Method for producing a texturate and protein-containing texturate

Abstract

The invention relates to a protein-containing texturate which is characterised by a special anisotropy comparable to meat. The texturate comprises a first protein mixture with a non-legume protein, in particular wheat protein, with a proportion of between 10 wt.% and 90 wt.% of the dry mass, and a second protein mixture, in particular with a legume protein or a side-stream product, with a proportion of between 10 wt.% and 90 wt.% of the dry mass. The moisture content is less than 40 wt.% and in particular less than 35 wt.%; a protein proportion of the texturate is between 35 wt.% and 60 wt.% of the dry mass. According to the invention, the texturate has fibres with a preferred direction and a length of more than 10 mm and in particular more than 15 mm, and has an anisotropy index of greater than 1 and in particular greater than 1.4.

Description

[0001] Method for producing a texture and protein-containing texture

[0002] This application claims priority from German patent application DE 10 2023 106 028 . 7 of March 10, 2023, the disclosure of which is hereby incorporated in its entirety by reference. This application further claims priority from German patent application DE 10 2023 127 053 . 2 of October 4, 2023, the disclosure of which is hereby incorporated in its entirety by reference.

[0003] The present invention relates to a method for producing a texturate and to such a texturate.

[0004] BACKGROUND

[0005] Plant proteins in the form of isolates or concentrates are now used in a variety of meat substitutes. This is due, on the one hand, to increased demand for vegetarian or vegan diets and, on the other, to consumer desire for sustainable and resource-efficient agriculture.

[0006] Vegan food products made from plant proteins have the advantage, among other things, that they can be produced from domestic or locally produced raw materials. Endemic plant varieties in particular also have the advantage of often being adapted to the respective climatic conditions, so that they can potentially be cultivated in a more resource-efficient manner than imported plant varieties. In contrast, there is a growing demand for various plant-based food products.

[0007] Traditionally, products based on vegetable proteins are manufactured by dry or wet extrusion. Dry extrusion is carried out at high temperatures T > 130 °C and a moisture content < 30 %. A short, narrow die without cooling is used for extrusion. This enables the production of directly expanded products, so-called TVP (textured vegetable proteins). In dry form, they are rather irregular, porous and glassy and, after being rehydrated, are further processed into the final products. Although they are called textured products, the final product has a sponge-like structure with no appreciable anisotropy, with either no or only very short fibers. They bear little resemblance to the sensory properties of meat analogues and are often used in blended products (e.g. burger patties, etc.) rather than for whole products.

[0008] Moisture extrusion (HME) is the current technology used by industry to produce fibrous, plant-protein-based products. The resulting products sometimes provide a satisfactory base, exhibiting an anisotropic, meat-like structure, texture, and appearance. Such products are manufactured using various technologies but have a higher water content of more than 50% by weight than the dry extrusion products mentioned above.

[0009] In wet extrusion, the dough is kneaded and pressed through an elongated cooling slot die or an extended cooling couette die. In both cases, the protein-based matrix is ​​extruded at relatively high temperatures (T > 130 °C) and high water contents (>50%) in the screw section of the extruder and then forced to flow through a subsequent cooling die, where the material is continuously cooled (typically to below <100 °C at the die exit) to prevent expansion, which could destroy the fibrous structures produced in the die section.

[0010] Although this method can be applied to various plant-based raw materials to produce fibrous, protein-based products that acceptably resemble meat products in appearance and, to some extent, in taste, they lack either the long fiber structures or the desired tenderness, both of which are necessary to successfully replicate meat properties. Nevertheless, there are products produced using this technology that can adequately replicate chicken or doner / gyro-like products. These products do not require long fibrous structures and are quite elastic in terms of bite and firmness.However, when it comes to adjusting juiciness, firmness and fiber length, conventional technologies do not offer the flexibility to achieve this in a targeted manner to authentically mimic different meat products such as beef or pork, which require more tender firmness and longer fiber structures.

[0011] However, it has been found that wet extrusion can only be used for base mixes with a protein content of more than 55%, as the creation of a very strong gel structure is a prerequisite for this process. However, this decreases drastically with decreasing protein content and increasing content of polysaccharides, fiber, starch or oil. Such high protein concentrations are usually produced by wet extraction followed by spray drying, which is a very energy-intensive process with a high carbon footprint. This also leads to an increase in the price of raw materials, making the final product less competitive compared to meat products.

[0012] Accordingly, there is a need to meet this demand without sacrificing sustainable and resource-saving agriculture.

[0013] SUMMARY OF THE INVENTION

[0014] This need is met by the subject matter of the independent patent claims. Further developments and embodiments of the proposed principle are specified in the subclaims.

[0015] Previous research assumed that fiber formation in the molded part and the exit nozzle results from multiphase gel formation at high temperatures and the subsequent deformation of this multiphase system by shear stresses in the molded part , with the mass being cooled to less than 100 ° C in order not to destroy the fibers .

