured plant protein, defined as a fibrous plant protein material having a protein content of at least 40 wt.% relative to dry matter, wherein the textured plant protein is prepared by extruding a feed composition at a moisture content of 18.1-25.9 wt.%, the feed composition comprising... a) Sources of plant protein from seeds, cereals, algae, fruits, leaves, or legumes, including at least 65 wt.% plant protein relative to dry matter; and b) Sources of tuber protein, including at least 75 wt.% tuber protein relative to dry matter; and c) Packing material.

[0022] In this document, texturized plant protein is defined as fibrous plant protein material obtained by extrusion at a moisture content of 18.1–25.9 wt.%. This is generally considered to be the LME process as defined elsewhere. The material is referred to as texturized plant protein, which is consistent with the conventional nomenclature of texturized protein, but the TVP of this invention may include proteins derived from sources not always considered “vegetable.” In the abbreviation TVP, the term “vegetable” should be interpreted as “plant-derived.”

[0023] The moisture content during extrusion is 18.1-25.9 wt.%, preferably 19.1-24 wt.%, and more preferably 19.2-22 wt.%.

[0024] As defined herein, a low moisture content during extrusion offers the following advantages: the resulting protein material has a high solids content and requires no further processing to achieve a long shelf life. Most of the moisture is released as the extrudate leaves the die. Without further processing, the resulting product has a shelf life of at least 3 months, preferably at least 6 months.

[0025] The tissueed plant protein of the present invention has a protein content of at least 40 wt.% relative to dry matter. Preferably, the protein content is 40-88.5 wt.% relative to dry matter, more preferably 40-84.5 wt.%, more preferably 40-69.9 wt.%, more preferably 50-69.9 wt.%, and most preferably 60-69.9 wt.% relative to dry matter.

[0026] The tissueed plant protein of this invention also has unexpected advantages, namely, it has high fiber content and high firmness.

[0027] For TVP products used as a meat substitute protein in various food products, high fiber content is an advantage, as fiber is a characteristic of meat proteins. The high fiber content of this product distinguishes it from products of existing technologies, particularly those extruded with low moisture content.

[0028] High firmness is also an important characteristic of TVP products, as firmness determines chewiness. High firmness provides a firm chewy texture, similar to that of animal meat, while lower firmness is generally considered to be more elastic, resulting in a softer product.

[0029] The textured plant protein of the present invention is prepared by extruding a feed composition at a moisture content of 18.1-25.9 wt.%, the feed composition comprising: protein from seeds, cereals, algae, fruits, leaves or legumes, including at least 65 wt.% plant protein relative to dry matter; a source of tuber protein, including at least 75 wt.% tuber protein relative to dry matter; and filler.

[0030] The feed composition refers to a mixture fed into an extruder. Preferably, the feed composition is a homogeneous powder mixture comprising a source of plant protein from seeds, cereals, algae, fruits, leaves, or legumes, a source of tuber protein, and the filler. The feed composition can be used as a dry mixture having a moisture content of 1-15 wt.%. Preferably, the feed composition is used under standard plant conditions, such as at a moisture content of 5-15 wt.%, preferably 5-12 wt.%.

[0031] Plant protein sources from seeds, cereals, algae, fruits, leaves, or legumes are preferably provided as powders. Depending on the protein concentration of the powder, the plant protein source may be referred to as a concentrate or an isolate. A protein concentrate is generally understood to be a protein source comprising more than 55 wt.% and less than 80 wt.% of protein relative to dry matter. A protein isolate is generally understood to be a protein source comprising at least 80 wt.% of protein relative to dry matter.

[0032] Plant protein sources from seeds, cereals, algae, fruits, leaves, or legumes include at least 65 wt.%, preferably at least 66 wt.%, more preferably at least 67 wt.%, more preferably at least 68 wt.%, more preferably at least 69 wt.%, more preferably at least 70 wt.%, more preferably at least 71 wt.%, more preferably at least 72 wt.%, more preferably at least 73 wt.%, more preferably at least 74 wt.%, more preferably at least 75 wt.%, more preferably at least 76 wt.%, more preferably at least 77 wt.%, more preferably at least 78 wt.%, more preferably at least 79 wt.%, and more preferably at least 80 wt.%, relative to dry matter. The plant protein source can be a plant protein concentrate (typically having a protein content of up to 80 wt.%) or a plant protein isolate (typically having a protein content of at least 80 wt.%). The preferred source of plant protein is a free-flowing powder.

[0033] Plant proteins derived from seeds, grains, algae, fruits, leaves, or legumes are typically commercially available or can be obtained by methods known to those skilled in the art.

[0034] Seed proteins are preferably derived from protein-rich seeds, such as those used for the isolation of vegetable oils. Preferred examples of seed proteins include canola protein, rapeseed protein, and flax protein.

[0035] Typical examples of cereal proteins include proteins obtained from wheat, rye, barley, oats, rice, sorghum, millet, or corn.

[0036] Algal proteins can be proteins derived from algae, including macroalgae (“seaweed”) and microalgae (single-celled algae, such as Chlorella or Spirulina).

[0037] Fruit protein can be derived from any kind of fruit, such as oranges, lemons, apples, pears, or bananas.

[0038] Preferred examples of leaf proteins are Rubisco proteins and duckweed proteins.

[0039] Preferred examples of legume proteins are those derived from soybeans, faba beans, mung beans, lentils, kidney beans, black beans, horse beans, lima beans, cowpeas, green peas, yellow peas, and chickpeas, as well as proteins derived from peanuts, lentils, or lupins.

[0040] In a more preferred embodiment, the plant protein source is provided as legume protein. Legume protein can be from any type of legume. Those skilled in the art know what kind of protein is legume protein; legume protein is protein derived from legume plants, preferably from the seeds of such plants. Therefore, legume protein can be derived from legumes such as beans, including beans such as soybeans, broad beans, mung beans, lentils, kidney beans, black beans, horse beans, or lima beans, and pea varieties such as (common) peas. Pisum sativum ), cowpeas, green peas, yellow peas, and chickpeas, as well as those derived from peanuts, lentils, or lupins. In a preferred embodiment, the legume protein is pulse protein. In a further preferred embodiment, the legume protein is pea protein.

[0041] To obtain a non-allergenic product, soy protein is preferably not used as a legume protein. Therefore, the non-allergenic TVP of the present invention prepared from legume protein sources includes any legume protein other than soybean. In a preferred embodiment, the legume protein source includes protein from peas, chickpeas, broad beans, kidney beans, black beans, mung beans, cowpeas, horse beans, lima beans, green peas, yellow peas, or lentils. In a further preferred embodiment, the legume protein source is from broad beans, peas, chickpeas, peanuts, lentils, or lupins, preferably peas, chickpeas, or broad beans, most preferably (common) peas. Pisum sativum ( ) is a source of protein.

[0042] In another preferred embodiment, the source of legume protein includes protein isolated from soybeans, broad beans, peas, or chickpeas, preferably from soybeans or peas.

[0043] In another preferred embodiment, the non-allergenic TVP of the present invention does not include wheat bran. In a very preferred embodiment, the TVP of the present invention does not include gluten and soy.

