Process and apparatus for cutting or reducing food product, such as meat replacement food product

Abstract

A process of making cuts in a food product comprising the steps of: (a) providing at least one cutting tool comprising at least one cutting element, such as a wire or a strip, for making cuts in the food product; (b) providing a slab of the food product and moving the slab in a first direction towards the at least one cutting tool; (c) reciprocally moving the at least one cutting tool in a direction crossing the first direction while the slab is moved through the at least one cutting tool, such that the at least one cutting element makes, for example, wave- shaped cuts in the slab.

Description

Process and apparatus for cutting or reducing food product, such as meat replacement food productField of the disclosure

[0001] The present disclosure relates to a process and apparatus for cutting or reducing food product, such as meat replacement food product or plant-based protein.Background art

[0002] Various devices and methods are known for cutting or reducing a food product which is moved in a first, longitudinal direction, for example a food product being extruded out of an extruder, by means of a cutting tool which is moved in a second direction, crosswise with respect to the first direction.

[0003] For example, WO 2000 / 21373 A3 discloses a device for pelleting extruded products comprises a housing with an inlet and an outlet for the product and a perforated disk inserted in between. After passage through the perforated disk the product is available in strands. To produce crumbly products, at least one cutting means is arranged at the outlet side of the perforated disk and is rotated in a substantially parallel direction to the perforated disk.

[0004] Other devices are known for shaping a food product which is moved in a first, longitudinal direction. For example, GB 1331042 A disclosed a device for producing crinkled food products are prepared by extruding a doughy material and passing the preformed material past a plurality of rotating corrugated rollers to impress a corrugated outline on the sides of the extruded material.Summary of the disclosure

[0005] It is an aim of the present disclosure to provide an alternative process for cutting or reducing a food product, or at least a step in such a process, in particular food product for which a random or irregular shape is desired, such as for example a meat replacement food product or plant-based protein for which a “meaty” appearance is desired.

[0006] It is further an aim of the present disclosure to provide at least one apparatus for performing such a process, or at least a step in such a process.

[0007] An aspect of the present disclosure provides a process of making cuts in a food product comprising the steps of: (a) providing at least one cutting tool comprising at least one cutting element, such as a wire or a strip, for making cuts in the food product; (b) providing a slab of the food product and moving the slab in a first direction towards the at least one cutting tool; (c) reciprocally moving the at least one cutting tool in a direction crossing the first direction while the slab is moved through the at least one cutting tool, such that the at least one cutting element makes, for example, wave-shaped cuts in the slab.

[0008] By use of the wave-shaped cuts, more random or irregular portions of food product are cut from the slab and / or straight and parallel cuts may be avoided. The portions may befurther reduced in subsequent steps by cutting, shredding, tearing and / or other reducing steps. The more random or irregular shapes of the food product portions before such subsequent steps helps to achieve more random or irregular shapes of the final product, i.e. helps to achieve for example a “meaty” appearance of the final food product.

[0009] In embodiments, the at least one cutting tool may comprise at least a first cutting tool and a second cutting tool, which are preferably individually movable. The cutting tools may for example be moved out of phase with each other, for example in antiphase. The cutting tools may for example be moved at different speeds of reciprocal movement with respect to each other.

[0010] In embodiments, the amplitude of the reciprocal movement of the at least one cutting tool may be at least the width of the slab. This means that each cutting tool has at least one cutting element that cuts entirely across the slab. In other embodiments, the amplitude may be less than the width of the slab, preferably with multiple cutting tools and / or elements together covering the full width of the slab.

[0011] In embodiments the orientation of at least one cutting tool and / or cutting element may varied during the reciprocal movement, so as to obtain a further degree of variation in the cuts or introduced a further irregularity in the cut portions. For example, the orientation of two or more cutting elements may be varied so that they “sway” between a first orientation in which they are parallel to each other and a second orientation wherein they are not parallel to each other, for example at an angle with respect to each other of for example 10°, 20°, 30°, or another angle.

[0012] In embodiments, the at least one cutting tool may comprise multiple cutting elements extending in different directions, for example first cutting elements extending in a first direction and second cutting elements extending in a second direction crossing with the first direction. The orientation of at least one of the first and / or second cutting elements on the at least one cutting tool may be varied during the reciprocal movement of the cutting tool.

[0013] In embodiments wherein there are multiple cutting tools and / or cutting elements, the amplitude of the reciprocal movements of the cutting tools and / or cutting elements may be less than or equal to the width of the slab and wherein the reciprocal movements jointly span the entire width of the slab.