[0016] Although this method has proven successful for producing fibrous protein-based products, typically similar to meat products, controlling the resulting fiber formation remains a challenge. This requires precise control of gel formation, cooling, and shear forces in the molded part, which in turn vary greatly, since such highly elastic materials exhibit wall slip and melt fracture phenomena that significantly affect the deformation history. Wall slip or melt fracture lead to a sudden pressure drop in the die and thus to expansion of the mass, and besides fiber disruption, to unstable behavior.

[0017] Definition of textured plant product

[0018] A food product developed primarily from plant-based ingredients and exhibiting textural anisotropy.

[0019] Definition of protein mixture

[0020] For the purposes of this application, the term "protein mixture" means a plant protein mixture. Such a plant protein mixture is usually obtained from a single plant species in the manufacturing process, although impurities from other plants may occur to a small extent.

[0021] Unless otherwise stated, a "plant protein" comprises a plant protein mixture from the respective plant, otherwise it is referred to as a "single plant protein". In addition to the actual plant proteins, the mixture can also contain other components such as starch, sugar, fiber, minerals, fats and oils. Individual amino acids can also be part of the protein mixture. The respective amounts are defined in more detail below in the terms concentrate and isolate. However, the term plant protein mixture is always used when the composition of the mixture differs from the original distribution of the respective plant species.

[0022] Similarly, a “pea protein” or a pea-based plant protein is a protein mixture which has been essentially obtained from peas, pea components or proteins of the pea plant and has been processed accordingly. A protein mixture can be obtained from the plant species as such, but can also be the result of a side stream. There are also various side streams, press cakes and residues which can be used as a protein source and thus represent protein mixtures within the meaning of this definition. These include, but are not limited to, residues from sugar production, the production of alcoholic beverages such as beer and wine, residues and side streams from oil production such as soybean oil, coconut oil and rapeseed oil, or plant-based milk production such as oat milk, pea milk or field bean milk.Further examples of various side streams from which protein mixtures can be produced or which contain these include okara (soy pulp), almond pulp, oat pulp, coconut pulp / meat, sunflower cake, rapeseed cake, linseed meal, hemp cake, cashew residues and peanut cake and corn gluten meal, whey protein, casein micelles, potato fruit water, chickpea pulp, lentil residues, spent brewer's yeast and spent malt (beer leavener).

[0023] Other plant proteins that can be processed as concentrate, as isolate (see the definitions there) but also in other forms as protein mixtures include, but are not limited to, textured soy protein, tempeh, hydrolyzed wheat protein, mycoprotein (fungal mycelium, for example from Fusarium venenatum), rice protein, potato protein, corn protein (zein protein), hemp protein, algae protein, e.g. from spirulina or chlorella, rapeseed protein, sunflower protein, cottonseed protein, pumpkin seed protein, quinoa protein, amaranth protein, millet protein, spelt protein, oat protein, barley protein, lemna protein, cassava protein, coconut protein, macadamia protein, cashew protein, chia protein, linseed protein, sacha inchi protein, watermelon seed protein, pistachio protein and yeast protein.

[0024] These proteins can in turn be divided into pulse proteins and non-pulse proteins. Depending on the desired texture, pulse protein mixtures can be combined with non-pulse protein mixtures and processed using the process presented. Definition of pulse protein

[0025] A legume protein is a protein mixture obtained from legumes. These include, in particular, broad beans, but also peas, lentils, mung beans, chickpeas, white beans, peanuts, and soy. Here, too, a protein mixture can be obtained either directly from the respective legume or as a sidestream product.

[0026] Definition of non-legume protein

[0027] A non-pulse protein is a protein mixture that includes plant proteins that do not originate from a pulse. They are therefore obtained from other crops that are not listed as pulses in the above definition and do not constitute such. In addition to wheat, this includes all other cereals and grains, such as oats, as well as hemp, potatoes, rice, hemp, pumpkin seeds, corn, as well as rapeseed and sunflower. Proteins from algae, yeast, fungal mycelium and / or fungal fruiting bodies also fall under the category of non-pulse proteins.

[0028] In this context, protein mixtures from these plants are also referred to as other protein mixtures, and thus distinguished from protein mixtures from or with legumes. Other protein mixtures include, among others, the plant proteins mentioned above.

[0029] Definition of concentrate and isolate

[0030] The terms plant protein isolate and plant protein concentrate each describe plant protein mixtures that differ in the concentration of their protein content. The other components of an isolate or concentrate are, for example, fats, sugars including starch and cellulose, which remain in the mixture when the concentrate or isolate is processed. The individual other components are reduced compared to the original concentration, but residues are still present in the isolate or concentrate in varying concentrations due to the different processing options. There is also a small amount of residual moisture in the isolate or concentrate. A plant protein isolate, for example, is a mixture of a plant protein in which the concentration of the protein in the mixture is in the range above 85 percent by weight, for example in the range from 87 to 97% by weight.In a plant protein concentrate, the weight percentage of plant protein is usually below 80% or even below 70%, for example, in the range of 35% to 75% or even up to approximately 80%. There is also a transition range, which, depending on the protein mix, ranges from 75% to 85%, and in which, depending on the manufacturer, protein variant, or other parameters, the term "concentrate" or "isolate" is used.

