Vegan meat substitute product and method for its production

Description

[0001] The present invention relates to a meat substitute product, in particular a vegan sausage or meatloaf product, and to a method for its production.

[0002] Many people enjoy consuming meat and sausage products, which consequently appear on the menu for many far more often than the two to three times a week recommended by doctors. It has long been known that excessive consumption of meat and sausage products is not beneficial to health. Nevertheless, many people find it very difficult to abstain from meat products, which is why they consume them daily or almost daily, despite knowing better.

[0003] Other people abstain from consuming meat products entirely, whether for health, ethical, or other reasons. Among both those who consume meat products and those who abstain, there is a large proportion who at least occasionally use meat substitutes to reduce their consumption of actual meat or to abstain from it permanently without having to forgo the taste of meat.

[0004] Numerous meat substitutes are already known from current technology, particularly those based on soy or pea protein. For example, vegan sausages, vegan currywurst, vegan meatballs, vegan patties, vegan schnitzel, vegan chicken substitute products, and vegan meat salad can be found in any well-stocked supermarket.

[0005] These previously known meat substitutes, however, have the particular disadvantage that their consistency differs from that of the meat-based products they are intended to imitate. In particular, the consistency is often softer, which many consumers find unusual. Combined with a taste that also differs from that of meat-based products, many consumers consider the quality of these previously known meat substitutes unsatisfactory and the taste experience disappointing.

[0006] The production of vegan sausage products is described in general terms in the "Whitepaper Meat Substitute Products Part 3 - Vegan Sausage", available on the internet at "https: / / www.handtmann.de / fileadmin / user_upload / GeschaeftsBereiche / Fuell-_und_Portio-niersysteme / 3._Aktuelles / Whitepaper_Modul / 2021_Handtmann_Whitepaper_Vegane_Wurst produkte_17-11-2021.pdf" by Albert Handtmann Maschinenfabrik GmbH & Co. KG.

[0007] German patent DE 10 2016 110 653 A1 describes the production of a food preparation containing animal parts and fungal mycelia, as well as the production of a vegan sausage. For this, a first emulsion containing, among other things, methylcellulose, rapeseed oil, and ice water is combined with a second emulsion containing, among other things, ice water, rapeseed oil, and pea starch. After the addition of, among other things, pea protein isolate, the mixture is emulsified in a Thermomix. The patent does not mention the importance of temperature control during the production of the aforementioned emulsions.

[0008] EP 1 493 337 A2 describes meat substitute products manufactured by first mixing methylcellulose and ice water, then adding vegetable protein, and finally vegetable oil and starch as thickeners and flavorings. Regarding the ice water content, it is disclosed that various amounts can be chosen, as long as the temperature during the manufacturing process is kept below the point at which the mixture hardens, i.e., the methylcellulose gels. Apart from the requirement that the temperature during the manufacturing process should be chosen so that the methylcellulose does not gel, no specific temperature ranges are disclosed.

[0009] The WO 2021 / 110760 A1 describes a plant-based composition without protein for the production of vegan sausage products.

[0010] WO 2022 / 086422 A1 describes a process for producing a meat substitute, in particular for the production of meatless burger patties. In this process, a plant protein-containing composition is mixed with a structured oil-in-water emulsion.

[0011] Despite the wide variety of vegan meat substitutes already available on the market, there is a need for a meat substitute that comes as close as possible to a meat-based product in terms of both consistency and taste, and that creates a pleasant mouthfeel when eaten. Object of the invention

[0012] The object of the present invention is to provide a method for producing an alternative meat substitute product which avoids the disadvantages known from the prior art and is characterized in particular by an improved consistency similar to a meat-containing product, as well as by an improved taste and mouthfeel. General description of the invention

[0013] The invention solves this problem with the features of the claims by providing a method for producing a meat substitute product as defined in claim 1.

[0014] According to the invention, the temperature of the first composition during homogenization is 0.0°C - 0.5°C, and the temperature of the second composition during homogenization is -2.0°C - 0.0°C.

[0015] For the purposes of the present invention, a semi-solid composition is understood to be a composition with a gelatinous consistency or a composition whose state of matter lies between solid and liquid.

[0016] Producing a non-vegan, i.e., meat-based, Bockwurst, Currywurst, or Brühwurst is quite simple compared to a plant-based Bockwurst, Currywurst, or Brühwurst, because the production of meat-based sausages can be carried out within a significantly wider temperature range. For example, it has no effect on the taste of the final product if the meat mixture for the sausages is prepared and homogenized at +4.0 °C or at +14 °C.

