Vegetable-based cooked meat-like products comprising titanium dioxide

Abstract

A plant-based cooked meat-like product is prepared by hydrating non-glutelin vegetable proteins with an aqueous titanium dioxide mixture and then mixing with a plant-based oil and hydrocolloid, vital gluten and edible acid to form a plant-based dough, the plant-based dough is formed into dough segments and cooked to an internal temperature of at least about 180 DEG F to form a plant-based cooked meat-like product. By selecting specific ingredients in an effective ratio and mixing these ingredients in a specific order, a plant-based cooked meat-like product having an excellent appearance and texture can be prepared.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 63 / 580,811, filed September 6, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0003] This invention relates to plant-based cooked meat imitations. Background Technology

[0004] For a variety of reasons, consumers are increasingly looking for protein alternatives to animal meat. At the same time, many consumers appreciate the unique flavor and texture that meat derived from animals offers. To this end, many companies are striving to provide plant-based meat alternatives that replicate the experience of cooking and consuming meat.

[0005] Examples of plant-based meat alternatives include Impossible Burger from Impossible Foods, Beyond Burger from Beyond Meat, and Ultimate Beefless Burger from Gardein. These and other products are discussed, for example, in https: / / www.healthline.com / nutrition / vegan-meat-substitutes#section4, which notes that Beyond Burger is made from pea protein, low-erucic acid canola oil, coconut oil, potato starch, and other ingredients.

[0006] Similarly, WO 2017 / 046659 describes an extruded meat substitute composition comprising one or more non-gluten-producing plant protein sources, one or more lipid sources, one or more carbohydrate sources, and water. In some embodiments, the one or more carbohydrate sources may include fruit, fruit powder, or chia seed extract, or any combination of any two or more of these. In this composition, the lipid source may include vegetable fats or oils; more than 60 such oils are listed.

[0007] Meat substitute products made from wheat (referred to as "wheat meat" or "vegetarian meat") are known and can be used as a base for vegetarian products. [https: / / www.thespruceeats.com / what-is-seitan-3376819](https: / / www.thespruceeats.com / what-is-seitan-3376819). Homemade recipes for making vegetarian meat are known, such as those described at [https: / / www.thespruceeats.com / how-to-make-seitan-3376639]. Such recipes describe a simple method of combining ingredients such as vital wheat gluten powder, chickpea flour, nutritional yeast, ginger powder, and garlic powder in a bowl, mixing, kneading, and cooking the product. Gladden's U.S. Patent Application Publication No. 2019 / 0191725 describes a method for making vegetarian meat snack foods in which a sponge dough containing a large amount of wheat gluten is formed into a bread-like shape and subjected to a series of cooling and cooking steps, including refrigeration, boiling, cooling, frying, and drying, to produce a bacon-like snack food product with a low water activity of less than 0.85.

[0008] Cavallini’s U.S. Patent No. 7,070,827 describes a plant-based meat substitute made by successively blending methylcellulose into a water / ice mixture to form a creamy substance, and then blending it with modified gluten (a plant protein product that is highly soluble in water and can form a gel by mild heat treatment), an oil for making an emulsion matrix, and modified food starch and flavoring ingredients to form a flavored emulsion matrix. Summary of the Invention

[0009] For the purposes of this discussion, imitation meat products are foods that mimic meat but do not contain any animal meat ingredients. Previous attempts to prepare imitation meat products have generally failed to achieve the desired sensory experience because they lack one or more of the visual and textural characteristics intended to simulate animal meat. Furthermore, achieving the desired consistency and texture of imitation meat products using only non-animal-derived ingredients without incorporating numerous additives with long ingredient lists, artificial-sounding names, and undesirable properties for the average consumer is challenging.

[0010] It has been discovered that plant-based processed meat imitations with excellent appearance and texture can be prepared by selecting specific ingredients in effective ratios and mixing them in a specific order. A plant-based processed meat imitation is formed via a multi-step method comprising: a) Mix water with titanium dioxide to form an aqueous titanium dioxide mixture. b) Mix non-gluten plant protein with a mixture of hydrated titanium dioxide to form hydrated non-gluten plant protein. c) Mixing hydrated non-glutenin plant proteins with plant-based oils and hydrocolloids to form protein intermediate compositions. d) The protein intermediate composition is mixed with gluten powder to form a protein / gluten mixture intermediate composition. e) Mixing a protein / gluten blend intermediate composition with an edible acid to form a plant-based dough, and f) Assigning plant-based dough into sausage casings to form dough segments, and g) Cook the dough pieces to an internal temperature of at least about 180℉ to form a plant-based cooked meat imitation product; Plant-based processed meat imitations include: Titanium dioxide, approximately 0.5% by weight to approximately 6% by weight. Approximately 3% to approximately 20% by weight of non-gluten plant protein, Water, approximately 40% to approximately 87% by weight From approximately 0.5% by weight to approximately 6% by weight of oil, About 2% to about 10% by weight of hydrocolloids, From about 5% to about 20% by weight of gluten, and Sufficient amounts of edible acids to provide a pH of about 4.5 to about 7 for plant-based cooked meat imitations.

[0011] Unbound by theory, titanium dioxide is believed to disrupt the matrix structure of plant-based dough before or during cooking, and / or to play a role in gas escape in plant-based dough before or during cooking, to provide a unique structural feature that provides a perceptible sensory improvement in appearance and bite characteristics of the final plant-based cooked meat-like product compared to similar products that do not contain the titanium dioxide described herein.

[0012] It has been found that, on the one hand, the resulting plant-based processed meat imitations exhibit excellent bite characteristics, with a dense texture containing visually observable voids, resulting in visible physical discontinuities in the product. On the other hand, the resulting plant-based processed meat imitations exhibit visually observable fibrous features that mimic the texture of processed meat. By incorporating appropriate flavorings and colorings, plant-based processed meat imitations that effectively mimic specific processed meat products (such as sliced ​​chicken, turkey, ham, or beef) can be readily prepared.