[0031] Depending on the processing and manufacturing process, a plant protein concentrate or plant protein isolate can be obtained from a plant species. Thus, the manufacturing process significantly influences not only the concentration of the plant protein mixture, but also, if necessary, the composition of the remaining components and the residual moisture content.

[0032] In addition, there is also low-concentration protein paste made from the various fruits mentioned above, which arise as side-stream products from existing product processes or are intermediate products and can thus be processed directly in a more resource-efficient manner.

[0033] Definition of other ingredients

[0034] In some aspects, additional functionality in protein composition, taste, textural composition, visual or tactile properties can be achieved by at least one additional ingredient. It should be noted here, firstly, that the above-mentioned protein mixtures from the various carrier plants are mixed, both in terms of the different crops and also in terms of concentration. An example would be mixtures of pea protein and broad bean protein, but possibly also additions of wheat or rice protein to a protein mixture from soy or pea.

[0035] Other ingredients such as salt, spices, additional starch, sugar, syrup, sugary fruit juices, fats or oils may also be present. These can be added either as part of the raw mixture at the beginning or alternatively or additionally during processing. Surprisingly, it has been found that sugar, oils and salts, or ingredients containing salt or oil, e.g. grape juice concentrate or soy sauce, can not only lead to an adjustment in taste but also to a change in texture. These additional ingredients can be present in free form, but can also be bound in highly concentrated form in corresponding raw materials, e.g. sugar in syrup.

[0036] Another possibility is the addition of functional ingredients, such as flavors, and / or additional protein or amino acid sources to adjust certain properties or improve human bioavailability. Generally, the additional mixtures, as well as one or more of the above-mentioned substances, are referred to as additional ingredients or additional components.

[0037] Definition of basic mixture

[0038] A base mix is ​​a combination of a protein mixture, whether from a single plant species or a mixture of several plant species, as a plant protein isolate, plant protein concentrate, paste, sidestream product, or a combination thereof, and water. Optionally, additional protein mixtures and / or at least one other ingredient and / or at least one other component can be added to create the base mix.

[0039] The water content of the base mix is ​​adjusted to the desired level for extrusion as needed. This is due to the fact that the protein mixture also added has a varying water content depending on the processing stage. For very moist mixes, such as paste or okara, little or no water may need to be added. In some cases, it is even conceivable that dry ingredients may need to be added to reduce the overall water content of the dough.

[0040] The dough is then further processed in the extruder. Alternatively, the individual components can also be added to the extruder during extrusion.

[0041] The proportions in the base mix are generally expressed in weight percent, excluding water, based on the respective dry matter content. A base mix with 40% protein by weight based on dry matter and a moisture content of 50% can be obtained from various concentrates or isolates with corresponding amounts of water. There may also be sidestream products that exhibit this distribution.

[0042] Accordingly, the proportion of each ingredient in the base mix typically varies due to the different distribution of the components within the ingredients. In particular, less water usually needs to be added, as the protein mixture or other ingredients also contain water.

[0043] In principle, this also applies to other added components such as salts, sugars or fats, as these are also present in the protein mixture in varying quantities.

[0044] Definition of extrudate

[0045] In the following, the dough mass processed in an extruder by kneading or other mechanical processing at the extruder outlet, especially at the end of the screw section, is referred to as the extrudate or viscoelastic mass. The associated process is called extrusion. The texturate then corresponds to the finished, stretch-formed and otherwise processed extrudate.

[0046] Definition of texturing

[0047] A process by which an extrudate achieves an anisotropy in its texture. An extrudate with anisotropy is therefore also referred to as a texturate. Texturing can occur in the extruder, depending on its implementation, but usually only afterward through additional means and measures.

[0048] Definition of anisotropy

[0049] A condition in which the product exhibits different mechanical properties depending on the measurement direction. This is quantified by an anisotropy index, which is measured by hydrating the product to a water content between 65% and 75% and then cutting it in two orthogonal directions.

[0050] One direction should run along a fiber, the other perpendicular to it, in order to determine the maximum anisotropy value in the sample. In this application, the anisotropy index is the ratio of the force required to cut the samples in the direction orthogonal to the fibers to the force required in the direction parallel to them. An anisotropic product has an anisotropy index that is not equal to one, but greater than one.