[0044] Plant proteins from seeds, cereals, algae, fruits, leaves, or legumes can be natural proteins or coagulated proteins. In a preferred embodiment, the plant protein is nonfunctional. In a further preferred embodiment, the plant protein is a coagulated protein. Plant proteins from seeds, cereals, algae, fruits, leaves, or legumes can be isolates or concentrates, such as those typically obtained by dry milling and air classification or wet milling after hulling (Food Protein Handbook, GO Phillips and P.A. Williams, Woodhead Publishing Ltd., 2011, Chapter 9).

[0045] Dry milling, followed by air classification, selects the fine, protein-rich fractions, typically providing protein concentrates with up to 75 wt.% protein, depending primarily on the plant species.

[0046] During wet milling (or “wet fractionation”), proteins are extracted from plant flour (defined as a source of plant protein containing less than 55 wt.% protein) under alkaline or acidic conditions, and the dissolved proteins are then separated from the residue by centrifugation or similar techniques. The proteins are recovered by isoelectric precipitation or ultrafiltration, thereby providing a plant protein isolate with a protein content of up to 95 wt.% protein by dry weight. Because such isolates or concentrates are commercially available, the sources of plant proteins are well-known to technicians in the food product industry.

[0047] The tuber protein source comprises at least 75 wt.%, preferably at least 76 wt.%, more preferably at least 77 wt.%, more preferably at least 78 wt.%, more preferably at least 79 wt.%, more preferably at least 80 wt.%, and even more preferably at least 81 wt.% of tuber protein relative to dry matter. The tuber protein source may be referred to as tuber protein concentrate (typically having a tuber protein content of up to 80 wt.%) or tuber protein isolate (typically having a tuber protein content of at least 80 wt.%); the tuber protein source is preferably free-flowing powder.

[0048] The source of tuber protein can be derived from any type of tuber. In this document, the term "tuber" is given its conventional meaning and refers to any type of tuber. Specifically, "tuber" in this definition includes structures that can also be called roots. Therefore, the term "tuber" as defined herein can be replaced by the phrase "root or tuber".

[0049] Preferably, the tubers referred to herein are edible tubers that can be grown in environments suitable for human food production. Tubers inherently contain protein; preferred types of tubers are also rich in starch, such as tubers used for starch separation. Tuber protein should be understood to refer to protein derived from a single tuber or from a specific protein fraction of a tuber, but in exceptional cases, tuber protein may comprise a mixture of proteins derived from two or more tubers.

[0050] Preferably, in this document, tubers include potatoes ( Solanum tuberosum ),sweet potato( Ipomoea batatas ), cassava (including Manihot esculenta Synonyms M.utilissima Also known as cassava (manio), cassava (mandioca), or cassava (yuca), and also includes... M.palmata Synonyms M.dulcis Also known as sweet cassava (yucadulce) or yam (Dioscorea genus). Dioscorea spp ) and / or taro ( Colocasia esculenta More preferably, the tubers include potatoes, sweet potatoes, cassava, or yams; even more preferably, the tubers include potatoes, sweet potatoes, or cassava; even more preferably, the tubers include potatoes or sweet potatoes; and most preferably, the tubers include potatoes. Solanum tuberosum ).

[0051] Preferred tuber proteins include potato protein, sweet potato protein, cassava protein, yam protein, and / or taro protein. Most preferably, the tuber protein source can be a tuber protease inhibitor isolate, a tuber potato glycoprotein isolate, or a tuber isolate comprising a mixture of protease inhibitors and potato glycoproteins. In this document, the tuber protein source can be a natural tuber protein isolate or a denatured tuber protein isolate (such as that obtained through the coagulation of tuber proteins).

[0052] Preferably, the tuber protein source includes natural potato protein, such as that obtainable according to the method in WO 2014 / 011042, or coagulated potato protein, such as that obtainable according to the methods in WO 2017 / 142406 or WO 2016 / 133448. Potato protein is a preferred type of tuber protein because it is known to be an excellent source of essential amino acids, with an average DIAAS greater than 100. Therefore, potato protein has an essential amino acid score close to that of animal protein (Herreman et al., Food Science & Nutrition, 2020, 00:1-13, A comprehensive overview of the quality of plant and animal-derived proteins based on digestible essential amino acid scores).

[0053] Most preferably, the source of tuber protein includes coagulated potato protein.

[0054] Both natural tuber protein and coagulated tuber protein (including natural potato protein and coagulated potato protein) are commercially available.

[0055] The filler is preferably inert. The filler is preferably a dry-flowing powder. The filler can be a monosaccharide, such as glucose, maltose, fructose, or glucose. Preferably, the filler comprises a polysaccharide, such as starch or plant fiber, most preferably starch. The starch can be modified or natural (unmodified) starch. Preferably, the starch is natural starch.

[0056] Starch can be glutinous starch, defined as starch comprising more than 95 wt.% amylopectin, or ordinary starch, defined as starch comprising between 60 and 90 wt.%, preferably between 65 and 85 wt.% amylopectin.

[0057] Starch can be from any source, including, for example, wheat starch, corn starch, sweet potato starch, and potato starch. Preferably, the starch is derived from a source other than plant protein sources. Starch is preferably derived from roots or tubers, more preferably tuber starch, and most preferably potato starch. In a more preferred embodiment, the starch is glutinous or non-glutinous natural potato starch, most preferably natural potato starch (NPS).

[0058] Fillers can also be plant fibers. In this document, plant fibers refer to commercially available materials, typically in the form of free-flowing powder, that can be added to feed compositions. Many types of plant fibers are commonly known in the art. Examples include soybean cotyledon fiber, pea fiber, potato fiber, and cereal fiber, where cereal fiber includes wheat fiber, barley fiber, or oat fiber.

[0059] As described herein, plant fibers typically comprise a variety of indigestible carbohydrates, including pectin, hemicellulose, and / or gums, and also include insoluble cell wall components remaining after acid and alkali hydrolysis.

[0060] Typically, the filler is preferably present in a significant amount, such as, for example, at least 11.5 wt.%, preferably at least 15.5 wt.%, and more preferably at least 20 wt.%, relative to the dry weight of the feed composition. The filler may be present in the feed composition in amounts up to 50.0 wt.%, up to 45.0 wt.%, up to 40.0 wt.%, up to 35.0 wt.%, up to 30.0 wt.%, up to 25.0 wt.%, or up to 20.0 wt.%. Preferred amounts of the filler include 11.5-50.0 wt.%, preferably 15.5-45.0 wt.%, and more preferably 15.5-40.0 wt.%.

[0061] In a preferred embodiment, the amount of tuber protein in the feed composition is 2.5-95 wt.%, preferably 3-90 wt.%, more preferably 5-75 wt.%, more preferably 7-50 wt.%, and even more preferably 8-35 wt.%, relative to the total protein content. In a further preferred embodiment, the amount of tuber protein in the feed composition is 2.5-50 wt.%, preferably 2.5-40 wt.%, more preferably 5-30 wt.%, and even more preferably 7.5-25 wt.%, relative to the total weight of the feed composition. In a preferred embodiment, the amount of tuber protein in the feed composition is 7.0-35 wt.%, relative to the total weight of the feed composition.