[0017] In the current state of the art, the manufacturing process for vegan meat substitutes is often carried out completely analogously to the respective manufacturing processes for meat-based products, i.e., it is also carried out in the same (comparatively wide) temperature range.

[0018] Within the scope of the present invention, it has been found that simply transferring the process parameters from a manufacturing process for meat-based products to a manufacturing process for the respective meat substitutes results in products with unsatisfactory properties, in particular a consistency that is too soft and creates an unpleasant mouthfeel. Furthermore, a series of experiments has shown that the temperature during the various steps of the manufacturing process for the meat substitutes has a critical influence on their quality. The temperature of the ingredients or compositions in the various steps of the manufacturing process must remain within very narrow, defined ranges.It was found that the temperature of the semi-solid or solid first composition, containing methylcellulose, vegetable oil, and ice water, must be maintained at 0.0°C to 0.5°C during homogenization, and the temperature of the semi-solid or solid second composition, containing pea protein isolate, vegetable oil, and ice water, must be maintained at -2.0°C to 0.0°C during homogenization. Only if these temperature specifications are observed and strictly adhered to during production can a meat substitute product according to the invention be produced that has a meat-like consistency and a pleasant mouthfeel. Even a single instance of exceeding or falling below the aforementioned temperature ranges, however, leads to products with significantly inferior properties. For the purposes of the present invention, "ice water" is understood to mean a mixture of ice and water.These components do not necessarily need to be mixed and added together before being added; they can also be added separately. The first composition can therefore be produced, for example, by mixing and homogenizing methylcellulose, vegetable oil, ice, and water, with the ice and water optionally being added separately. Preferably, the proportion of ice in the ice water is at least 50% by weight, more preferably 50–60% by weight, and particularly preferably 50–55% by weight. The movement of the respective compositions in the cutter increases their temperature, and this increase is more rapid with increasing rotational speed. The temperature of the first and second compositions can be controlled by adjusting the amount of ice water or ice and water added.

[0019] In a preferred embodiment, the homogenization of the ingredients to obtain the first composition takes place in a cutter with a preferred capacity of 80-120 L, particularly 90-110 L, and even more preferably 95-105 L, at 2,500-3,000 rpm, while the homogenization of the ingredients to obtain the second composition takes place in a cutter with preferably the same capacity, particularly at 2,300-2,700 rpm. With the aforementioned cutter capacity, the cutting length of the blades is preferably 25-30 cm.

[0020] The cutter used for this embodiment is in particular a Seydelmann cutter of type K 96 H.

[0021] Where the present disclosure mentions rotational speeds of the cutter, these preferably also refer to a cutter with a preferred capacity of 80-120 L, in particular of 90-110 L, and even more preferably of 95-105 L, and with a cutting length of the knives of preferably 25-30 cm.

[0022] In principle, homogenizing the ingredients to maintain both compositions can also be carried out in any other cutter. If working in cutters with a larger capacity and correspondingly longer blades, homogenization can be performed at lower speeds, as the greater length of the blades allows for a higher cutting speed in m / s. Conversely, if working in cutters with a smaller capacity and correspondingly shorter blades, homogenization should be carried out at higher speeds.

[0023] The first composition according to the invention contains 8-12 wt.% vegetable oil, 3-7 wt.% methylcellulose and 80-87 wt.% ice water.

[0024] The proportion of vegetable oil in the first composition is particularly preferred to be 9-11% by weight.

[0025] Particularly preferably, the proportion of methylcellulose in the first composition is 5-7 wt.%.

[0026] The proportion of ice water in the first composition is particularly preferred to be 84-86 wt.%.

[0027] The vegetable oil used to produce the first composition is preferably selected from the group consisting of sunflower oil, rapeseed oil, soybean oil, grapeseed oil, olive oil, corn oil, linseed oil and safflower oil.

[0028] The vegetable oil is preferably placed in the cutter, and the methylcellulose is added to it. The cutter is then preferably operated at a speed of 2,500–3,000 rpm. Subsequently, the ice water is added, whereby the temperature of the mass to be homogenized, which will form the first composition, is controlled by the addition of the ice water (or by the addition of ice and water) so that it is between 0.0°C and 0.5°C. Before removing the first composition from the cutter, care must be taken to ensure that the ice has completely dissolved.