[0051] The anisotropy index can be determined in a variety of ways, including using a texture analyzer, e.g. TA. XTPLUSC CONNECT TEXTURE ANALYZER from Winopal, using a fixed cutting blade (e.g. LIGHT KNIFE BLADE A / LKB from Winopal). The product is cooked until the value specified above is reached. The anisotropy index of chicken or turkey is in the range of 1.2 to 2, while that of beef or pork is more variable and depends on the type of meat. Generally speaking, these two types of meat have somewhat higher anisotropy indices.

[0052] Definition of fiber

[0053] Fibers within the meaning of this application are elastic, cohesive layers that are aligned along a main direction, referred to as the fiber direction. Fibers within the meaning of this application exhibit strong anisotropy, which means that they can be detached or separated from the rest of the product if the fibers are pulled in a direction other than their fiber direction (e.g. from the transverse direction when they are aligned lengthwise, or vice versa). The fibers are therefore relatively loose or detachable if they are pulled in a direction orthogonal to the fiber direction, and elastic and cohesive if they are pulled along the fiber direction. Individual fibers can be detached from the product simply by pulling with the hand.

[0054] Fiber length is defined as the maximum length of the layer that detaches from the product without tearing, while retaining its strong anisotropy and elasticity along the fiber direction. The average fiber length is usually smaller and follows a normal distribution. Unless otherwise stated, the fiber length generally refers to the average fiber length.

[0055] Definition pieces

[0056] Cohesive parts of the textured vegetable product with a thickness exceeding 2 mm and dimensions ( length and width ) exceeding 10 mm .

[0057] Definition of thermomechanical treatment

[0058] A process during extrusion in which the dough is exposed to a specific temperature range while being mechanically processed. Mechanical processing may include kneading, rolling, rolling, crushing, and other forms in which a force or torque is applied to the dough.

[0059] Definition of axial and transverse strain

[0060] The deformation of the material along the longitudinal (axial) and / or lateral (transverse) axis, which occurs in a nozzle channel mounted after the screw section of the extruder. The material is thereby stretched along the respective axis. If the stretching occurs after the extruder exit, the extrudate is stretched accordingly.

[0061] Definition of material temperature

[0062] The temperature reached by the protein mixture during thermomechanical treatment in the extrusion process. Unless otherwise stated, the temperatures indicated refer to the material temperature. Definition of online and offline cutting

[0063] Cutting methods that are applied either immediately as the product exits the extruder ( online ) or after a delay after extrusion ( offline ).

[0064] The inventor has recognized that dry texturates or semi-moist texturates with different protein contents can be produced, and that these can be created in both the warm and cold extrudate by applying suitable stretching forces after extrusion. By combining these measures, an anisotropy can be imposed on the texturate, which can be adjusted over a range from 1 to approximately 1.8 and higher, so that the anisotropy of pork or beef can be imitated in the range from 1.2 to greater than 1.7, e.g. up to 2. At the same time, not only can oriented fibers be produced, but their length can also be adjusted up to 20 cm and more.

[0065] Accordingly, in some aspects, the inventor proposes a method for producing an anisotropic plant-based texturate, wherein the texturate has a water content of less than 50% by weight and more than 50% by weight based on the dry mass of non-soya-based ingredients. In the texturate, a protein content of more than 30% by weight based on the dry mass. The method comprises the steps of providing at least one protein mixture with at least 50% by weight based on the dry mass of ingredients other than soya. The term "other than soya" means that the ingredients do not originate from the soya plant, in particular that no soya protein is contained in this amount of ingredients.

[0066] A base mixture is then produced from the provided protein mixture and water, such that the water content of the base mixture is in the range of 25% to 55% by weight. This dough is then formed into a dough which is then extruded by means of a thermomechanical treatment, during which the material reaches a temperature in the range of 110 to 160 °C. Due to the lower amount of water, this is a dry extrusion or semi-moist extrusion in contrast to conventional moist extrusions ("high moisture extrusions"). The extrudate is then subjected to a first axial and / or transverse stretching, in particular in a channel with a changing cross-section, to produce a texturate. The texturate is then cut to produce pieces with thicknesses greater than 2 mm and lengths and widths greater than 10 mm.

[0067] The process thus creates a texturized product that, in some aspects, has a protein content of between 35% and 60% based on the dry matter. Due to the applied stretching, it has an anisotropy that can be further enhanced and / or stabilized through additional measures. Likewise, fibers are present whose length can be adjusted over a wide range, allowing a variety of different meat products to be imitated. These include turkey, chicken, pork, duck, and others.

[0068] In some aspects, the anisotropy of the texturate is to be increased after or even before cutting. For this purpose, a second axial and / or transverse stretch is exerted on the already stretched texturate, in particular by rolling, pressing or rolling the texturate. Likewise, in some aspects, an anisotropy in the texturate can be increased and also frozen by rolling, pressing, shearing or rolling or other mechanical treatment of the texturate. “Frozen” is understood to mean that the texturate hardly relaxes at all or not at all after this process, so that the anisotropy is no longer significantly reduced. A small relaxation shortly after the process is harmless, but the additional step should make the increased anisotropy irreversible.