[0013] It was also found that adding edible acid to an intermediate mixture already containing a composition of plant protein and gluten in an amount sufficient to provide dough with a pH of about 4.5 to about 7 provided a plant-based cooked meat imitation product with excellent appearance and texture characteristics similar to cooked meat. In one aspect, it was found that adding edible acid resulted in a lighter color in the final cooked meat product compared to similar compositions without edible acid. In another aspect, it was found that adding edible acid as a final addition before cooking provided excellent texture characteristics with a fibrous appearance when the imitation meat was torn, compared to similar compositions in which edible acid was introduced at an earlier stage of the process. Furthermore, it was found that adding edible acid as a final addition before cooking provided excellent resilience when the imitation meat was physically manipulated (e.g., by folding product slices), contrasting with similar compositions in which edible acid was introduced at an earlier stage of the process, resulting in a product that was easily decomposed and "fragile" during physical manipulation. Attached Figure Description

[0014] The patent or application document contains at least one color-drawn drawing. A copy of the patent or application publication with the color drawing will be provided by the patent office upon request and payment of the necessary fees.

[0015] The accompanying drawings, incorporated in and constituting a part of this application, illustrate several aspects of the invention and, together with the description of these embodiments, serve to explain the principles of the invention. Where photographs are used, they are provided in grayscale. Corresponding color copies of such grayscale photographs are provided in this provisional application as supplementary information for proper reference in various jurisdictions and for presentation in jurisdictions where the submission of color drawings is permitted.

[0016] A brief description of the attached diagram is as follows: Figure 1 These are photos comparing plant-based processed meat products that do not contain titanium dioxide.

[0017] Figure 2 This is a photo of a plant-based cooked meat substitute containing titanium dioxide.

[0018] Figure 3 This is a photo of a plant-based roast beef-style deli meat product that has been manually torn open to reveal its edge structure. Detailed Implementation

[0019] The aspects of the invention described below are not intended to be exhaustive or to limit the invention to the exact forms disclosed in the detailed description below. Rather, the aspects chosen and described are intended to facilitate understanding and comprehension of the general principles and practice of the invention by way of illustration or example for those skilled in the art.

[0020] As a first step in the method of the present invention, water is mixed with titanium dioxide to form a hydrated titanium dioxide mixture, which is then used to hydrate non-glutenin plant proteins. It has been found that by introducing titanium dioxide as a first step, the method of the present invention ensures that titanium dioxide is effectively distributed throughout the final plant-based deli meat product. It has been found that when titanium dioxide is added later in the method, i.e., after the addition of plant-based oils and hydrocolloids or after the addition of gluten, following the hydration of the plant proteins, the desired texture of the final plant-based deli meat product is obtained unevenly or not at all.

[0021] The titanium dioxide used in the method of this invention is a food-grade product, which is an ultrafine powder product that is dispersible in water. In one aspect, the titanium dioxide has a particle size of less than about 150 nm. An example of commercially available food-grade titanium dioxide is Kowet titanium dioxide 5000095X25 from Sensient.

[0022] Titanium dioxide is added to water in an amount that effectively provides a plant-based cooked meat imitation product containing about 0.05% to about 3% by weight of titanium dioxide. In another aspect, titanium dioxide is added to water in an amount that effectively provides a plant-based cooked meat imitation product containing about 0.1% to about 1% by weight of titanium dioxide.

[0023] A mixture of hydrated titanium dioxide was mixed with non-gluten plant protein to form hydrated non-gluten plant protein.

[0024] In one aspect, the non-gluten-containing plant protein used in the method of the present invention is obtained from a plant protein source selected from the group consisting of: alfalfa, algae, barley, kidney beans, broad beans, chia, clover, chickpeas, corn, cowpeas, peanuts, sweet peas, pigeon beans, fava beans, kidney beans, mung beans, navy beans, soybeans, legumes, lentils, lupins, peas, coconuts, carob, nuts, peanuts, peas, almonds, potatoes, cereals, sorghum, forniamycin, quinoa, fungi, seaweed, or mixtures thereof. In another aspect, the non-gluten-containing plant protein used in the method of the present invention is obtained from a plant protein source selected from the group consisting of: kidney beans, broad beans, corn, peas, chickpeas, cowpeas, peanuts, sweet peas, pigeon beans, broad beans, kidney beans, mung beans, navy beans, soybeans, legumes, lentils, potatoes, or mixtures thereof.

[0025] In one aspect, the non-gluten-producing plant protein used in the method of the present invention is obtained from a plant protein source selected from the group consisting of: kidney beans, corn, peas, broad beans, soybeans, potatoes, and mixtures thereof. In another aspect, the non-gluten-producing plant protein used in the method of the present invention is obtained from a plant protein source selected from the group consisting of soybeans, peas, or mixtures thereof. In yet another aspect, the non-gluten-producing plant protein is pea protein.

[0026] The use of textured soy protein, textured pea protein, or mixtures thereof has yielded very good results. In one respect, non-gluten plant proteins are preferably textured pea protein.

[0027] On the one hand, the non-gluten plant proteins present in dough do not contain mechanically textured protein components (i.e., non-gluten plant proteins that have been textured by mechanical methods such as extrusion, shear unit technology, etc.).

[0028] In one aspect, the non-gluten plant protein used in the method of the present invention is provided as a non-gluten plant protein composition, i.e., a composition comprising plant protein and non-protein components derived from plant protein sources. In another aspect, the non-gluten plant protein composition may be a non-gluten plant protein concentrate composition, i.e., the source composition contains not less than 55% protein on an anhydrous basis. The non-gluten plant protein composition may also be a non-gluten plant protein isolate composition, i.e., the source composition contains not less than 85% protein on an anhydrous basis.