[0014] In embodiments, the food product may be a meat replacement product or plant-based protein, preferably an extruded product.

[0015] In embodiments, the at least one cutting tool may be mounted on an outlet of an extruder which produces the slab of food product. This means, for example, the following possible locations for the cut to take place: at the outlet of the actual extruder, or at the outlet of the cooling die following the extruder (alternative protein products may pass through a cooling die which creates the fiber; many products may not utilize a cooling die but may stillbenefit from a wire cutting action as described herein to obtain a more “meaty” appearance). In an exemplary embodiment, the extruder may comprise a cylinder, wherein the at least one cutting tool comprises a cutting wheel which is mounted on an outlet side of the cylinder and is reciprocally rotated for making the wave-shaped cuts. In an embodiment thereof, the extruder may produce a plurality of extruded slabs, distributed along the circumference of the cylinder.

[0016] An aspect of the present disclosure, which may be combined with other aspects and embodiments disclosed herein, provides an apparatus for making cuts in a food product, comprising: at least one cutting tool comprising at least one cutting element, such as a wire or a strip, for making cuts in the food product; a transport device for moving a slab of the food product in a first direction towards the at least one cutting tool; and at least one actuator for reciprocally moving the at least one cutting tool in a direction crossing the first direction while the slab is moved through the at least one cutting tool, such that the at least one wire makes wave-shaped cuts in the slab.

[0017] In embodiments, the apparatus may comprise features for implementing the steps of processes disclosed herein.

[0018] In a particular embodiment, the transport device may be part of an extruder that is provided for producing slabs of food product, for example a transport member which is provided for pushing ingredients of the food product through the extruder towards its outlet. In embodiments, CNC communication may be provided between a control unit for the cutting tool and a control unit of the extruder system so that, for example, the speed of the reciprocal movement may be synchronised with the transport speed of the extruded slab.Brief description of the drawings

[0019] Embodiments of the present disclosure will be discussed in more detail below, with reference to the attached drawings.

[0020] Fig. 1 shows schematically a first embodiment of a process according to the disclosure.

[0021] Fig. 2 shows schematically a second embodiment of a process according to the disclosure.

[0022] Fig. 3 shows schematically a third embodiment of a process according to the disclosure.

[0023] Figs. 4-10 show schematically examples of cuts made in a slab of food product by means of embodiments of a process or apparatus according to the present disclosure.

[0024] Figs. 11A-C show views of an embodiment of an apparatus according to the present disclosure.

[0025] Figs. 12A-C show views of another embodiment of an apparatus according to the present disclosure.

[0026] Fig. 13 shows a view of a possible downstream apparatus for further reducing cut portions obtained by means of a process or apparatus as disclosed herein, for example the process and / or apparatus of any of the Figs. 1-12.Description of embodiments

[0027] Below, particular embodiments according to the disclosure are described with reference to certain drawings but the disclosure is not limited thereto. The drawings described are only schematic and are non-limiting. In the drawings, the size of some of the elements may be exaggerated and not drawn on scale for illustrative purposes. The dimensions and the relative dimensions do not necessarily correspond to actual reductions to practice of the disclosure.

[0028] Furthermore, the terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. The terms are interchangeable under appropriate circumstances and the embodiments of the disclosure can operate in other sequences than described or illustrated herein.

[0029] Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. The terms so used are interchangeable under appropriate circumstances and the embodiments of the disclosure described herein can operate in other orientations than described or illustrated herein.

[0030] Furthermore, the various embodiments, although referred to as “preferred” are to be construed as exemplary manners in which the disclosure may be implemented rather than as limiting the scope of the disclosure.

[0031] The term “comprising”, used in the claims, should not be interpreted as being restricted to the elements or steps listed thereafter; it does not exclude other elements or steps. It needs to be interpreted as specifying the presence of the stated features, integers, steps or components as referred to, but does not preclude the presence or addition of one or more other features, integers, steps or components, or groups thereof. Thus, the scope of the expression “a device comprising A and B” should not be limited to devices consisting only of components A and B, rather with respect to the present disclosure, the only enumerated components of the device are A and B, and further the claim should be interpreted as including equivalents of those components.