[0062] In the feed composition, the amount of plant protein from seeds, cereals, algae, fruits, leaves, or legumes is preferably at least 50 wt.%, more preferably at least 60 wt.%, more preferably at least 70 wt.%, and most preferably at least 75 wt.%, relative to the total protein. That is, in a more preferred embodiment, the amount of plant protein from seeds, cereals, algae, fruits, leaves, or legumes exceeds the amount of tuber protein on a total weight basis (including moisture content of the raw materials). In the feed composition, the ratio of plant protein from seeds, cereals, algae, fruits, leaves, or legumes to tuber protein is preferably 19:1 to 1:1, more preferably 19:1 to 3:1.

[0063] In a more preferred embodiment, the feed composition comprises at least 50 wt.%, preferably at least 60 wt.%, of protein from seeds, cereals, algae, fruits, leaves, or legumes relative to dry matter. In the feed composition, the amount of tuber protein relative to dry matter is preferably 2.5-50 wt.%, more preferably 5-30 wt.%.

[0064] A significant advantage of this invention is that, due to the presence of tuber protein, a fibrous and firm product can be obtained. Furthermore, the product typically has a water absorption index (WAI) suitable for use as a TVP product, for example, in meat substitutes.

[0065] In some embodiments, the feed composition preferably comprises less than 15 wt.%, more preferably less than 10 wt.%, more preferably less than 5 wt.%, and most preferably less than 2 wt.% of lipids. In other embodiments, the feed composition preferably comprises at least 1 wt.%, more preferably at least 2 wt.%, more preferably at least 3 wt.%, more preferably at least 4 wt.%, and more preferably at least 5 wt.% of lipids. In this document, lipids are oils or fats that may be naturally present in the raw materials or may be added separately to the feed composition.

[0066] In this document, lipids include, for example, free fatty acids, monoglycerides, diglycerides, or triglycerides, sucrose fatty acid esters, and sorbitol fatty acid esters. The amount of lipids is defined as the total weight of fatty acids present in the feed composition.

[0067] In a more preferred embodiment, the feed composition does not include separately added lipids, so no additional fats or oils are added to the feed composition prior to extrusion.

[0068] In a further preferred embodiment, the plant protein source from seeds, cereals, algae, fruits, leaves, or legumes used in the feed composition includes less than 12 wt.%, preferably less than 10 wt.%, of lipids. In some embodiments, the plant protein source from seeds, cereals, algae, fruits, leaves, or legumes includes at least some lipids. In a preferred embodiment, the lipid content of the plant protein source from seeds, cereals, algae, fruits, leaves, or legumes is 3-10 wt.%, preferably 4-9 wt.%.

[0069] The source of tuber protein in the feed composition preferably comprises less than 6 wt.%, more preferably less than 5 wt.%, more preferably less than 4 wt.%, more preferably less than 3 wt.%, more preferably less than 2 wt.%, and more preferably less than 1 wt.% lipids. In some embodiments, the source of tuber protein includes at least some lipids. In some preferred embodiments, the lipid content in the source of tuber protein is 0.1-5 wt.% lipids.

[0070] The defined feed composition is processed by low-moisture extrusion as defined above. The low-moisture extrusion setup for obtaining the TVP of the present invention preferably includes an extruder comprising a barrel section comprising at least three blocks, preferably at least five blocks, a first block of the barrel section including a feed inlet adapted to feed the feed composition into the extruder, a second block downstream of the first block of the barrel section including a water inlet adapted to introduce water into the extruder, and one or more further downstream blocks adapted to set a temperature along the barrel section to form an increasing temperature gradient. The extruder also includes a die head downstream of the barrel section, and one or more screw elements adapted to convey the feed composition through the barrel section to the die head.

[0071] The first block in the barrel section includes a feed inlet adapted to feed the feed composition, as defined herein, into the extruder. The second block in the barrel section, located downstream of the first block, includes a water inlet adapted to introduce water into the extruder to achieve the desired moisture content, as described elsewhere, between 18.1-25.9 wt.%, preferably between 19.1-24 wt.%, (based on the total weight of the composition). The first and second blocks are preferably operated at near-ambient conditions (20-30°C). One or more further downstream blocks in the barrel section are preferably equipped with heating and cooling devices to allow for temperature setting along the barrel section to create an increasing temperature gradient. In a preferred embodiment, the temperature gradually increases to a maximum temperature of 100-250°C, preferably 130-225°C, more preferably 142-200°C, and most preferably 142-180°C. In a more preferred embodiment, the extrusion conditions include a minimum temperature of at least 142°C, more preferably at least 145°C, and even more preferably at least 150°C in the barrel.

[0072] Although the barrel section must form an increasing temperature gradient, it is conceivable that in some configurations, the barrel section may include one or more barrel sections in which a decreasing temperature gradient or a constant temperature exists. As those skilled in the art will understand, such a barrel section can be combined with, for example, one, two, or more barrel sections having an increasing temperature gradient.

[0073] The barrel section also includes a die head located downstream of the barrel section and one or more screw elements adapted to convey the feed composition through the barrel section to the die head. In a preferred embodiment, the barrel section is equipped with a twin-screw rotating in the same direction. More preferably, the screw configuration includes reverse pitch elements and conveying elements, preferably alternating between reverse pitch elements and conveying elements. In a further preferred embodiment, the screw configuration includes 2-10 reverse pitch elements. The reverse pitch elements are preferably located between 10D and 20D. In a more preferred embodiment, a kneading block is provided downstream of the reverse pitch elements (preferably the most downstream reverse pitch element), preferably having an alternating angle between 35° and 55°, most preferably between 40° and 50°. In a further preferred embodiment, the die head includes a die head having one or two or more outlets, preferably one or two outlets, through which the extruded feed material exits the extruder.

[0074] The extrusion conditions for obtaining the TVP of the present invention preferably include a temperature of 100-250°C in the barrel section, more preferably 130-200°C, even more preferably 142-200°C, and most preferably 142-180°C. This value refers to the highest temperature observed in the temperature gradient.

[0075] Alternatively or additionally, the condition includes a pressure of 1.5-80 bar, preferably 2-50 bar, more preferably 15-40 bar at the die head (i.e., after the screw and before the die head); and / or a specific mechanical energy (SME) of 0.05-0.35 kWh / kg, preferably 0.10-0.28 kWh / kg, more preferably 0.14-0.25 kWh / kg.

[0076] The extruder can operate at 100-1800 screw revolutions per minute (rpm), preferably 200-1250 rpm; alternatively, the extruder can preferably operate at 250-1600 rpm. Higher speeds, such as 500-1600 rpm, preferably 900-1500 rpm, provide higher output and thus improve production efficiency.

[0077] In an exemplary embodiment, the extruder may be a ZSK 27 extruder (a co-rotating twin-screw extruder sold by Coperion). In this particular embodiment, further described in the examples, the extruder comprises six sections with a total length of 24D. The screw diameter D is 27mm. Therefore, the barrel and screw have a total length of 648mm and a screw diameter of 27mm.