[0029] The non-gluten-containing plant protein composition may contain a small amount of non-gluten, for example, up to about 10% by weight of plant protein in the non-gluten-containing plant protein composition. Preferably, the non-gluten-containing plant protein composition is gluten-free or substantially gluten-free, for example, the plant protein in the non-gluten-containing plant protein composition is less than 2% by weight, less than 1.5% by weight, less than 1% by weight, less than 0.5% by weight, less than 0.1% by weight, 0.001% by weight to 2% by weight, 0.001% by weight to 1% by weight, 0.001% by weight to 0.5% by weight, or 0.001% by weight to 0.1% by weight.

[0030] In one aspect, the non-gluten plant protein used in the method of the present invention is a powdered non-gluten plant protein having a particle size range of about 20 μm to about 150 μm or having a particle size of -100 US mesh (i.e., the non-gluten plant protein passes through a US 100 mesh sieve with a nominal opening size of about 150 μm). In another aspect, the non-gluten plant protein used in the method of the present invention is a textured non-gluten plant protein having a particle size range of about 0.2 mm to about 20 mm.

[0031] On one hand, non-gluten-containing plant protein is provided in an amount that effectively provides plant-based deli meat substitutes containing approximately 3% to approximately 20% by weight of non-gluten-containing plant protein. On the other hand, non-gluten-containing plant protein is provided in an amount that effectively provides plant-based deli meat substitutes containing approximately 4% to approximately 10% by weight of non-gluten-containing plant protein. To avoid confusion, it should be noted that the amount of non-gluten-containing plant protein is defined as the protein content itself, without taking into account non-protein components that may be present in the plant protein source. For example, adding 100g of a soy protein isolate containing 80% by weight of soy protein will contribute 80g of non-gluten-containing plant protein to the plant-based deli meat substitute.

[0032] Plant proteins are hydrated by mixing with water in any suitable container, such as a mixer or blender. In one aspect, water is mixed with the plant protein composition at a water:(plant protein) weight ratio of about 2:1 to about 4:1. In another aspect, water is mixed with the plant protein composition at a water:(plant protein) weight ratio of about 2.5:1 to about 3.5:1.

[0033] In one aspect, water is mixed with the plant protein composition at a water temperature of about 40℉ to about 90℉. In another aspect, water is mixed with the plant protein composition at a water temperature of about 40℉ to about 75℉. In yet another aspect, water is mixed with the plant protein composition at a water temperature of about 60℉ to about 75℉.

[0034] The resulting hydrated non-gluten plant protein was mixed with plant-based oils and hydrocolloids to form a protein intermediate composition.

[0035] On one hand, plant-based oils are selected from the group consisting of: avocado, low-erucic acid rapeseed, coconut, cocoa, corn, cottonseed, flax, olive, palm, palm kernel, peanut, rapeseed, safflower, soybean, and sunflower oil, as well as mixtures thereof. Sunflower oil, coconut oil, and mixtures thereof have proven to be very effective. On the other hand, plant-based oils are selected from unsaturated plant-based oils. On the other hand, plant-based oils are selected from polyunsaturated plant-based oils.

[0036] In one aspect, plant-based oils are mixed with hydrated non-glutenin plant proteins to effectively provide a plant-based deli meat substitute containing approximately 0.5% to approximately 6% by weight of oil. In another aspect, plant-based oils are mixed with hydrated non-glutenin plant proteins to effectively provide a plant-based deli meat substitute containing approximately 2% to approximately 4% by weight of oil.

[0037] On the one hand, the hydrocolloids incorporated into plant-based processed meat imitations are selected from the group consisting of: hydrocolloid gums, hydrocolloid starches, hydrocolloid water-soluble fibers, and mixtures thereof.

[0038] On one hand, the hydrocolloids present in plant-based cooked meat imitations include at least one hydrocolloid gum component, at least one hydrocolloid starch component, and at least one hydrocolloid water-soluble fiber component.

[0039] On one hand, the hydrocolloid gum components are selected from locust bean gum, carrageenan (seaweed extract), guar gum, xanthan gum, gellan gum, sclerotium glucan, agar, pectin, alginate, gum arabic, and mixtures thereof.

[0040] On one hand, the hydrocolloid water-soluble fiber component is selected from water-soluble fibers or a mixture of soluble and insoluble fibers, such as konjac glucan and citrus fiber.

[0041] In one aspect, the hydrocolloid starch component is selected from starches derived from sources including, but not limited to, the fruits, seeds, and roots or tubers of plants. In another aspect, starch sources include, but are not limited to, rice, wheat, corn, potato, cassava, arrowroot, buckwheat, banana, barley, cassava, kudzu root, taro, sago, sorghum, sweet potato, taro, and yam. In yet another aspect, the starch is selected from tapioca starch, cassava starch, and mixtures thereof.

[0042] On one hand, starch can be one or more modified starches, that is, starches that have been altered from their natural state, resulting in changes to one or more of their chemical or physical properties. Starch can be modified, for example, by enzymes, oxidation, or substitution with various compounds. Starch can be modified to increase its stability to heat, acid, or freezing; improve its texture; increase or decrease its viscosity; increase or decrease its gelatinization time; and increase or decrease its solubility, etc. Modified starches can be partially or completely degraded into shorter chains or glucose molecules, or modified by substitution to have a different chemical composition. On the other hand, starch can be nOSA starch, that is, modified starch that has been partially substituted with n-octenyl succinic anhydride.

[0043] On the one hand, plant-based oils and hydrocolloids can be mixed simultaneously with hydrated non-glutenin plant proteins, or either component can be mixed with hydrated non-glutenin plant proteins before the other component.