[0069] In some aspects, the rolling step reduces the firmness of the texturate compared to the firmness of the texturate before rolling, in some aspects by 30% to 60%. This further adapts the product to existing meat products in terms of mouthfeel. Likewise, the rolling, rolling or other mechanical measures mentioned above can increase the average fiber length of the texturate by more than 10 mm, in particular more than 20 mm, and in particular more than 30 mm. In particular, the average fiber length can also increase to more than 100 mm.

[0070] Some aspects concern the surface of an expansion nozzle during the initial expansion process. It is advantageous to design the surface of the expansion nozzle so that, at least in some sections, it exhibits lower sliding friction than the surface of the extruder. This reduces sliding friction and reduces slippage, which can lead to undesirable gel fracture. This can include, among other things, a different surface coating, particularly one made of Teflon and ceramic.

[0071] In some aspects, the texturate is dried, for example by air drying. Drying is carried out until the texturate has a moisture content of less than 20% by weight and in particular less than 10% by weight. Slicing can take place before or after, preferably beforehand. Drying significantly increases the shelf life of the finished product. Alternatively, the texturate can also be hydrated to a moisture content of between 40% and 80% by weight and in particular between 50% and 70% by weight and in particular between 55% and 75% by weight. This also adapts the texturate to different types of meat.

[0072] Another option is to further treat the pure or hydrated texturate to increase its similarity to existing meat products or to create new product groups. For this purpose, the texturate can be fried or deep-fried, for example. It can also be marinated or coated with an emulsion. This increases its shelf life, and the texturate can be sold directly to the end consumer. Smoking, for example, to produce jerky-like products is possible. Combinations of the above-mentioned measures are also conceivable.

[0073] A further aspect relates to the provision of at least one protein mixture. The mixture can be provided with different protein proportions as an isolate, concentrate or also as a side stream. For example, the protein proportion is between 20% and 95% by weight and in particular between 25% and 80% by weight and in particular between 30% and 70% by weight and in particular less than 60% by weight, in each case based on the dry mass of the protein mixture. Other values ​​are also possible. It should be noted, however, that mixtures with a low protein proportion, lower than in some concentrates, can also be used and that the texturates with the properties mentioned can therefore be produced in the proposed manner.

[0074] The protein mixtures can be combined with each other, e.g., various mixtures of the types listed in the definitions. In addition, other ingredients such as starch, polysaccharides, dietary fiber, fibers, fats, oils, and flavorings can be added. However, it is also possible for these ingredients to already be part of the mixtures or to be part of added sidestream products. Overall, the proposed process significantly reduces the costs of producing texturates through appropriate selection of ingredients.

[0075] In some aspects of the process, a base mix is ​​produced by adjusting the moisture content of the base mix so that the protein content of the base mix is ​​greater than 35% by weight and less than 60% by weight based on the dry matter. Accordingly, the process can be used to produce various texturates with different protein concentrations, while still exhibiting anisotropy and pronounced fiber formation. Of course, depending on the added components, protein concentrations of up to 85% by weight based on the dry matter are also possible.

[0076] In some aspects, the protein mixture provided comprises a combination of a wheat protein mixture and at least one of a legume protein mixture, in particular a pea protein mixture, a field bean protein mixture and an oat milk side stream. In some aspects, the proportion of dry matter of wheat protein in the protein mixture provided is between 10% by weight and 90% by weight and in particular between 20% by weight and 70% by weight and in particular between 40% by weight and 70% by weight and in particular between 30% by weight and 60% by weight and in particular between 10% by weight and 50% by weight. Other weight specifications and ranges are also possible.A proportion of the other protein in the dry matter of the protein mixture provided is between 35% and 60% by weight and in particular between 20% and 80% by weight and in particular between 40% and 70% by weight and in particular between 10% and 50% by weight.

[0077] In a further aspect, the protein mixture provided further comprises a side stream product, a beer driver or the like. The side stream product can in particular originate from plant-based milk production, but can also be part of the exemplary side stream products mentioned at the beginning. Such a side stream product can already have a considerable water content, so that the addition for producing the dough can possibly be dispensed with. In some aspects, dry matter from other protein mixtures or ingredients is added in order to reduce the water content, so that the dough can be extruded in dry or semi-moist condition. Typically, in such extrusions the moisture content is below 55% by weight of the base mixture and in particular also below 50% by weight.