[0029] The second composition contains, according to the invention, 5-15 wt.% pea protein isolate, 30-40 wt.% vegetable oil and 50-60 wt.% ice water.

[0030] The proportion of pea protein isolate in the second composition is particularly preferred to be 8-12 wt.%.

[0031] The proportion of vegetable oil in the second composition is particularly preferred to be 33-37 wt.%.

[0032] The proportion of ice water in the second composition is particularly preferred to be 53-57 wt.%.

[0033] The vegetable oil used to manufacture the second composition is preferably selected from the group consisting of sunflower oil, rapeseed oil, soybean oil, grapeseed oil, olive oil, corn oil, linseed oil, and safflower oil. Optionally, the vegetable oil used to manufacture the second composition is the same vegetable oil as that used to manufacture the first composition and is, in particular, sunflower oil or rapeseed oil.

[0034] To produce the second composition, ice water or ice is preferably placed in the cutter, and pea protein isolate is added. Once the pea protein isolate has completely dissolved, water (if only ice was initially used) is optionally added, followed by the vegetable oil, and the composition is preferably homogenized at a speed of 2,100–3,000 rpm. During the production of the second composition, the temperature of the mass to be homogenized, which will form the second composition, never exceeds 0 °C. Preferably, the temperature remains below 0 °C continuously during homogenization.

[0035] Both the first composition and the second composition are preferably stored cool after their manufacture, in particular at a temperature between 0°C and 1°C.

[0036] The first composition containing methylcellulose and the second composition containing pea protein isolate form the basis for the production of various meat substitute products such as currywurst, scalded sausage, bockwurst, and liverwurst. Depending on the type of meat substitute product desired, the other ingredients, particularly the flavorings, can vary. However, the processing method for the first and second compositions to produce the respective meat substitute products according to the invention is identical and is described below.

[0037] In the inventive process for producing a meat substitute, the first composition and the second composition are introduced into a water-based solution which, in addition to water, also contains thickeners and flavorings. Preferably, the thickener is selected from the group consisting of locust bean gum, xanthan gum, konjac gum, carrageenan, guar gum, agar-agar, starch, rice flour, and mixtures thereof.

[0038] Preferably, the water-based solution contains salt as well as other spices or flavorings. The water-based solution is prepared by first dissolving a thickening agent in water, preferably under rotation in a cutter, whereby the viscosity of the solution increases significantly. The spices or flavorings can be added at any point and are, for example, added to the water together with the thickening agent.

[0039] According to the invention, the water-based solution into which the first and second compositions are introduced is produced by supplying water and adding the thickening agent and optional further ingredients at a preferred temperature of -9.0 to -7.0°C and homogenizing, whereby a water-based solution is formed.

[0040] First, the second composition, containing pea protein isolate, and then the first composition, containing methylcellulose, are added to the water-based solution. After each composition is added, the mixture is homogenized in the cutter at 2,100–3,000 rpm. These high speeds are another difference from the prior art production process, which uses speeds of approximately 1,000–1,500 rpm. However, it was found that significantly fewer air inclusions occur in the product at the considerably higher speeds of 2,100–3,000 rpm. Homogenization after the addition of the first composition yields the meat substitute.

[0041] The proportion of the first composition incorporated into the water-based solution is 27.0–33.0 wt.%, based on the total weight of the meat substitute, and the proportion of the second composition incorporated into the water-based solution is 37.0–43.0 wt.%, based on the total weight of the meat substitute. The proportion of the water-based solution in the meat substitute is preferably 28.0–32.0 wt.%, based on the total weight of the meat substitute.

[0042] In a preferred embodiment, the meat substitute obtained in step c) of the process according to the invention is removed from the cutter at a temperature below 0°C and placed into a casing. The casing is an artificial casing, optionally a cellulose-containing or a cellulose-free artificial casing, particularly one based on polyamide. It has been found that a cellulose-free artificial casing is advantageous in that it can be more easily removed from the meat substitute product, since the cellulose contained in a cellulose-containing artificial casing combines with the methylcellulose contained in the meat substitute. Therefore, when the meat substitute products are removed from the cellulose-containing artificial casing, residues of the meat substitute often remain adhered to it.

[0043] Regardless of whether the meat substitute is placed in a cellulose-containing or a cellulose-free artificial casing in the process according to the invention, the meat substitute inside the casing is subsequently heated using hot steam. The hot steam preferably has a temperature in the range of 85-90 °C.