[0044] In one aspect, hydrocolloids are mixed with hydrated non-glutenin plant proteins in an amount that effectively provides a plant-based cooked meat substitute product containing about 1.5% to about 10% by weight of hydrocolloids. In another aspect, hydrocolloids are mixed with hydrated non-glutenin plant proteins in an amount that effectively provides a plant-based cooked meat substitute product containing about 1.5% to about 5% by weight of hydrocolloids.

[0045] On one hand, hydrocolloids contain: Carrageenan, approximately 0.1% to approximately 5% by weight. Konjac beta-glucan, approximately 0.1% to approximately 5% by weight, Citrus fiber, approximately 0.1% to approximately 5% by weight. Tapioca starch of approximately 0.1% to approximately 5% by weight, all amounts based on the total amount of plant-based cooked meat substitute products.

[0046] For the purposes of this disclosure, "gluten" refers to a protein extract of wheat flour prepared by removing most of the starch, fiber, pentosans, and water-soluble substances from wheat flour. Gluten is commercially available and can be obtained by any suitable method, such as, for example, as disclosed in U.S. Patent No. 3,790,553. In one aspect, gluten has a protein content of 70% to 99% by dry weight. In another aspect, gluten has a protein content of about 75% to about 80% by dry weight. However, those skilled in the art will recognize that gluten is a protein found in and / or derived from wheat, barley, rye, oats, and closely related species and / or hybrids of wheat, barley, rye, and oats. As used herein, "gluten" means gluten from such plant sources and mixtures of gluten from such plant sources. However, for clarity, the term “glutenin” as used in this article does not refer to protein derived from corn or rice, even though the terms “corn glutenin” and “rice glutenin” are used in certain contexts, such as in animal feed.

[0047] In one aspect, wheat gluten is mixed with a protein intermediate composition to effectively provide a plant-based deli meat substitute containing about 10% to about 20% by weight of wheat gluten. In another aspect, wheat gluten is mixed with a protein intermediate composition to effectively provide a plant-based deli meat substitute containing about 12% to about 18% by weight of wheat gluten. To avoid confusion, it should be noted that this identified amount of wheat gluten refers to the gluten content itself, without considering non-protein components that may be present in the wheat gluten source. For example, adding 100g of wheat protein concentrate containing 75% by weight of gluten will contribute 75g of wheat gluten to the plant-based deli meat substitute.

[0048] For the purposes of this disclosure, "edible acid" can be any acid suitable for use in food. In one aspect, the acid is selected from the group consisting of citric acid, lactic acid, acetic acid, or mixtures thereof. In another aspect, acetic acid is provided as vinegar.

[0049] In one aspect, edible acids are incorporated in an amount sufficient to provide dough with a pH of about 4.5 to about 7. In another aspect, edible acids are incorporated in an amount sufficient to provide dough with a pH of about 5.5 to about 6.5. In another aspect, edible acids are incorporated in an amount sufficient to provide dough with a pH of about 5.5 to about 6. In another aspect, edible acids are incorporated in an amount sufficient to provide dough with a pH of about 6 to about 6.5. In yet another aspect, acid is additionally incorporated during dough mixing in an amount sufficient to provide dough with a pH of about 4.5 to about 5.5.

[0050] On one hand, plant-based cooked meat imitations are sausage analogs, characterized by a pH in the range of about 4.5 to 5.5.

[0051] On the one hand, plant-based cooked meat substitutes contain about 0.5% to about 5% by weight of edible acids.

[0052] On one hand, plant-based cooked meat substitutes may contain one or more additives to meet desired product characteristics. On the other hand, additives are selected from flavoring agents, coloring agents, preservatives (i.e., ingredients that prevent or delay microbial growth and / or spoilage), stabilizers, vitamins and minerals, and mixtures thereof.

[0053] On one hand, plant-based processed meat products contain seasonings selected from the following: paprika, garlic, cayenne pepper, red chili pepper, black pepper, nutmeg, allspice, celery seed, coriander, myrtle, and mixtures thereof.

[0054] On one hand, plant-based processed meat products contain seasonings selected from the following: paprika, garlic, cayenne pepper, red chili pepper, black pepper, nutmeg, allspice, celery seed, coriander, myrtle, and mixtures thereof.

[0055] On the one hand, plant-based cooked meat imitations contain sugar and / or salt.

[0056] In one aspect, plant-based deli meat-like products use flavor formulations selected to simulate the flavor of meat-based dough products. In another aspect, plant-based deli meat-like products use flavor formulations selected to simulate the flavor of beef. In another aspect, plant-based deli meat-like products use flavor formulations selected to simulate the flavor of pork. In another aspect, plant-based deli meat-like products use flavor formulations selected to simulate the flavor of chicken. In yet another aspect, plant-based deli meat-like products use flavor formulations selected to simulate the flavor of turkey.

[0057] On the one hand, plant-based processed meat imitations use flavor ingredients selected to provide flavor characteristics that are not meat flavor.

[0058] On one hand, plant-based processed meat imitations contain coloring agents, which can be natural coloring agents. On the other hand, plant-based processed meat imitations contain fruit or vegetable juices as natural coloring agents, such as beet juice, carrot juice, or pomegranate juice.

[0059] On the one hand, one or more additional ingredients may be introduced into plant-based dough products before or at the same time as the introduction of oil and hydrocolloids, or before or at the same time as the introduction of gluten, or before or at the same time as the introduction of edible acids, or after the introduction of edible acids and before the distribution of plant-based dough into casings.

[0060] On one hand, an additional ingredient, acting as an oil-soluble flavoring / coloring agent, can be added to the oil before mixing with other ingredients. On the other hand, an additional ingredient, acting as a liquid water-soluble flavoring / coloring agent, can be added to the water before mixing with other ingredients.