[0032] Figs. 1-3 shows schematically embodiments of processes according to the disclosure for cutting or reducing a slab of food product by means of at least one cutting tool. In eachembodiment, the process comprises the steps of providing a slab of a food product and moving the slab in a first direction towards the at least one cutting tool, and reciprocally moving the at least one cutting tool in a direction crossing the first direction while the slab is moved through the at least one cutting tool, such that the at least one cutting element makes wave-shaped cuts in the slab. The movements are indicated on the figures by means of the arrows.

[0033] In the embodiments shown, the wave-shaped cuts have substantially sinusoidal shapes but this is not essential, other wave-shaped or curved cuts are also possible within the scope of the present disclosure.

[0034] In Fig. 1, the slab 1 is cut by means of one cutting tool 2 with a plurality of cutting elements 3 (e.g. metal wires or thin metal strips), which is moved reciprocally in a direction perpendicular to the direction of movement of the slab. The amplitude of the reciprocal movement is preferably about the full width of the slab, such that the cutting elements make cuts in the slab and also cut off portions of the slab. In other embodiments, the amplitude may be smaller, so that the cutting elements 3 make mostly wave-shaped cuts in the slab, and a separate cutting tool (not shown) may be provided to cut off portions of the slab.

[0035] In Fig. 2, the slab 1 is cut by means of a first and a second cutting tool 2, 2’ each having at least one cutting element 3 (e.g. metal wires or thin metal strips). The cutting tools 2, 2’ are moved reciprocally in a direction perpendicular to the direction of movement of the slab. The cutting tools 2, 2’ are preferably moved out of phase with each other, for example in antiphase (the first tool 2 is moved left while the second tool 2’ is moved right and vice versa). The cutting tools 2, 2’ may be moved at the same speed or at different speeds. Preferably, the movements of the cutting tools 2, 2’ are synchronised. The amplitude of the reciprocal movements may be about the full width of the slab, or preferably at least such that the reciprocal movements together span the full width of the slab with the effect that the cutting elements 3 make cuts in the slab and also cut off portions of the slab. In other embodiments, the amplitude may be smaller, so that the cutting elements 3 make mostly wave-shaped cuts in the slab, and a separate cutting tool (not shown) may be provided to cut off portions of the slab.

[0036] In Fig. 3, the slab 1 is cut by means of first, second and third cutting tools 2, 2’, 2” each having one cutting element 3 (e.g. metal wires or thin metal strips). The cutting tools 2, 2’, 2” are moved reciprocally in a direction perpendicular to the direction of movement of the slab. The cutting tools 2, 2’ are preferably moved out of phase with each other, for example in antiphase (the first tool 2 is moved left while the second tool 2’ is moved right and vice versa). The amplitude of the reciprocal movements may be about the full width of the slab, or preferably at least such that the reciprocal movements together span the full width of the slab with the effect that the cutting elements 3 make cuts in the slab and also cut off portions of the slab. In other embodiments, the amplitude may be smaller, so that the cutting elements 3 makemostly wave-shaped cuts in the slab, and a separate cutting tool (not shown) may be provided to cut off portions of the slab.

[0037] Figs. 4-10 show schematically examples of cuts 4 made in a slab 1 of food product by means of embodiments of a process or apparatus according to the present disclosure.

[0038] In Fig. 4, the slab 1 is cut by means of one cutting element which makes wave-shaped cuts 4 across the full width of the slab. This embodiment can be achieved for example using a single cutting tool 2 as shown in Fig. 1 but with one cutting element 3.

[0039] In Fig. 5, the slab 1 is cut by means of two cutting elements which make wave-shaped cuts 4 across the full width of the slab. The two cutting elements are moved in antiphase with respect to each other. This embodiment can be achieved for example using two cutting tools2, 2’ as shown in Fig. 2, each having one cutting element 3.

[0040] In Fig. 6, the slab 1 is cut by means of three cutting elements which make waveshaped cuts 4 across the full width of the slab. The three cutting elements 3 are moved out of phase with respect to each other, in particular 120° out of phase with respect to each other. This embodiment can be achieved for example using the cutting tools 2, 2’, 2” shown in Fig.3.

[0041] In Fig. 7, the slab 1 is cut by means of two cutting elements which each make waveshaped cuts 4 over about half the width of the slab. The two cutting elements are moved in antiphase with respect to each other. The cuts 4 of the two cutting elements together span the full width of the slab. This embodiment can be achieved for example using two cutting tools 2, 2’ as shown in Fig. 2, each having one cutting element 3.