[0078] In this exemplary embodiment, the screw configuration includes 3 to 7, preferably 4 to 6, and most preferably 5, reverse pitch elements that are alternately wound with the conveying element. The reverse pitch elements are preferably positioned towards the end of the screw starting at position 14D. The downstream of the most downstream reverse pitch element is preferably at the kneading block (approximately 45° staggered angle) at position 21.5D, and immediately before the conveying element at position 23D, just before the screw tip. The die head includes two tapered cavities comprising a cylindrical die head opening having a diameter of 3 mm and a length of 2 mm.

[0079] In this particular embodiment, the temperatures in the first (feed) block and the second (water addition) block can be close to ambient temperature. The third and fourth blocks operate at a temperature of 50-100°C, preferably 60-90°C, and the fifth and sixth blocks operate at a temperature of 100-250°C, preferably 142-200°C, most preferably 142-180°C, and more preferably 150-190°C. The minimum temperature at a certain point in the barrel is preferably at least 150°C, preferably at least 160°C.

[0080] Based on total weight (including moisture), the output is 15 to 25 kg / h, operating at 500 rpm. As those skilled in the art will understand, the output can be higher at higher rotational speeds. The output can be 10-100 kg / h, preferably 15-80 kg / h. At 800-1600 rpm, the output can be 40-80 kg / h.

[0081] In this particular embodiment, the pressure at the die head is 1.5-80 bar, preferably 2-50 bar, more preferably 10-30 bar, and the extruder operates at a specific mechanical energy (SME) of 0.05-0.35 kWh / kg, preferably 0.10-0.28 kWh / kg, more preferably 0.14-0.25 kWh / kg.

[0082] Using the described feed composition and the above-described low-moisture extrusion process, the TVP of the present invention, which has high fiber content and firmness, can generally be obtained. The textured plant protein has a moisture content of 1-20 wt.%, preferably 5-15 wt.%, more preferably 5-12 wt.%.

[0083] Tissue-processed plant proteins preferably include, on a wt.% basis relative to dry matter, a) less than 15 wt.%, preferably less than 10 wt.%, more preferably less than 5 wt.% of lipids; and / or b) at least 1 wt.%, preferably at least 2 wt.%, more preferably at least 3 wt.%, more preferably at least 4 wt.%, and more preferably at least 5 wt.% of lipids.

[0084] The tissueed plant protein preferably includes less than 150 ppm, more preferably less than 100 ppm, more preferably less than 80 ppm, more preferably less than 50 ppm, and more preferably less than 30 ppm of total triglycoalkaloids (TGA).

[0085] Technicians can adjust the feed composition to obtain the preferred TVP of the present invention.

[0086] To increase microbial stability and / or shelf life, the TVP of the present invention can be further dried to a moisture content of less than 10 wt.%, preferably less than 8 wt.%, more preferably less than 7 wt.%. Additional drying can be achieved by any method known in the art.

[0087] The TVP of the present invention is capable of absorbing moisture. Moisture absorption can be expressed by the water absorbency index (WAI); WAI represents how much water a dry TVP can absorb in weight equivalents (expressed as a percentage). The TVP of the present invention preferably has a WAI of 100-1000, more preferably 250-750, more preferably 300-650, more preferably 350-650, and more preferably 390-650.

[0088] In a further preferred embodiment, to further simulate even real meat fibers, the TVP of the present invention can be provided with additional texturing, flavoring, or coloring. To achieve this, suitable flavoring agents, colorants, and / or conditioning agents can be incorporated into the feed composition or provided with added water. Suitable conditioning agents, flavoring agents, and colorants include salts, such as sodium chloride or potassium chloride, as well as hydroxides, carbonates, bicarbonates, phosphates, and monohydrogen phosphates of alkali metals and alkaline earth metals. Preferred alkali metal and alkaline earth metal hydroxides are hydroxides of sodium, calcium, magnesium, and / or potassium. Salts also include various organic acid salts, such as citrates and lactates. The group of suitable conditioning agents, flavoring agents, and colorants also includes various food-grade organic acids, such as citric acid and lactic acid.

[0089] In addition, lipid compounds such as free fatty acids, monoglycerides, diglycerides or triglycerides, sucrose fatty acid esters, and sorbitol fatty acid esters, including polyoxyethylene sorbitol fatty acid esters, can be added.

[0090] As is known in the art, the amount of protein in the TVP composition of the present invention can be determined by Kjeldahl nitrogen analysis with a correction factor of 6.25 (EC Regulation No. 152 / 2009, Annex III, Method C, Dairy Products, equivalent to NEN-EN-ISO8968-1).

[0091] The amount of trisaccharide alkaloids can be measured using AOAC official method 997.13.

[0092] The amount of lipids can be determined by a gravimetric method that includes acid hydrolysis and subsequent determination of the total weight of fatty acids. In this paper, all fatty acids are C2-C26 fatty acids.

[0093] Compared to other low-moisture extruded TVP products, the TVP of this invention is characterized by high fiber content and high compactness.

[0094] The fiber content of the TVP of the present invention was visually determined using the method described in the examples. On a 5-point scale, a fiber content value of 2 or greater, preferably 3 or greater, and more preferably 4 or greater, is considered high. When occasionally required, the fiber content of TVP prepared from a specific feed composition can be increased by extruding at a lower moisture content.

[0095] As illustrated in the embodiments, the compactness of the TVP of the present invention is determined using a texture analyzer, for example, using the Warner-Bratzler method. Compactness can be expressed as absolute compactness (in Newtons, "N") or relative to sample thickness (in Newtons per millimeter, "N / mm"). The sample thickness of the TVP of the present invention is typically 5-25 mm, preferably 6-15 mm, and more preferably 7-12 mm. Sample thickness is the diameter of the sample perpendicular to the fiber direction (i.e., perpendicular to the machine direction) after extrusion and after complete hydration and equilibrium with environmental conditions.

[0096] The absolute compactness, measured in Newtons, depends on the sample thickness. The absolute compactness of the TVP produced according to the present invention is typically 5-30 N, preferably 8-25 N, such as, for example, 8-15 N, preferably 9-14 N, or 12-30 N, preferably 15-25 N. Relative compactness takes into account variations in sample thickness and is expressed in N / mm. Relative compactness is typically 1.0-3.0, such as, for example, 1.0-1.8 N / mm, or 1.5-2.3 N / mm. A relatively compactness greater than 1.0 N / mm, preferably greater than 1.1 N / mm, more preferably greater than 1.2 N / mm, is considered high. When occasionally required, the absolute and relative compactness of TVP prepared from a specific feed composition can be increased by extrusion at a higher moisture content.

[0097] TVP characteristics, including fiberity and compactness, are determined by the feed composition and extrusion conditions. To obtain the TVP of the present invention that meets the desired characteristics, those skilled in the art can balance the fiberity and compactness of TVP from a specific feed composition based on the above guidance.