[0061] On one hand, additional ingredients include calcium salts, such as calcium lactate, calcium citrate, or calcium chloride. It has been found that plant-based deli meat substitutes containing calcium salts, as described herein, exhibit enhanced structural features compared to similar products that do not contain such calcium salts, providing a perceptible sensory improvement in the appearance and bite characteristics of the final plant-based deli meat substitute.

[0062] In one aspect, calcium salt is present in an amount that effectively provides a plant-based cooked meat substitute product containing about 0.05% to about 1% by weight of calcium salt. In another aspect, calcium salt is present in an amount that effectively provides a plant-based cooked meat substitute product containing about 0.1% to about 0.5% by weight of calcium salt.

[0063] Any suitable mixing apparatus can be used to perform the above-described mixing steps to prepare plant-based cooked meat imitations. Examples of suitable apparatus include mixers or mixing devices using impellers, such as paddle mixers. In one aspect, the mixer is configured and operated in a manner that prevents it from applying excessive bulk pressure to the composition to be mixed. It has been found that applying excessive bulk pressure to the composition results in an overly dense product that does not conform to the desired texture. In another aspect, mixing is not carried out in an extruder applying pressure of 1.5 MPa or higher.

[0064] The protein / gluten blend intermediate composition was mixed with edible acid. It has been found that when the analog dough was mixed with gluten under neutral pH conditions, the dough became very stiff and unsuitable for sausage formation, and also did not absorb water well. Conversely, when the analog dough was mixed with gluten and edible acid, gluten filaments were produced to provide elastic filaments that did not excessively increase the dough's viscosity. It has been found that mixing the protein / gluten blend intermediate composition with edible acid under these conditions imparts an elastic structure to the plant-based dough, thereby providing an enhanced meat-like texture in the final plant-based deli meat substitute. Additionally, when the analog dough was mixed with gluten and edible acid, the resulting composition did absorb water very well, providing a dough that absorbs water during mixing and is easy to handle for mixing with additional ingredients and dispensing into casings for cooking.

[0065] On one hand, a protein / gluten blend intermediate composition is mixed with an edible acid under gluten filament forming shear conditions (i.e., under sufficient shear to provide dough that stretches when physically pulled apart), and wherein all water is absorbed into the dough when water is present at 50% of the dough formulation.

[0066] On one hand, a high-shear mixer is used for mixing under shear conditions that allow gluten filaments to form. On the other hand, the mixing equipment is a food chopper, bowl chopper, or food processor.

[0067] For the purposes of this specification, a food chopper is a food cutter having a surface for receiving food to be cut, and one or more vertically movable cutting blades configured to chop a plant-derived composition into small pieces.

[0068] In one aspect, the mixing device is a bowl chopper. For the purposes of this specification, a bowl chopper is a food cutter having a rotating bowl for receiving food to be cut, and one or more vertically oriented blades (also referred to in the art as “blades”) attached to a horizontally oriented rotating blade shaft. The rotating bowl rotates about a vertical axis, and the blades cut by the rotation of the horizontally oriented rotating blade shaft. The blades are aligned relative to one or more inner walls of the bowl so that they can chop and mix the food within the bowl. When the lateral position of the rotating blade shaft is substantially fixed, the bowl and its contents rotate relative to the blades, thereby causing the contents to move continuously against the blades as the bowl rotates. In one aspect, the blades may operate only in the forward direction, or in another aspect, in both the forward and reverse directions. Bowl choppers are commercially available and are described, for example, in U.S. Patent No. 5,996,917, the disclosure of which is incorporated herein by reference. The use of a bowl chopper in the method of the invention is particularly advantageous because it efficiently performs the cutting function while mixing materials.

[0069] In one aspect, the mixing device is a food processor. For the purposes of this specification, a food processor is a food mixer having a food container for receiving food to be mixed, the food container being fitted with a hub configured to be coupled to a drive shaft of the food processor. One or more blades are rotatably coupled to the hub. If desired, the blades may have edges suitable for cutting the food in the food container. In the case of a food processor, the blades are horizontally oriented, while the hub and drive shaft are generally vertically oriented. In one aspect, the blades may operate only in the forward direction, or in another aspect, in both the forward and reverse directions. Such food processors are commercially available. In one aspect, the food processor is a Robo coupe type food processor.

[0070] On one hand, a vacuum is applied to the plant-based dough or other intermediate at any appropriate stage of the preparation method to degas the dough or intermediate in an amount sufficient to remove or substantially reduce undesirable cavitation or air bubbles. Cavitation and air bubbles can adversely affect the visual appeal and texture of charred meat imitations. Any suitable vacuum system can be used to “degas” the dough or intermediate to remove cavitation.

[0071] On the one hand, after mixing but before being allocated to casings, the dough has a glossy and elastic consistency, indicating that it is ready to be allocated to casings.

[0072] On one hand, it is preferable to incorporate additional food particles, such as cheese, vegetable, or fruit pieces, into the dough after mixing but before allocating them to the casings. However, if desired, such food particles can be added earlier in the process. Examples of vegetable pieces that can be incorporated include bell peppers, dried tomatoes, pickles, and red bell pepper pieces.

[0073] The plant-based dough is then portioned into sausage casings to form dough segments.

[0074] On one hand, the casing is an artificial casing. On the other hand, the casing is an artificial casing made from natural materials. On one hand, the casing is an artificial casing made from natural materials selected from cellulose casings and collagen casings. On one hand, the casing is an artificial casing made from natural materials that allows gas, smoke, and water vapor to pass through. On one hand, the artificial casing made from natural materials is edible and therefore does not need to be removed from the packaged plant-based deli meat substitute when consumed by consumers.

[0075] On the one hand, sausage casings are artificial casings made of synthetic materials. On the other hand, sausage casings are artificial casings made of thermoplastic materials (“synthetic casings”). Synthetic casings have high mechanical strength, are relatively heat-resistant, and are impermeable to smoke, gases, and water vapor.