[0078] In some examples, the dry matter content of the side stream product in the base mix is ​​between 10% and 90% by weight, and in particular between 40% and 70% by weight, and in particular between 5% and 40% by weight or between 10% and 20% by weight. A salt content in the dry matter of the protein mix is ​​usually less than 5% by weight and / or a dry matter content of carbohydrates including starch and sugars is less than 20% by weight. Another aspect deals with the anisotropy index, which is the ratio of the cutting force across the grain to the cutting force along the grain of the texturate. This is usually measured at a moisture content between 65% and 75%, so in some aspects the texturate is rehydrated to determine the index.Measurements at other moisture contents are possible, but the anisotropy ratio depends on the moisture content. In some cases, this is greater than 1.25, and in particular, it is greater than 1.4, and in particular, it is between 1.3 and 1.8. The indices of various meats, such as pork, beef, or veal, are typically within this range, making the method particularly suitable for simulating the fiber length and anisotropy of such meats.

[0079] In some further aspects, an average fiber length is greater than 15 mm and in particular is in the range between 15 mm and 25 mm and in particular between 20 mm and 30 mm.

[0080] In some aspects, a special die is used to produce the texturate, in particular without active cooling to generate continuous extensional deformation, which leads to the fiber formation according to the invention and thus to anisotropy. By applying extension-dominated flow, or more precisely sliding, within the die, a longitudinal or transverse velocity component of the hot extrudate in the die is generated due to a changing shape and / or a decreasing cross-section. The use of different materials as wall material makes it possible to adjust the contribution of shear stresses, which in some cases can be reduced to almost zero by using a PTFE or ceramic wall. This reduces the risk of flow instabilities in the die and enables very well-defined deformation by longitudinal and / or transverse extension of the extrudate.This allows both longitudinal and transverse tensile stresses to be generated simply by the nozzle geometry. Depending on the design, the temperature during this process is above 100 °C and the pressure inside the nozzle is also above 5 bar. The resulting structure has a meat-like characteristic due to a fibrous structure whose length is greater than 8 cm and in particular greater than 10 cm. The water content of this intermediate product is in the range of less than 50% by weight, in particular less than 30% by weight.

[0081] At the exit of the expansion die, a directly expanded texturate is formed, which is then rehydrated or rolled, as mentioned above, to loosen / open the fiber structures so that they are not too tight visually and sensorially. This also includes, among other things, a further pressing or rolling process that creates a tensile stress in a direction different from the direction of the tensile stress that acted on the texturate when the extrudate was pressed through the expansion die.

[0082] The type of tensile stress, i.e., longitudinal or transverse stress, can be determined by the nozzle geometry. This includes, among other things, the shape of the inlet cross-section, the shape of the outlet cross-section, and the transition thereto. Likewise, the sliding behavior is influenced by the choice or variation of the wall material (PTFE, ceramic, or stainless steel) as well as by variation of the design parameters listed in this application. In this way, the type and intensity of the tensile stress can be adjusted, allowing even protein mixtures that are otherwise difficult to produce to be textured.

[0083] The special expansion nozzle is characterized in that its inlet cross-sectional area is larger than an outlet cross-sectional area and a length is at least a factor of 1 and thus significantly larger than the inlet cross-section, or that a width and / or height of the inlet differs from a width and / or height of the outlet.

[0084] According to the proposed principle, the strain deformation mentioned above occurs either in a longitudinal direction, i.e. along the advance, or in a transverse direction, i.e. perpendicular to the advance. This is also referred to as longitudinal strain or transverse strain, whereby transverse strain can occur in two directions. A combination of such strains is possible and can be adjusted using the parameters mentioned above, including the wall material and nozzle geometry. The strain stresses occur, among other things, through sliding along the wall, so that little or no shear flow occurs. It is particularly important here that the viscosity of the extrudate should not be too low, since otherwise the required strains cannot be generated.

[0085] In this way, the continued elevated temperature, particularly above the evaporation temperature of water, and the existing pressure result in long, connected fibers resembling a meat structure due to continuous stretching and the resulting tensile stresses. The stretched extrudate leaves the die, resulting in a sudden drop in temperature and pressure in some aspects. Due to a not necessarily homogeneous distribution, the expansion leads to a localized, water-rich phase (also referred to as the soft phase), which creates the anisotropy according to the invention. Evaporation makes these water-rich, soft phases even looser.

[0086] During strain deformation, the flow velocity increases. During longitudinal strain, the flow velocity changes along the direction of advance, while during transverse strain it changes perpendicularly to this, i.e. the viscous mass is stretched in a direction transverse to the direction of advance. Since there are two mutually orthogonal transverse directions, it can be provided that during the application of strain stress, the flow velocity is increased in a first direction transverse to the direction of advance, while it remains the same or decreases in a second direction. In this way, the mass flow can be kept constant.

[0087] Accordingly, in some aspects, during the application of a tensile stress, the extrudate is stretched more along a first direction perpendicular to the advance direction than along the advance direction and a second direction perpendicular to the advance and first directions.