[0098] This invention also discloses a method for preparing the tissue-processed plant protein of this invention, comprising: a) Provide a feed composition as defined above, said feed composition having a moisture content of 1-15 wt.%, preferably 5-12 wt.%, relative to the total weight of the feed composition; b) Introducing a feed composition into an extruder, the extruder including a barrel section comprising at least three blocks, preferably at least five blocks, a first block of the barrel section including a feed inlet adapted to feed the feed composition into the extruder, a second block located downstream of the first block of the barrel section including a water inlet adapted to introduce water into the extruder, and one or more further downstream blocks adapted to set a temperature along the barrel section to form an increasing temperature gradient, the extruder also including a die head located downstream of the barrel section, and one or more screw elements adapted to convey the feed composition through the barrel section to the die head; c) Extruding the feed composition under the following extrusion conditions, with a moisture content of 18.1-25.9 wt.%, preferably 19.1-24 wt.%, relative to the total weight of the feed composition: The internal temperature of the barrel is 100-250°C, preferably 130-225°C, more preferably 142-200°C, and most preferably 142-180°C; and / or A die head pressure of 1.5-80 bar, preferably 2-50 bar, and more preferably 15-40 bar; and / or Specific mechanical energy (SME) of 0.05-0.35 kWh / kg, preferably 0.10-0.28 kWh / kg.

[0099] In this document, extrusion refers to the movement of the feed composition through the barrel by a rotating screw toward the die head, and subsequently exiting the extruder through an outlet in the die head. The extruded feed composition preferably exits the extruder as an expanded strip through one or more outlets in the die head. In a more preferred embodiment, as known in the art, the expanded strip is then pulverized, for example, using a pelletizer (rotary cutter). The expanded strip is preferably pulverized into portions having a length of 0.5-7 cm, preferably 2-5 cm, in the machine direction.

[0100] In a further preferred embodiment, the method further includes drying the expanded strips or pulverized portion to a moisture content of less than 10 wt.%, preferably less than 8 wt.%, more preferably less than 7 wt.%. This further increases the microbial stability and / or shelf life of the TVP of the present invention. The drying can be achieved by any method known in the art.

[0101] All features of the method of the present invention have been described above with reference to the TVP of the present invention. Any description of the features described in the context of the TVP of the present invention also applies to the method of the present invention.

[0102] Uses of TVP The TVP of the present invention is particularly applicable to food products, preferably human food products. Therefore, the present invention also provides food products comprising textured plant proteins as defined above.

[0103] The high fiber content and high compactness of the TVP of the present invention endow the food products of the present invention with a palatable structure, without the disadvantages of products extruded with high moisture content. This increases the processability and usability of the TVP of the present invention in the food product industry. Before its use in food products, the TVP strips obtained after extrusion, or preferably smaller fractions thereof, are further pulverized into smaller particles, such as 0.1-20 mm, preferably 0.5-15 mm, more preferably 0.5-10 mm, or even 0.5-5 mm. Particle size can be determined by sieve analysis, a method known in the art.

[0104] The preferred food products of the present invention are food products at least partially based on meat or similar meat. The food products of the present invention are preferably those in which the TVP of the present invention is used as a substitute for animal-derived meat. In this document, animal-derived meat refers to any kind of meat, including meat of mammals such as beef, pork, sheep, or goat, preferably beef, and also includes poultry such as chicken and turkey, as well as fish and crustacean meat. Therefore, the present invention also provides the use of the TVP of the present invention as a substitute for animal-derived meat in food products.

[0105] Preferably, the food product of the present invention is an extended meat product, a vegetarian or vegan meat substitute, or a vegetarian or vegan dietary component.

[0106] In this document, extended meat products are food products that include animal-derived meat, but in which a portion of the animal-derived meat has been replaced by the TVP of the present invention. Examples of extended food products include beef burgers, sausages, or meatballs that include a lower amount of animal-derived meat than conventional animal-derived beef burgers, sausages, or meatballs, and in which a portion of the animal-derived meat has been replaced by the TVP of the present invention. Extended meat products have the advantage of reducing the consumption of animal-derived meat while retaining animal-derived meat as a flavor and structural component.

[0107] Vegan or vegan meat alternatives are meat substitutes that do not contain animal-derived meat. Vegan meat alternatives may contain non-meat animal-derived components (such as eggs or dairy, and in some cases, fish and / or crustacean meat, depending on individual preference), while vegan meat alternatives are entirely plant-based and do not contain any animal-derived components.

[0108] Preferred vegetarian or vegan meat substitutes or extended meat products are (vegan or vegan) hamburgers, meatballs, skewers, chicken nuggets, sausages, minced meat, fried cutlets, ribs, sliced ​​meat, fish balls, or chunks of meat.

[0109] A vegetarian or vegan diet is a portion of a diet that traditionally includes meat, but it has been further developed to encompass variations that exclude meat from animal sources (vegan, which may sometimes still include fish and / or crustacean meat) or completely exclude products from animal sources (vegan). Completely excluding products from animal sources (vegan) means that meat from animal sources and other animal-derived products (including eggs, gelatin, milk, etc.) are not present.

[0110] Examples include vegetarian or vegan Bolognese sauce, chili con carne (“vegan chili sin carne”), pie fillings, taco fillings, burrito fillings, or stews. These examples should not be considered limiting, as food products that typically include meat can be made using the TVP of this invention as an animal-derived meat substitute.

[0111] The present invention also provides a method for producing vegetarian or vegan meat substitutes as defined above, comprising: a) Hydrate tissueed plant proteins as defined above to obtain hydrated TVP; b) Combining textured plant proteins with one or more ingredients selected from the group consisting of starch, plant fiber, coloring agents, flavoring agents, fats, oils, emulsifiers, proteins, probiotics, yeast extracts, binders, and salts to obtain a pristine mixture; c) Shape the original mixture into the desired shape.

[0112] In a more preferred embodiment, the method for preparing vegetarian or vegan meat substitutes includes the step of pulverizing hydrated TVP. Pulverization can be performed before or after hydration.

[0113] If grinding is performed before hydration, the grinding is preferably to a particle size of 0.1-20 mm, more preferably 0.5-15 mm. If grinding is performed after hydration, the particle size of the hydrated and ground TVP is preferably 0.1-20 mm, more preferably 0.5-15 mm. The grinding step preferably produces a particle size typical of hydrated TVP for the type of meat substitute being made. For example, for hamburgers, the TVP of the present invention typically has a particle size of 0.5-5 mm before hydration.

[0114] In addition to using the TVP of the present invention, this method reflects methods commonly known in the art for preparing vegetarian or vegan meat substitutes. In short: Hydration of tissueed plant proteins can be achieved by any method known in the art. Preferred hydration methods include immersing TVP in an aqueous solution containing additional components such as salt or sugar for at least 5 minutes, preferably at least 15 minutes.

[0115] Hydration is complete when the TVP of the present invention is substantially completely balanced with water, indicating a water content of about 40-80 wt.%. This may take up to 5 hours, but preferably up to 2 hours, more preferably up to 1 hour.

[0116] The second step involves combining the hydrated TVP with other food ingredients, thereby providing a pristine mixture. The lipids may be added as a pre-emulsion or emulsified in the presence of the hydrated TVP. The preparation of the pre-emulsion may include mixing lipids, water, and binders and / or emulsifiers; emulsification in the presence of the hydrated TVP may include preparing an emulsion comprising the hydrated textured plant protein, lipids, water, emulsifiers, and / or binders. In a preferred embodiment, the pristine mixture comprises an emulsion, wherein the emulsion comprises the hydrated textured plant protein, lipids, emulsifiers, and water.