[0076] On one hand, the casings are made from materials selected from polyamide (PA), polyethylene (PE), polypropylene (PP), polyvinylidene chloride (PVDC), and polyester (PET). The above classification of casings is published in the FAO (Food and Agriculture Organization of the United Nations) Enterprise Documentation Database under the keyword "Casings" with the title "Meat processing technology for small and medium-scale producers".

[0077] On one hand, the casing is made of a single or multiple membranes, at least one of which contains a film-forming synthetic polymer.

[0078] In one aspect, the casing is made of a single or multiple layers of film, wherein at least one layer contains a film-forming synthetic polymer. Such casings for processed meat products are well known in the art. In one aspect, casings (such as sausage casings) are typically made of 1 to 5 layers of film. In one aspect, the film-forming polymer of at least one layer is a thermoplastic synthetic polymer. In one aspect, the thermoplastic synthetic polymer is polyamide, polyethylene, polypropylene, polyvinylidene chloride, or polyester. In one aspect, the film layers may contain adjuvants, such as plasticizers, colorants, or other known additives, but they should not significantly affect the film-forming properties of the synthetic polymer and other properties provided to the casing by the synthetic polymer, such as its known impermeability to smoke, water vapor, or other gases. In one aspect, according to DIN 53122, at 38°C and 100% relative humidity, water vapor-impermeable casings have a water vapor permeability not exceeding 10 g / m²·d or not exceeding 9 g / m²·d. Various water vapor impermeable casings are disclosed in the art, such as those disclosed in European Patent Application Nos. EP 0 603 676 and EP 1 817 962 and International Patent Application Nos. WO 2005 / 11323 and WO 2017 / 192445; the disclosures of which are incorporated herein by reference to discussions relating to the preparation, properties and uses of the casings provided therein.

[0079] On the one hand, the casing allows water vapor to pass through.

[0080] On the one hand, when the casing is filled, it typically has a roughly cylindrical shape, but other cross-sections can also be suitable.

[0081] In one aspect, the packaged, uncooked dough segments thus prepared are then cooked to an internal temperature of at least about 180℉, for example, at least about 190℉ or at least about 195℉, to form packaged, cooked dough segments. In another aspect, the packaged, uncooked dough segments thus prepared are then cooked to an internal temperature of about 180℉ to about 220℉, for example, about 185℉ to about 210℉ or about 190℉ to about 210℉, to form packaged, cooked dough segments.

[0082] On one hand, the casing is permeable to water vapor. It has been found that cooking packaged uncooked dough segments with water vapor-permeable casings in a steam oven is particularly effective in achieving the desired textural properties of the final cooked product. Without being bound by theory, it is believed that cooking the packaged uncooked dough segments in the presence of steam facilitates the desired degree of gelation of proteins and additional components in the dough segments, thereby providing a final plant-based deli meat-like product exhibiting excellent texture and other sensory properties. On the other hand, the packaged uncooked dough segments can then be cooked in a steam oven at a humidity greater than 80% and an oven temperature of approximately 180℉ to approximately 220℉.

[0083] The packaged, cooked dough segments prepared therefrom can be cooled to an internal temperature of about 30℉ to about 45℉ for appropriate storage purposes.

[0084] Furthermore, it has been found that cooling the dough segments facilitates the removal of casings from the cooked dough segments. Unbound by theory, it is believed that cooling enhances the textural differences and / or reduces the adhesion between the cooked dough segments and the casings, allowing the casings to be removed without damaging the surface of the cooked dough segments. In one instance, the packaged cooked dough segments are cooled to an internal temperature of approximately 30℉ to approximately 40℉. In another instance, the packaged cooked dough segments are cooled to an internal temperature of approximately 30℉ to approximately 36℉.

[0085] On the one hand, after cooling the packaged, cooked dough segments, the casings can be removed by appropriate methods to provide unpackaged, plant-based dough segment products.

[0086] In one aspect, plant-based deli meat substitutes are offered in outer packaging trays. This type of packaging is characterized by a breathable outer packaging, in which the plant-based deli meat substitute is placed on an absorbent pad within a foam or plastic tray. In another aspect, the product is offered in off-the-shelf trays, where the plant-based deli meat substitute is packaged and sealed in plastic-capped packaging at the factory. In yet another aspect, the product is offered in chub form, where the plant-based deli meat substitute is packaged for slicing at the point of purchase (e.g., at a deli counter) or at the point of use (e.g., in a restaurant or by a home user). In yet another aspect, the product is offered in casings, where it is cooked. In yet another aspect, plant-based deli meat substitutes are packaged in any of these forms in sizes of 0.25 lb, 0.5 lb, 1 lb, 2 lb, 3 lb, 5 lb, and 10 lb.

[0087] On the one hand, plant-based cooked meat imitations do not contain any kind of animal-derived material.

[0088] In one aspect, the method for preparing plant-based cooked meat imitations does not include an extrusion step with a pressure exceeding 1.5 MPa.

[0089] On the one hand, plant-based processed meat imitations contain no more than 1% by weight of methylcellulose. On the other hand, plant-based processed meat imitations do not contain methylcellulose.

[0090] Example

[0091] Example 1 - Comparison of Titanium Dioxide-Free Plant-Based Cooked Meat Imitation Products

[0092] The ingredients shown in Tables 1 and 2 were obtained, and plant-based cooked meat products were prepared using process method 1 described below.

[0093] Table 1 - Blend A

[0094] Table 2. Final Mixture

[0095] Process Method 1 .

[0096] a) Mixing blends (Fatosa mixer) : 1. Add water to the mixer.

[0097] 2. Add the soy protein isolate to the mixer.

[0098] 3. Mix thoroughly to hydrate all SPI properties (3 minutes).