[0044] Preferably, the meat substitute is heated with hot steam in several steps, which preferably also include a smoking step. In the first step, the meat substitute is preferably heated to a chamber temperature (temperature in the heating chamber of a steam-operated heating device) of approximately 85-90°C and held at this temperature for approximately 15-30 minutes. It is then smoked at this temperature for approximately 30-45 minutes, before being cooked again at this temperature in hot steam for approximately 50-60 minutes.

[0045] The meat substitute product obtained in this way is then preferably removed from the intestine and optionally (especially in the case of liverwurst imitation) cut or portioned.

[0046] Furthermore, a meat substitute product obtainable by the aforementioned inventive method, in particular a vegan currywurst, scalded sausage, bockwurst or a vegan liver loaf, is disclosed. Detailed description of the invention

[0047] The invention will now be described in more detail using an exemplary embodiment. Example 1: Comparison of a meat substitute product manufactured according to the invention with meat substitute products manufactured in other ways

[0048] To compare the quality of meat substitutes produced according to the invention with the quality of other meat substitutes, a vegan currywurst is produced according to the inventive method. First, an initial composition is prepared containing 3-7 wt% methylcellulose, 8-12 wt% sunflower oil, and 80-87 wt% ice water. The ingredients are homogenized in a cutter at a speed of 2,500-3,000 rpm to form a solid, white composition. The temperature is kept constant below 0.5 °C during this process.

[0049] Furthermore, a second composition is produced, containing 5-15 wt% pea protein isolate, 30-40 wt% sunflower oil, and 50-60 wt% ice water. The ingredients are homogenized in a cutter at a speed of 2,300-2,700 rpm to form a solid composition. The temperature is kept constant below 0.0 °C during this process.

[0050] To prepare the water-based solution into which the first and second compositions are introduced, water is first added. Konjac gum, carrageenan, fried onion flavoring, curry, salt, and other spices are then added to this solution, and it is homogenized at a temperature between -6°C and -7°C.

[0051] The second composition, containing pea protein isolate, and then the first composition, containing methylcellulose, are first introduced into the water-based solution obtained in this way. After the introduction of each of the two compositions, the mixture is homogenized in the cutter at 2,100-3,000 rpm, and the meat substitute is obtained by homogenizing it after the first composition has been introduced into the water-based solution.

[0052] The proportion of the first composition introduced into the water-based solution was approximately 30 wt.%, the proportion of the second composition introduced into the water-based solution was approximately 40.0 wt.%, and the proportion of the water-based solution in the meat substitute mass was approximately 30 wt.%, each based on the total weight of the meat substitute mass.

[0053] The meat substitute is removed from the cutter at a temperature of approximately -0.5°C and placed into a casing. Inside the casing, it is then heated to a temperature of approximately 86-87°C using hot steam in a steam-powered heating device. Once a chamber temperature of 86-87°C is reached, it is maintained at this temperature for approximately 20 minutes. It is then smoked for approximately 35 minutes and subsequently cooked for another hour, each time at the aforementioned temperature of 86-87°C.

[0054] The resulting meat substitute product, in the form of a vegan currywurst, is allowed to cool and removed from the intestine.

[0055] To test the influence of temperature during the production of the first and second compositions, vegan currywursts were also produced in a second (non-inventive) and a third (non-inventive) production process. These were produced in exactly the same way in each step as the vegan currywurst produced according to the inventive process described in the first part of the example, with the exception that in the second (non-inventive) production process for producing the first composition, the temperature was allowed to rise to approximately 3 °C, and in the third (non-inventive) production process for producing the second composition, the temperature was allowed to rise to approximately 2 °C. The currywurst in which the temperature was allowed to rise to approximately 3 °C during the production of the first composition is referred to as comparison currywurst A.The currywurst, in which the temperature was allowed to rise to approximately 2 °C during the production of the second composition, is referred to as comparison currywurst B.

[0056] In addition to the aforementioned meat substitute products, another vegan currywurst based on pea protein (comparison currywurst C), known from the state of the art and available in supermarkets, was acquired.

[0057] The aforementioned four vegan currywursts were subsequently tested and evaluated by test subjects. The results of the sensory examination, which was conducted as an objective blind test with 30 test subjects, are summarized in Table 1 below: Table 1: Results of the sensory test criterion Inventive currywurst Comparison currywurst A Comparison currywurst B Comparison currywurst C Overall like 9,9 4,9 4,5 2,2 The taste 10,0 8,2 8,1 3,1 Consistency / Firmness 9,9 3,0 2,8 1,1 Appearance / Optics 9,8 6,3 6,3 4,0 MW = Mean of the rating on a scale of 1 to 10, 1 = worst rating, 10 = best rating

[0058] As a result of the sensory test, it can be stated that the vegan currywurst produced by a method according to the invention was rated significantly better in all categories by the 30 test subjects than the three non-inventive comparison currywursts A, B and C.