[0117] The lipids can be any type of lipid, preferably plant-derived lipids, such as vegetable oils, seed oils, or fruit oils. In a preferred embodiment, the lipids comprise at least 95 wt.%, preferably at least 98 wt.%, of triglycerides relative to the total weight of the lipids. Suitable types of lipids include coconut oil, palm oil, sunflower oil, olive oil, etc. For vegetarian meat substitutes, butter or cream can also be used.

[0118] The water is preferably clean and suitable for human consumption. In a preferred embodiment, the water used in the emulsion is tap water.

[0119] The adhesive can be any adhesive suitable for bonding vegetarian or vegan meat substitutes. Preferred adhesives include cellulose adhesives, alginate adhesives, gums, starch (including natural and modified starches), or flour. Alternatively, the adhesive can be a protein adhesive, such as gelatin (for vegetarian products), or a thermogelatinized protein (for vegetarian or vegan products), such as natural potato protein, preferably a natural potato protein isolate.

[0120] The emulsion is preferably prepared by high-speed mixing of the components. Any order of addition is suitable as long as it produces a malleable emulsion. Optional ingredients, such as flavoring agents, coloring agents, salt, leavening agents, and conditioning agents, may be added during or after emulsion formation. Those skilled in the art can determine, based on common general knowledge, which optional agents are suitable to be included in which type of vegetarian or vegan meat substitute.

[0121] Finally, the original mixture, preferably an emulsion, is shaped into the desired form. The shape can be any shape, but is preferably a conventional shape of the vegetarian or vegan meat alternative discussed. Thus, a hamburger, for example, can be provided in a "patty" (flat disc) shape, while a sausage can be provided in a long and optionally curved cylindrical shape.

[0122] The present invention also provides a method for preparing a food product selected from vegetarian or vegan dietary components or extended meat products, the method comprising providing one or more ingredients to the vegetarian or vegan dietary components or extended meat products; hydrating the textured plant protein as described above; and combining the one or more ingredients with the hydrated textured plant protein.

[0123] Methods for preparing vegetarian or vegan dietary components or extended meat products preferably include one or more of the following steps: providing ingredients, mixing ingredients, heating one or more ingredients individually or as a mixture, and cooling one or more ingredients individually or as a mixture. Furthermore, the method may include performing cooking steps such as kneading, aerating, stirring, baking, frying, boiling, simmering, mashing, settling, shaping, stretching, and / or soaking.

[0124] For the purpose of clarity and concise description, features described herein are part of the same or separate embodiments; however, it should be understood that the scope of the invention may include embodiments having all or some of the features described.

[0125] The invention will now be illustrated by the following non-limiting embodiments.

[0126] Experimental Section raw materials • Tuber protein isolate: Avebe coagulated potato protein, prepared according to the method described in WO 2017 / 142406.

[0127] • Legume protein isolate: Pea protein isolate from Roquette (trade name Nutralys F85M) • Plant fiber: Pea fiber obtained from Roquette (trade name L50M).

[0128] Table 1: Composition analysis of raw materials expressed as dry solids

[0129] method The following chemical analyses were applied to both raw materials and extruded products. Textural analysis was performed only on the extruded products.

[0130] Protein content Protein content was determined by Kjeldahl nitrogen analysis using a correction factor of 6.25. This method is based on Regulation (EC) No. 152 / 2009, Annex III, Method C, Dairy Products, equivalent to NEN-EN-ISO 8968-1.

[0131] Lipid analysis The amount of lipids was determined by Soxhlet extraction following acid hydrolysis, using petroleum ether and gravimetric analysis (according to EC152-2009, Annex III, Method H, Sub-method B).

[0132] crude fiber The amount of crude fiber was determined by acid and alkaline hydrolysis in accordance with AOAC 991.43 and based on Method I of Annex III to EC Regulation No. 152 / 2009. Crude fiber refers to the amount of fiber present in the protein starting material, not plant fiber, which is fiber that can be added to the feed composition as a separate powder.

[0133] carbohydrate The amount of carbohydrates was determined by subjecting the sample to an acid hydrolysis step that converts polysaccharides into free sugars, followed by HPLC analysis using a pulsed amperometric detector (PAD). Total carbohydrates are expressed as the total weight of the acid-hydrolyzed fructose, galactose, and glucose. Free sugars were determined by HPLC analysis of the aqueous extract that had not undergone acid hydrolysis; free sugars included fructose, galactose, glucose, lactose, maltose, and sucrose.

[0134] TGA Total glycoalkaloids (TGA) were determined using AOAC official method 997.13.

[0135] fibrous The extruded samples were hydrated by immersion in water for 10–15 minutes and then drained on a sieve for 10–15 minutes. Test samples were selected from the hydrated extruded samples to ensure uniform size and shape; the size range studied was 3–5 cm. The hydrated test samples were protected from dehydration when no active treatment was performed.

[0136] The fibrousness of hydrated test samples was assessed using a visual rating scale ranging from 1 to 5. A grade "1" indicates an open, non-fibrous structure ("honeycomb"), while a grade "5" indicates a highly fibrous structure (no "honeycomb" structure and high fibrousness). The fibrousness rating scale depicting the fibrousness levels 1-5 is as follows: Figure 1 As shown.

[0137] Firmness Compactness was determined using the Warner-Britzler method with a texture analyzer (ShimadzuEZ Test EZ-SX). Hydration and selection of samples were performed according to the description of fibrousness. Sample diameter was measured prior to evaluation.

[0138] Place the sample in the center of the sample support, ensuring the Warner Bratzler blade is oriented perpendicular to the fiber direction (if the fiber direction is observable). Completely cut the sample by moving the Warner Bratzler blade downwards by 40 mm, ensuring the blade has moved completely across the platform. Set the measurement speed to 4 mm / sec.

[0139] Record the peak force (in Newtons) and use it to represent absolute compactness. Relative compactness, expressed in N / mm, can be calculated by dividing the compactness (in N) by the diameter. Measure six times at each test point and report the average value.

[0140] Extrusion Extrusion tests were conducted using a Coperion ZSK 27 twin-screw co-rotating extruder. The ZSK 27 extruder is a food-grade, laboratory-scale machine (27 mm in diameter). This extruder has three peripheral devices attached to it: a water pump feeder (feeder 1), a solid material feeder (feeder 2), and a pellet mill with a compressed air outlet.

[0141] The extruder barrel consists of six modular blocks with a total length of 24D (4D×6). The screw diameter D is 27mm. Therefore, the barrel and screw have a total length of 648mm. The die disc used has two tapered cavities. The two tapered cavities terminate in two cylindrical die openings (“exit holes”) with a diameter of 3mm and a length of 2mm.

[0142] The screw configuration used has a series of seven reverse pitch elements wound around the conveying element. The reverse pitch elements are positioned towards the end of the screw, starting at position 14D. Following the reverse pitch elements is the pinch block (45° staggered angle) at position 21.5D and the conveying element immediately preceding the screw tip at position 23D. The screw speed was 500 rpm in all experiments.

[0143] The temperature distribution is based on a steep increase in temperature after the water supply point (second block). The temperatures in the third (60°C) and fourth (90°C) blocks are set at 60 to 90°C. Higher temperatures are reached in the fifth (140°C) and sixth (160°C) blocks to further reduce the viscosity of the melt and promote protein cleavage caused by a series of reverse pitches.