[0099] 4. Add oil and mix thoroughly (2.5 minutes).

[0100] 5. Add all flavorings and mix thoroughly (2.5 minutes).

[0101] 6. Add all hydrocolloids (Citrifi + carrageenan) and mix thoroughly (2.5 minutes).

[0102] 7. Add salt, sugar, calcium lactate and tapioca starch and mix well (3 minutes).

[0103] 8. Add the gluten powder and mix for 2 minutes.

[0104] 9. Transfer the paste to the robot Coupe / bowl chopper.

[0105] b) Emulsification (Robot Coupe / Bowl Chopper)

[0106] 1. Add vinegar to the blend.

[0107] 2. Run the bowl chopper alternately at speeds 3 (800 RPM) and 4 (1600 RPM) until it forms a flexible, stringy texture.

[0108] 3. Partially evacuate the upper part of the vacuum chamber / bowl chopper.

[0109] c) Filling (658 Handtmann filler) : 1. Set filler - use only alternative veins.

[0110] 2. Add the vacuum-sealed blend to the filler (using the smallest 1” filler tube).

[0111] 3. Fill into Viscofan plastic / high-barrier smoke-proof casing M20-07422-500062197 BTC 150.0000 00 53, 500 000000 089 00 (P20-0224).

[0112] 3. Shape - Circle.

[0113] 4. Cooking and cooling.

[0114] cooking : 1. Cook each section in the pilot oven according to the following cooking cycle.

[0115] Step 1: 160°F, at 100% humidity, for 30 minutes.

[0116] Step 2: 180°F, at 100% humidity, for 60 minutes.

[0117] Step 3: At 200°F and 100% humidity, until the internal temperature reaches 180°F.

[0118] Step 4: 200F, at 100% humidity, for 90 minutes (>196F).

[0119] Step 5: Take a 30-minute cold shower with a fan at 100% power.

[0120] 2. Cool according to USDA cooling requirements.

[0121] Slicing and Packaging : 1. Slice thickness 1.6mm; straight stack - 0.5 lb, 15 slices / stack).

[0122] 2. Vacuum packing in Multivac 4-up (standard film - top film; bottom film)

[0123] Packing and storage : 1. Pack and store in a freezer.

[0124] Example 2 - Plant-based cooked meat imitation products containing titanium dioxide

[0125] The ingredients shown in Tables 3 and 4 were obtained, and plant-based cooked meat imitation products were prepared using process method 2.

[0126] Table 3 - Blend A

[0127] Table 4. Final Mixture

[0128] Process Method 2 .

[0129] Processing steps : a) Preparation of blend A (Ultrasource Fatosa) : 1. Mix TiO2 in water.

[0130] 2. Add SPI to the mixer.

[0131] 3. Add the water-TiO2 mixture to the mixer and mix thoroughly to properly hydrate all SPI (3 minutes).

[0132] 4. Add oil and mix thoroughly (2.5 minutes).

[0133] 5. Add all flavorings and mix thoroughly (2.5 minutes).

[0134] 6. Add all hydrocolloids (Citrifi + carrageenan) and mix thoroughly (2.5 minutes).

[0135] 7. Add salt, sugar, calcium lactate and tapioca starch and mix well (3 minutes).

[0136] 8. Add the gluten powder and mix for 2 minutes.

[0137] 9. Transfer the paste to a bowl chopper.

[0138] b) Bowl chopper : 1. Add vinegar to the blend.

[0139] 2. Run the bowl chopper alternately at speeds 3 (800 RPM) and 4 (1600 RPM) until it forms a flexible, stringy texture.

[0140] 3. Partially evacuate the upper part of the vacuum chamber / bowl chopper.

[0141] c) Filling (658 Handtmann filler) : 1. Add the vacuum-sealed blend to the filler (using the smallest 1” filler tube).

[0142] 2. Fill into Viscofan plastic fumigation casing M20-07422-500062197 BTC 150.0000 00 53,500 000000089 00 (P20-0224).

[0143] 3. Shape - Circle.

[0144] 4. Cook and process on the same day.

[0145] cooking : 1. Cook each section in the pilot oven according to the following cooking cycle.

[0146] Step 1: 160°F, at 100% humidity, for 30 minutes.

[0147] Step 2: 180°F, at 100% humidity, for 60 minutes.

[0148] Step 3: At 200°F and 100% humidity, until the internal temperature reaches 180°F.

[0149] Step 4: 200F, at 100% humidity, for 90 minutes (>196F).

[0150] Step 5: 60 minutes, take a cold shower with a fan at 100% power.

[0151] 2. Cool according to USDA cooling requirements.

[0152] Slicing and Packaging : 1. Slice on a Webber slicer. (Slice thickness 1.7mm; straight stack - 0.5 lb, 15 slices / stack).

[0153] 2. Vacuum pack in Multivac 4-up (standard film - top film - P20-0230; bottom film - P20-0245).

[0154] Example 3 Product Comparison

[0155] Figure 1 It shows a photo of the product in Comparative Example 1, and Figure 2 The photograph shows the product of Example 2, which is a plant-based cooked meat imitation product containing titanium dioxide. As can be seen in the photograph, the product of Comparative Example 1 has little or no observable texture and has an overall compact appearance, with a surface that appears uniform and without voids or obvious fibrous structures.

[0156] In contrast, the product of Example 2, which contains titanium dioxide, is lighter in color and has a surface with visually observable voids, resulting in visible physical discontinuities in the product.

[0157] Figure 3 This is a photograph of a plant-based roast beef-style deli meat product prepared generally as described in Example 2 using beef flavoring agents and coloring components. In this process, gluten and acid components are added at the end, as mentioned above, which provide excellent textural properties in the final meat-like product. As can be seen in the image, when the roast beef-style deli meat product has been manually torn, the jagged edges of the torn meat reveal microfiber lines extending from the meat, giving it the overall appearance of a fibrous sliced ​​deli meat product.