[0042] In Fig. 8, the slab 1 is cut by means of two cutting elements which each make waveshaped cuts 4 over more than half the width of the slab. The two cutting elements are moved in antiphase with respect to each other. The cuts 4 of the two cutting elements together span the full width of the slab. This embodiment can be achieved for example using two cutting tools 2, 2’ as shown in Fig. 2, each having one cutting element 3.

[0043] In Fig. 9, the slab 1 is cut by means of two cutting elements which each make waveshaped cuts 4 over the full width of the slab. The two cutting elements are moved at different speeds, in particular the period of reciprocal movement of the one is twice the period of reciprocal movement of the other.

[0044] In Fig. 10, the slab 1 is cut by means of two pairs of cutting elements which each make wave-shaped cuts 4 over about half the width of the slab. The two pairs of cutting elements are moved in antiphase with respect to each other. The cuts 4 of the two cutting elements together span the full width of the slab. This embodiment can be achieved for example using two cutting tools 2, 2’ as shown in Fig. 2, each having two cutting elements 3.

[0045] Figs. 11A-C show views of an embodiment of an apparatus according to the present disclosure. The apparatus comprises at least one cutting tool, in particular a cutting wheel 5,comprising at least one cutting element, in particular a plurality of cutting wires, for making cuts in the food product. The apparatus comprises a transport device for moving a slab of the food product in a first direction towards the cutting wheel. In particular, the apparatus comprises an extruder 7 and a transport device in the extruder supplies the slab of food product towards an outlet of the extruder. The cutting wheel 5 is mounted directly on the outlet of the extruder. The apparatus further comprises an actuator 6 for reciprocally moving, in particular rotating, the cutting wheel 5 in a direction crossing the direction of movement of the slab 1. The actuator moves the cutting wheel reciprocally, such that the wires of the cutting wheel make waveshaped cuts in the slab.

[0046] In particular, the extruder 7 is a cylindrical extruder which produces four slabs of food product, e.g. meat replacement food product. The cutting wheel comprises six cutting wires which extend diametrically across the cutting wheel, such that each slab is at any time being cut by multiple (two or three) cutting wire portions. The cutting wheel 5 is moved reciprocally between the positions of Fig. 11A and Fig. 11C.

[0047] Figs. 12A-C show views of another embodiment of an apparatus according to the present disclosure. The apparatus comprises a cutting tool 5’, comprising cutting elements 41, 42 extending in crossing directions. The apparatus comprises an extruder 7 and a transport device in the extruder supplies the slab of food product towards an outlet of the extruder. In this embodiment, the extruder 7 produces a somewhat thicker slab of food product which is cut by the cutting tool 5’ in two directions, in particular vertically by means of the first cutting elements 41 and horizontally by means of the second cutting elements 42. The cutting tool 5’ is mounted directly on the outlet of the extruder and is moved reciprocally by means of an actuator. The actuator moves the cutting tool 5’ reciprocally, such that the first cutting elements 41 make wave-shaped cuts in the slab. During the reciprocal movement, the second cutting elements 42 cut the slab into thinner portions. In order to avoid parallel cuts and / or introduce a further irregularity, the second cutting elements 42 are made to “sway” on the cutting tool (see Fig. 12A vs. Fig. 12C), i.e. the orientation of the cutting elements 42 is varied between parallel and non-parallel orientations so as to obtain a further degree of variation in the cuts or introduce a further irregularity in the cut portions. For example, the orientation of the cutting elements 42 may be varied so that they “sway” between a first orientation in which they are parallel to each other (Fig. 12A) and a second orientation wherein they are for example at an angle with respect to each other of for example 10°, 20°, 30°, or another angle.

[0048] The apparatuses of Figs. 11 and 12 may be fitted with one or more cutting tools as disclosed herein, preferably at the outlet of the extruder, for obtaining the cuts as shown in Figs. 4-10 or others as disclosed herein. Generally, the cutting tools may be moved and controlled such that straight edges are avoided or camouflaged in the end product (after subsequent reducing steps). A controller may be provided for this purpose, i.e. to control oneor more of the speed of the reciprocal movement, the amplitude, the phase between subsequent cutting tools, the orientation (variation) of cutting tools and / or cutting elements. By means of this controller and appropriate cutting tools, parameters such as size of food product portions, fiber length, thickness, shape, or others may be varied and programmed.

[0049] In embodiments, the cutting elements (wire or strip) may be made to oscillate (vibrate) along their length to facilitate cutting of fibers, or to break surface tension if the food product is sticky. On a cylindrical extruder (such as Fig. 11) such oscillation may be achieved by rotating the cutting wheel in an eccentric motion instead of pure rotation around its center. On a linear extruder (such as Fig. 12) known vibration tools to cut confections line pies and cakes may be used.