[0144] The high temperature at the die head causes water to be released suddenly as steam as it leaves the extruder. This steam release causes the extrudate to expand significantly. Without being bound by any theory, it is speculated that the rearrangement and formation of protein-protein bonds upon exiting the extruder leads to the protein-fibrous structure.

[0145] Table 2: Temperature distribution set in the barrel used for extrusion

[0146] Example 1 Pea protein isolates, potato protein isolates, and various pea / potato protein mixtures were extruded under different low-moisture conditions using the conventional extrusion setup described above. For comparative purposes, a series of pea protein / pea fiber mixtures (prior art) were prepared using the same method. The proportions of the mixtures were based on the total weight of the raw materials (“original (asis)”).

[0147] The compositional analysis of the extruded protein products is shown in Table 3.

[0148] Table 3: Composition analysis of extruded products (g / kg dry matter, unless otherwise stated)

[0149] Peas = pea protein; Fiber = pea fiber; Potato = potato protein; Broad beans = broad bean protein (20% MC). The numbers in the title represent the percentage in the feed (wt.%).

[0150] The extrusion parameters and textural analysis of the extruded products are shown in Table 4. The results indicate that while neither pea protein nor potato protein provides acceptable fibrousness under the applied extrusion conditions, a mixture of pea protein and potato protein does provide a fibrous structure. The extruded mixture of pea protein and potato protein also exhibits acceptable firmness. Therefore, the addition of potato protein provides both fibrousness and firmness. This effect occurs regardless of the presence or absence of filler (Example 3).

[0151] Table 4: Extrusion parameters and results of visual and textural analysis

[0152] Peas = pea protein; Fiber = pea fiber; Potato = potato protein; P = die pressure; T = temperature; SME = specific mechanical energy; Protein = protein content; A. Compactness = absolute compactness; R. Compactness = relative compactness.

[0153] Example 2 Using the same screw configuration as in Example 1, experiments were conducted at a yield of 25 kg / h at 500 rpm. Pure pea protein and various pea / potato protein mixtures were extruded under various low-moisture conditions using the conventional extrusion setup described above. The proportions of the mixtures were based on the original weight of the raw materials. For comparative purposes, a series of pea protein / pea fiber (prior art) mixtures were prepared using the same method.

[0154] Table 5 shows that the extruded mixture of pea protein and potato protein has acceptable firmness and fibrousness. Extruded pea / fiber or pure pea protein lacks firmness or fibrousness. Therefore, the addition of potato protein provides both firmness and fibrousness. This effect is achieved regardless of the presence or absence of filler (Example 3).

[0155] Table 5: Extrusion parameters and results of visual and textural analysis

[0156] Example 3 Pea protein isolates, potato protein isolates, and various pea / potato protein mixtures were extruded under different low-moisture conditions in the presence of varying amounts of filler, according to the conventional extrusion setup described above. The filler was starch (natural potato starch, Avebe).

[0157] The screw configuration used for extrusion is "Screw Configuration 2". Screw Configuration 2 includes a series of five counter-pitch elements interleaved with the kneading and conveying elements. The first kneading element (45° staggered angle) is positioned at position 6D, and the second kneading element is positioned at position 11D (90° staggered angle). The five counter-pitch elements are positioned toward the end of the screw starting at position 16D. Following the counter-pitch elements is another kneading element (45° staggered angle) at position 21D and a conveying element immediately preceding the screw tip at position 23D.

[0158] Using screw configuration 2, the feed composition is extruded under low moisture conditions as defined herein, using the temperature distribution in the barrel section as described above, but a higher rotational speed is applied to obtain higher output and production efficiency.

[0159] The quantity refers to the total amount of filler present in the feed, and the total amount of pea protein and potato protein obtained by recalculating based on the amount of starting material used, relative to dry matter.

[0160] The results showed that, in the presence of filler, the presence of potato protein in the extruded mixture imparted fibrousness and firmness at protein contents as low as 65 wt.%.

[0161] Table 6: Extrusion parameters and results of visual and textural analysis

[0162] Peas = pea protein; Fiber = pea fiber; Potato = potato protein; P = die pressure; T = temperature; SME = specific mechanical energy; Protein = protein content; A. Compactness = absolute compactness; R. Compactness = relative compactness; WAI = water absorption index as described in Example 4.

[0163] Fiberiness is assessed on a 5-point scale, where 5 indicates high fiberiness and 1 indicates no fiberiness.

[0164] Tightness was assessed on a 5-point scale, where 5 indicates high tightness and 1 indicates low tightness; 4 and 5 were considered acceptable.

[0165] Colors are evaluated on a 5-point scale, where 5 indicates a suitable light color and 1 indicates too high (dark) coloring; 4 and 5 are considered acceptable.

[0166] Juiciness is assessed through sensory evaluation (yes / no).

[0167] Example 4 Further TVP was prepared using screw configuration 2, without filler. The plant protein source to be combined with the tuber protein prior to extrusion was different.

[0168] The feed compositions included the potato protein and pea protein mixture used in Example 1, and the potato protein (as above) and broad bean protein mixture. The broad bean protein was obtained from Univar (Univar 90-C-EU) and had a protein content of 93.4 wt.% based on Kjeldahl nitrogen determination. The compositional analysis report of the broad bean proteins used is described in Table 1.

[0169] Extrusion parameters and TVP characteristics are shown in Table 7. The compositional analysis of TVP obtained from 75 wt.% broad bean protein and 25 wt.% potato protein at 20% moisture content is reported in Table 3.

[0170] The water absorption index (WAI) is a measure of the amount of water absorbed by TVP under standardized conditions. First, the dry weight of the TVP is determined by correcting for its original weight with moisture content: m 干 =m原始 × ((100 - moisture%) / 100). To determine WAI, accurately weigh approximately 10g of TVP and immerse it in a bowl of water using a sieve for 10 minutes. Remove the sieve containing TVP from the water, allowing the water to drip under gravity to remove excess unabsorbed water. Then weigh the soaked TVP and calculate WAI: WAI = 100 (m) 浸泡的 -m 干 ) / m 干 .

[0171] The WAI of the TVP of the present invention is provided in Table 7.

[0172] Table 7: Extrusion parameters and results of visual and textural analysis

[0173] Example 5 The TVP sample according to the invention (Invention 2) was applied to a meat substitute in a "raw" meat-type hamburger. The hamburger was prepared using the ingredients listed in Table 8. Before preparing the hamburger, the TVP sample was pulverized to obtain particles with a size of 0.5-5 mm.

[0174] Table 8: Recipes (wt. ratios) for making raw meat type meat substitute burgers

[0175] Preparation of meat substitutes: 1. Mix TVP and water in a hot mixer for 15 minutes at speed setting 2; 2. Mix all the dry powder ingredients to make a powder mixture; 3. When the hydrated TVP disintegrates, add the powder mixture and stir for 30 seconds (speed setting 3). 4. Mix the sunflower oil into the dough and stir for 1 minute (speed setting 4); 5. Shape the mixture into hamburger patties.