[0158] Product Reviews

[0159] The flavor, texture, bite, and fiber visibility of the products prepared from Comparative Example 1 (which does not contain titanium dioxide) and Example 2 (which contains titanium dioxide) were evaluated. Comparative Example 1 was found to exhibit good flavor, a good texture comparable to that of highly processed animal protein, and detectable fiber strands, which contributed to the appearance of the meat sample.

[0160] The product produced using titanium dioxide in Example 2 was found to exhibit good flavor and good texture, and also had a lighter color, more easily detectable fibrous strands, and enhanced discontinuity in the product, which contributed to its excellent meat-like appearance.

[0161] As used herein, the terms “about” or “approximately” mean within an acceptable range for a particular parameter, which is determined by one of ordinary skill in the art and depends in part on how the value is measured or determined, such as limitations of the sample preparation and measurement system. Examples of such limitations include sample preparation in wet / dry environments, different instruments, variations in sample height, and varying requirements for signal-to-noise ratio.

[0162] For all purposes, all patents, patent applications (including provisional applications), and publications cited herein are incorporated by reference as if individually incorporated. Unless otherwise specified, all parts and percentages are by weight, and all molecular weights are weight-average molecular weights. The above detailed description is given only for clarity of understanding. It should be understood that no unnecessary limitations are intended. The invention is not limited to the exact details shown and described, as variations that will be apparent to those skilled in the art will be included within the scope of the invention as defined by the claims.

Claims

1. A method for preparing plant-based cooked meat substitute products, the method comprising: a) Mix water with titanium dioxide to form an aqueous titanium dioxide mixture. b) Mix the non-gluten plant protein with the aqueous titanium dioxide mixture to form a hydrated non-gluten plant protein. c) The hydrated non-gluten plant protein is mixed with plant-based oils and hydrocolloids to form a protein intermediate composition. d) The protein intermediate composition is mixed with gluten powder to form a protein / gluten mixture intermediate composition. e) The protein / gluten mixture intermediate composition is mixed with an edible acid to form a plant-based dough. f) The plant-based dough is portioned into casings to form dough segments. g) Cook the dough segments to an internal temperature of at least about 180℉ to form a plant-based cooked meat imitation product; The plant-based cooked meat substitute product mentioned above includes: Titanium dioxide, approximately 0.5% by weight to approximately 6% by weight. Approximately 3% to approximately 20% by weight of non-gluten plant protein, Water, approximately 40% to approximately 87% by weight From approximately 0.5% by weight to approximately 6% by weight of oil, About 2% to about 10% by weight of hydrocolloids, From about 5% to about 20% by weight of gluten, and Sufficient amounts of edible acids to provide a pH of about 4.5 to about 7 for plant-based cooked meat imitations.

2. The method of claim 1, wherein the plant-based cooked meat imitation product is cooled to an internal temperature of about 30℉ to about 45℉ after cooking.

3. The method according to claim 1, wherein the titanium dioxide has a particle size of less than about 150 nm.

4. The method of claim 1, wherein the titanium dioxide is added to the water in an amount that effectively provides a plant-based cooked meat imitation product comprising about 0.05% to about 1% by weight of titanium dioxide.

5. The method of claim 1, wherein the non-gluten plant protein is obtained from a plant protein source selected from the group consisting of soybeans, peas, or mixtures thereof.

6. The method of claim 1, wherein the plant-based oil is selected from the group consisting of: avocado, low-erucic acid rapeseed, coconut, cocoa, corn, cottonseed, flax, olive, palm, palm kernel, peanut, rapeseed, safflower, soybean and sunflower oil, and mixtures thereof.

7. The method according to claim 1, wherein the hydrocolloid comprises at least one hydrocolloid gum component, at least one hydrocolloid starch component, and at least one hydrocolloid water-soluble fiber component.

8. The method of claim 1, wherein the hydrocolloid comprises starch selected from the group consisting of: tapioca starch, cassava starch, and mixtures thereof.

9. The method of claim 1, wherein the hydrocolloid comprises: Carrageenan, approximately 0.1% to approximately 5% by weight. Konjac beta-glucan, approximately 0.1% to approximately 5% by weight, Citrus fiber, approximately 0.1% to approximately 5% by weight, and Tapioca starch of approximately 0.1% to approximately 5% by weight, all amounts based on the total amount of plant-based cooked meat substitute products.

10. The method of claim 1, wherein the plant-based cooked meat imitation product has a pH of about 5.5 to about 6.

5.

11. The method of claim 1, wherein the plant-based cooked meat imitation product comprises about 0.5% by weight to about 5% by weight of edible acid.

12. The method of claim 1, wherein the edible acid is selected from the group consisting of citric acid, lactic acid, acetic acid, or mixtures thereof.

13. The method of claim 1, wherein the plant-based cooked meat product comprises one or more additional ingredients, said one or more additional ingredients being introduced into the plant-based dough before or simultaneously with the introduction of the oil and hydrocolloid, or before or simultaneously with the introduction of the gluten, or before or simultaneously with the introduction of the edible acid, or after the introduction of the edible acid and before dispensing the plant-based dough into casings.

14. The method of claim 13, wherein the one or more additional ingredients comprise a flavoring agent selected to mimic the flavor of a meat product selected from the group consisting of ham, beef, turkey, and chicken.

15. The method of claim 13, wherein the one or more additional ingredients comprise a calcium salt that effectively provides an amount of calcium salt comprising about 0.05% by weight to about 1% by weight of a plant-based cooked meat imitation product.

16. A plant-based cooked meat imitation product, said plant-based cooked meat imitation product being made by the method according to claim 1.

Images