[0050] The controller may be a CNC controller, in communication with other components of a production line both upstream and downstream. For example, the CNC controller may communicate with the extruder due to changes in feed rate and it may communicate with the discharge side for timing reasons.

[0051] The cutting elements on the cutting tools, for example a wire or thin strip, may be tensioned, for example in ways similar to musical string instruments are tensioned. The tensioning method may be quite simple and be achieved by a threaded pin, having a hole in one end to receive a wire, with the ability to be rotated with a tool, threads on the same pitch as the wire diameter, and a way to lock the rotation of the threaded pin. A bridge pin may be used in front of the threaded pin to take unwanted loads off of the threads.

[0052] Fig. 13 shows a view of a possible downstream apparatus, in particular a stand mixer apparatus, for further reducing cut portions obtained by means of a process or apparatus as disclosed herein, for example the process and / or apparatus of any of the Figs. 1-12. It has been found that by placing the cut portions (obtained by the cutting process as described herein) in a bowl of a stand mixer and subsequently “mixing” the contents of the bowl during a period of time, e.g. a relatively short period of time of for example 15-30 seconds, the cut portions may be torn up into smaller portions which have a meaty appearance.

Claims

Claims1. A process of making cuts in a food product comprising the steps of: a) providing at least one cutting tool comprising at least one cutting element, such as a wire or a strip, for making cuts in the food product; b) providing a slab of the food product and moving the slab in a first direction towards the at least one cutting tool; c) reciprocally moving the at least one cutting tool in a direction crossing the first direction while the slab is moved through the at least one cutting tool, such that the at least one cutting element makes, for example, wave-shaped cuts in the slab.

2. The process according to claim 1 , wherein the at least one cutting tool comprise at least a first cutting tool and a second cutting tool.

3. The process according to claim 2, wherein the cutting tools are moved out of phase with each other.

4. The process according to claim 2, wherein the first cutting tool is moved in antiphase with the second cutting tool.

5. The process according to claim 2, wherein the first cutting tool is moved at a different speed than the second cutting tool.

6. The process according to any one of the preceding claims, wherein the amplitude of the reciprocal movement of the at least one cutting tool is at least the width of the slab.

7. The process according to any one of the preceding claims, wherein the orientation of at least one cutting tool and / or cutting element is varied during the reciprocal movement.

8. The process according to any one of the preceding claims, wherein the at least one cutting tool comprises multiple cutting elements extending in different directions.

9. The process according to claim 8, wherein the at least cutting tool comprises first cutting elements extending in a first direction and second cutting elements extending in a second direction crossing with the first direction.

10. The process according to claim 9, wherein the orientation of at least one of the first and / or second cutting elements on the at least one cutting tool is varied during the reciprocal movement.The process according to any one of the preceding claims, wherein there are multiple cutting tools and / or cutting elements, wherein the amplitude of the reciprocal movements is less than or equal to the width of the slab and wherein the reciprocal movements jointly span the entire width of the slab. The process according to any one of the preceding claims, wherein the food product is a meat replacement product or plant-based protein. The process according to any one of the preceding claims, wherein the at least one cutting tool is / are mounted on an outlet of an extruder which produces the slab of food product. The process according to claim 13, wherein the extruder comprises a cylinder and wherein the at least one cutting tool comprises a cutting wheel which is mounted on an outlet side of the cylinder and is reciprocally rotated for making the wave-shaped cuts. The process according to claim 14, wherein the extruder produces a plurality of extruded slabs, distributed along the circumference of the cylinder. An apparatus for making cuts in a food product, comprising: at least one cutting tool comprising at least one cutting element, such as a wire or a strip, for making cuts in the food product; a transport device for moving a slab of the food product in a first direction towards the at least one cutting tool; and at least one actuator for reciprocally moving the at least one cutting tool in a direction crossing the first direction while the slab is moved through the at least one cutting tool, such that the at least one wire makes wave-shaped cuts in the slab. The apparatus according to claim 16, wherein the transport device is part of an extruder that is provided for producing slabs of food product. The apparatus according to claim 17, wherein the extruder is provided for producing slabs of meat replacement food product. The apparatus according to claim 16 or 17, wherein the at least one cutting tool is / are mounted on an outlet of the extruder.

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