[0088] This elongation can be achieved, for example, by performing transverse elongation deformation at temperatures greater than 100 °C by advancing the extrudate, increasing the flow velocity in a direction perpendicular to the direction of advance. Alternatively or additionally, longitudinal elongation deformation can also be performed at temperatures greater than 100 °C by advancing the extrudate, increasing the flow velocity in a direction along the direction of advance.

[0089] It is also possible that a propulsion velocity is, at least in part, lower than a flow velocity in a direction perpendicular to the propulsion direction. This means, for example, that in some sections the mass is widened faster than it is propelled.

[0090] In some aspects the elongation can be influenced by coating the wall, reducing the diameter of the expansion nozzle or reducing the length to width. The mass flow remains essentially constant and, due to the high viscosity, also laminar. To avoid rupture due to the tensile stresses, it is advisable to keep the friction between the mass and the wall low so that the mass slides against it. By advancing the extrudate, the mass is stretched at temperatures above 100°C and in particular between 105°C and 115°C. At the end of this stretching, the temperature of the intermediate product is in some aspects still above 100°C, for example in the range between 110°C and 135°C. In special aspects it can even be above 130°C.

[0091] Longitudinal or transverse strain deformation can occur continuously or in sections. In the first case, for example, this is achieved by a continuous decrease in the cross-sectional area. In some aspects, instead of the cross-sectional area, a ratio of width to height at the inlet and outlet is used, with the ratio also changing. In particular, one of the two quantities decreases between the inlet and outlet. Thus, transverse flows and strains can also be deliberately generated in this way.

[0092] In the cases mentioned, this means that the flow velocity of the mass is increased in sections, followed by one or more sections in which the flow velocity is essentially constant. The increase in flow velocity can occur along or perpendicular to the direction of propulsion of the mass. Alternatively, the flow velocity can also be increased continuously, so that strain deformation occurs over a longer section, possibly even up to the outlet of the strain nozzle. In some aspects, a transverse flow velocity (i.e. perpendicular to the flow direction) is determined by the ratio of the width of the inlet to the width of the outlet. In some aspects, the nozzle can also be short, provided that primarily transverse strain stresses are generated.

[0093] In some aspects, the transverse tensile stress is generated by the tensile nozzle in that its entrance has an entrance area that is larger than an exit area of ​​an exit of the tensile nozzle. Tensile stress can be generated by an tensile nozzle that has a maximum entrance width and a maximum exit width, each in a first direction, and a maximum entrance height and a maximum exit height in a second direction perpendicular thereto, wherein a maximum exit width in the first direction is greater than the maximum entrance width in the first direction and / or the maximum entrance width in the second direction is smaller than the maximum exit width in the second direction.

[0094] In some aspects, it is possible for a distance of propulsion of the extrudate in which a tensile stress is applied to the extrudate substantially perpendicular to a propulsion direction to be less than or equal to a maximum distance along which the extrudate is strain-deformed. In some aspects, the time for which the extrudate is propelled in sections of constant flow velocity is greater than the time for which the mass is propelled at increasing flow velocity.

[0095] The inventor further proposes a protein-containing anisotropic texturate. This comprises a first protein mixture with a non-legume protein, in particular a wheat protein, with a proportion of between 10% by weight and 90% by weight and in particular between 20% by weight and 50% by weight based on the dry matter, a second protein mixture in particular with a legume protein or a side stream product with a proportion of between 10% by weight and 90% by weight and in particular between 20% by weight and 70% by weight and in particular between 20% by weight and 50% by weight based on the dry matter, wherein this second protein mixture is not based on soy. The texturate also has a moisture content in the range of less than 50% by weight and in particular less than 40% by weight.

[0096] According to the proposed principle, the texturate has a protein content of between 35% and 60% by weight of the dry matter and possesses a fibrous structure with a preferred direction and a fiber length of more than 10 mm and, in particular, more than 15 mm. Due to the fibrous structure, the texturate exhibits anisotropy.

[0097] In some aspects, the anisotropy index of the texturate, measured at a moisture content between 65% and 75%, is greater than 1.25, in particular greater than 1.4, and in particular between 1.5 and 2. The anisotropy index of the texturate is therefore in a range similar to that of meat. In some aspects, there is a maximum deviation of 10% from an anisotropy index of pork, in particular pork schnitzel, and beef such as certain beef steaks, so that these types of meat are therefore very well imitated.

[0098] In some aspects, the texturate is formed with a sidestream product, with a dry matter content of between 25% and 80% by weight, and more preferably between 30% and 75% by weight, and more preferably between 40% and 70% by weight. The sidestream product may be a sidestream product from plant-based milk production or beer production.

[0099] In some further aspects, the texturate comprises a third protein mixture, which is formed in particular by a sidestream product. In this respect, the texturate can thus comprise a wheat protein mixture, a pulse protein mixture (including soy, provided the proportion is small) and a sidestream product. Examples are listed above. Depending on the recipe, the proportion is between 5% and 70% by weight and in particular between 5% and 40% by weight and in particular between 40% and 70% by weight and in particular between 10% and 20% by weight.