[0176] The hamburgers are pan-fried to a core temperature of 75-80°C. Before frying, the hamburgers can be stored in a refrigerator at -18°C for up to a year.

[0177] The resulting burgers were cohesive both before and after cooking. They had a pleasant, non-fragile texture with a distinctly meat-like consistency. This observation supports the conclusion that TVP products require high fiber and high firmness, which can be achieved through low-moisture extrusion of a mixture of legume and tuber proteins with fillers, as disclosed herein.

Claims

1. A texturized plant protein, said texturized plant protein being defined as a fibrous plant protein material having a protein content of at least 40 wt.% relative to dry matter, wherein, The textured plant protein is prepared by extruding a feed composition at a moisture content of 18.1-25.9 wt.%, the feed composition comprising: a) A source of plant protein from seeds, cereals, algae, fruits, leaves, or legumes, wherein the plant protein source comprises at least 65 wt.% plant protein relative to dry matter; and b) The source of tuber protein, wherein the source of tuber protein comprises at least 75 wt.% tuber protein relative to dry matter; and c) Packing material.

2. The tissue-processed plant protein according to claim 1, wherein, The amount of filler is at least 11.5 wt., preferably at least 15.5 wt., relative to the dry weight of the feed composition.

3. The tissueed plant protein according to claim 1 or 2, wherein, The filler includes starch or plant fiber, preferably starch.

4. The tissue-processed plant protein according to any one of claims 1-3, wherein, The protein content relative to dry matter is 40-88.5 wt.%, preferably 40-84.5 wt.%, more preferably 40-69.9 wt.%, more preferably 50-69.9 wt.%, and even more preferably 60-69.9 wt.%.

5. The tissueed plant protein according to any one of claims 1-4, prepared from a feed composition comprising, relative to total protein, 2.5-95 wt.%, preferably 5-90 wt.%, more preferably 7.5-75 wt.%, more preferably 10-50 wt.% of tuber protein.

6. The textured plant protein according to any one of claims 1-5, prepared from a feed composition comprising, relative to total protein, at least 50 wt.%, preferably at least 60 wt.%, more preferably at least 70 wt.%, and most preferably at least 75 wt.%, of plant protein derived from seeds, cereals, algae, fruits, leaves, or legumes.

7. The tissueed plant protein according to any one of claims 1-6, wherein the tissueed plant protein has a moisture content of 5-12 wt.%.

8. The tissueed plant protein according to any one of claims 1-7, in wt.% comprising, relative to dry matter, a) less than 15 wt.%, preferably less than 10 wt.%, more preferably less than 5 wt.%, even more preferably less than 2 wt.% of lipids; and / or b) at least 1 wt.%, preferably at least 2 wt.%, more preferably at least 3 wt.%, more preferably at least 4 wt.%, and more preferably at least 5 wt.% of lipids.

9. The tissueed plant protein according to any one of claims 1-8, comprising less than 150 ppm, preferably less than 100 ppm, more preferably less than 80 ppm, more preferably less than 50 ppm, and more preferably less than 30 ppm of total trisaccharide alkaloids (TGA).

10. The tissueed plant protein according to any one of claims 1-9, wherein, The sources of plant protein include legume protein.

11. The tissueed plant protein according to any one of claims 1-10, which can be obtained by a process comprising: a) Provide a feed composition as defined in any one of claims 1-10, said feed composition having a moisture content of 1-15 wt.%, preferably 5-12 wt.%, relative to the total weight of said feed composition; b) Introducing the feed composition into an extruder, the extruder including a barrel section comprising at least three blocks, preferably at least five blocks, a first block of the barrel section including a feed inlet adapted to feed the feed composition into the extruder, a second block located downstream of the first block of the barrel section including a water inlet adapted to introduce water into the extruder, and one or more further downstream blocks adapted to set a temperature along the barrel section to form an increasing temperature gradient, the extruder also including a die head located downstream of the barrel section, and one or more screw elements adapted to convey the feed composition through the barrel section to the die head; c) Extruding the feed composition under the following extrusion conditions, with a moisture content of 18.1-25.9 wt.%, preferably 19.1-24 wt.%, relative to the total weight of the feed composition: The internal temperature of the barrel is 100-250°C, preferably 130-225°C, more preferably 142-200°C, and most preferably 142-180°C; and / or A die head pressure of 1.5-80 bar, preferably 2-50 bar, more preferably 15-40 bar; and / or Specific mechanical energy (SME) of 0.05-0.35 kWh / kg, preferably 0.10-0.28 kWh / kg.

12. A method for preparing low-moisture extruded textured plant protein as defined in any one of claims 1-11, comprising: a) Provide a feed composition as defined in any one of claims 1-7, the feed composition having a moisture content of 1-15 wt.%, preferably 5-12 wt.%, relative to the total weight of the feed composition; b) Introducing the feed composition into an extruder, the extruder including a barrel section comprising at least three blocks, preferably at least five blocks, a first block of the barrel section including a feed inlet adapted to feed the feed composition into the extruder, a second block located downstream of the first block of the barrel section including a water inlet adapted to introduce water into the extruder, and one or more further downstream blocks adapted to set a temperature along the barrel section to form an increasing temperature gradient, the extruder also including a die head located downstream of the barrel section, and one or more screw elements adapted to convey the feed composition through the barrel section to the die head; c) The feed composition is extruded under the following extrusion conditions, with a moisture content of 18.1-25.9 wt.%, preferably 19.1-24 wt.%, relative to the total weight of the feed composition: The internal temperature of the barrel is 100-250°C, preferably 130-225°C, more preferably 142-200°C, and most preferably 142-180°C; and / or A die head pressure of 1.5-80 bar, preferably 2-50 bar, more preferably 15-40 bar; and / or Specific mechanical energy (SME) of 0.05-0.35 kWh / kg, preferably 0.10-0.28 kWh / kg.

13. A food product comprising textured plant protein as defined in any one of claims 1-11.

14. The food product according to claim 13, wherein, The food product is an extended meat product, or a vegetarian or vegan meat substitute, preferably a hamburger, meatball, kebab, chicken nugget, sausage, minced meat, fried pork cutlet, ribs, sliced ​​meat, fish ball, or chunks of meat, or the food product is a vegetarian or vegan dietary component, preferably a spicy meat sauce, Bolognese sauce, pie filling, taco filling, wrap filling, or stew.

15. A method for producing a vegetarian or vegan meat substitute as defined in claim 14, comprising: a) Hydration of tissueed plant proteins as defined in any one of claims 1-11; b) Combining hydrated, textured plant proteins with one or more ingredients selected from the group consisting of starch, plant fiber, coloring agents, flavoring agents, fats, oils, emulsifiers, proteins, probiotics, yeast extracts, binders, and salts to obtain a pristine mixture; c) Shape the original mixture into the desired shape.

16. A method for preparing vegetarian or vegan dietary components, or extended meat products, comprising: Provide one or more ingredients for the vegetarian or vegan dietary components, or for extended meat products; Hydrated, as defined in any one of claims 1-11, of the tissueed plant proteins; Combine one or more of the aforementioned components with hydrated, tissue-processed plant proteins.

17. Use of textured plant protein as defined in any one of claims 1-11 as a substitute for animal-derived meat in food products.

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