[0059] In particular, the consistency / firmness criterion was rated very poorly by the test subjects for all the comparison currywursts A, B, and C, while the consistency / firmness of the currywurst produced according to the invention was the only meat substitute product to receive good ratings. When asked, the test subjects reported that the consistency / firmness of the currywurst produced according to the invention was predominantly perceived as extremely similar to that of a meat-based currywurst, while several test subjects stated that the consistency of the commercially available comparison currywurst C was crumbly, which the test subjects found strange.The comparison currywursts A and B, which differed from the inventive method only in the temperature used to prepare the first and second components, were also rated significantly worse by the test subjects than the currywurst produced according to the inventive method. Regarding these comparison currywursts A and B, the test subjects reported that while the taste was quite good, the consistency was far too spongy and most closely resembled that of egg custard, leaving an unpleasant mouthfeel. Visually, both comparison currywursts A and B were perceived as being of similar quality to the inventive currywurst from the outside; however, the test subjects noted that air bubbles were visible when the sausages were cut, giving the cut surfaces a spongy appearance. This led to a lower overall rating for appearance.

[0060] The results of the sensory test demonstrate that adherence to the narrow temperature range according to the invention during the production of the first and second compositions is essential for the quality of the resulting meat substitute product.

[0061] The features of the invention disclosed in the foregoing description, in the example and in the claims can be essential for the realization of the invention in its various embodiments, both individually and in any combination.

Claims

1. Method for production of a meat substitute product, comprising the following steps: a) Preparing a semi-solid or solid first composition by mixing and homogenizing 3-7% by weight of methylcellulose, 8-12% by weight of vegetable oil and 80-87% by weight of ice water, as well as optional further ingredients; b) Preparing a semi-solid or solid second composition by mixing and homogenizing 5-15% by weight of pea protein isolate, 30-40% by weight of vegetable oil and 50-60% by weight of ice water, as well as optional further ingredients; c) Introducing the first composition and the second composition into a water-based solution which, in addition to water, also contains a thickening agent and flavorings, and homogenizing, thereby obtaining a meat substitute mass, wherein the water-based solution into which the first and second compositions are introduced, is prepared by supplying water and adding the thickening agent and optional further ingredients at a temperature of -9.0 to -7.0°C and by homogenizing, thereby forming the water-based solution into which the first and second compositions are then introduced, wherein at first the second composition and after that the first composition is introduced into the water-based solution, wherein after each of the two compositions is introduced, it is homogenized in the cutter at 2,100-3,000 rpm, wherein through the homogenizing after addition of the first composition the meat substitute mass is obtained; d) Introducing the meat substitute mass into a casing; e) Heating the meat substitute mass contained in the casing by means of hot steam; characterized in that the temperature of the first composition during homogenization is 0.0° - 0.5°C and the temperature of the second composition during homogenization is -2.0°C - 0.0°C, and the proportion of the first composition is 27.0-33.0% by weight based on the total weight of the meat substitute mass, and the proportion of the second composition is 37.0-43.0% by weight based on the total weight of the meat substitute mass.

2. Process according to claim 1, characterized in that the homogenization of the ingredients for obtaining the first composition takes place in a cutter at 2,500-3,000 rpm and the homogenization of the ingredients for obtaining the second composition is carried out in a cutter at 2,000-3,000 rpm, wherein the cutter in both cases preferably has a volumetric capacity of 80-120 L.

3. Process according to one of the preceding claims, characterized in that the thickening agent is selected from locust bean gum, xanthan gum, konjac gum, carrageenan, guar gum, agar-agar, starch, rice flour, and mixtures thereof.

4. Process according to one of the preceding claims, characterized in that the meat substitute mass is removed from the cutter at a temperature below 0°C and introduced into the casing.

5. Process according to one of the preceding claims, characterized in that the casing into which the meat substitute mass is introduced is a plastic casing comprising or consisting of polyamide.

6. Process according to one of the preceding claims, characterized in that the heating of the meat substitute mass contained in the casing is carried out by means of hot steam at a temperature of 85-90°C.