[0100] In a further aspect, the moisture content is reduced and is in the range of less than 25% by weight and in particular less than 15% by weight. The texturate can also be further processed, e.g., marinated, deep-fried, boiled, smoked, or roasted. It is also possible to coat the texturate with an emulsion or breading, or to roll pieces of the texturate in it, in order to further approximate the haptic or visual properties, or even the sensory properties such as flavor, to existing meat products.

[0101] The emulsion or coating may contain flavorings, salt, sugar, natural flavorings, spices, including cayenne pepper, coriander seed powder, cumin powder, ginger powder, paprika powder, turmeric powder, cardamom powder, yeast extract, onion powder, tomato powder, honey powder, mustard, smoke flavoring, acid (citric acid), garlic powder, paprika extract, chili powder, acidity regulator (sodium acetates), parsley, and oregano. These may be mixed with syrup, fats, or oils to form an emulsion that coats the textured product and its pieces.

[0102] A further aspect relates to a processed texturate comprising a protein-containing texturate according to the proposed principle, wherein the processed texturate has a moisture content by hydration of between 40% by weight and 110% by weight, and in particular between 45% by weight and 70% by weight, and in particular more than 55% by weight.

[0103] In some other aspects, a gas is added during kneading, i.e. in the screw section of the extruder, in order to loosen up the dough and also the subsequent extrudate. The gas can be added in the screw section of the extruder at one point, for example in the initial area of ​​the extruder, but also at different points. In some aspects, the gas is added at a pressure that is later increased during extrusion, particularly in the screw section. This "dissolves" the gas in the material of the extrudate and remains bound in the material. Only during the later stretching deformation and particularly at the end when the texturate is discharged does the pressure decrease again, so that the gas contributes to loosening the extrudate. The gas used for this purpose can be carbon dioxide, nitrogen and in some cases even air.

[0104] In some cases, a gas-generating material can be added to the dough. This material decomposes during further processing, particularly during the kneading in the extruder, and thus contributes to gas formation. A typical such material is baking soda (sodium bicarbonate), which decomposes with citrates or other mild acids to form carbon dioxide. Both substances can be added to the basic mix initially as dry materials and only begin to react when water is added. If the water is added in the screw section of the extruder, premature escape of the gas is also prevented. In some applications, only baking soda is added, and during kneading, due to the high temperature, it decomposes back into carbon dioxide and sodium carbonate.

[0105] BRIEF DESCRIPTION OF THE DRAWINGS

[0106] Further aspects and embodiments according to the proposed principle will become apparent with reference to the various embodiments and examples described in detail in conjunction with the accompanying drawings. Figure 1 shows a mixing extruder as can be used for the proposed method for producing anisotropic textures according to the proposed principle;

[0107] Figures 2A to 2D each show an image of a textured article in pieces as produced by different aspects of the proposed method;

[0108] Figures 3A and 3B show two further designs of expansion nozzles according to the proposed principle;

[0109] Figures 4A to 4C show three further designs of expansion nozzles according to the proposed principle;

[0110] Figures 5A to 5E are embodiments of rollers as used in the method according to the invention;

[0111] Figures 6A to 6C are three embodiments of methods for producing a texture according to the proposed principle.

[0112] DETAILED DESCRIPTION

[0113] The following embodiments and examples show various aspects and their combinations according to the proposed principle. The embodiments and examples are not always true to scale. Likewise, various elements may be shown enlarged or reduced in size to emphasize individual aspects. It goes without saying that the individual aspects and features of the embodiments and examples shown in the figures can easily be combined with one another without thereby impairing the inventive principle.

[0114] Furthermore, the individual figures, features, and aspects are not necessarily shown in the correct size, and the proportions between the individual elements may not always be correct. Some aspects and features are emphasized by being shown enlarged. However, terms such as "top", "above", "below", "below", "larger", "smaller", and the like are correctly represented with reference to the elements in the figures. This makes it possible to infer such relationships between the elements from the illustrations.

[0115] Figure 1 shows part of an extruder arrangement such as can be used to carry out the proposed method and to produce texturates with greater anisotropy and fiber length. The extruder arrangement is designed with a mixing extruder 1 with a twin worm gear, in which the fed mass is kneaded by means of two worm gears and driven forward towards an outlet of the mixing extruder. For this purpose, the mixing extruder 1 comprises a motor with a gear 10, to which the two worm gears are anchored. Connected to this are several sections 11a, 11b, 11c, 11d and 11e of the mixing extruder.

[0116] The respective sections are mechanically sealed to one another via flanges or other means. In this way, the mixing extruder shown can be either lengthened by adding individual sections or shortened by removing them. The screw sections 12a, 12b, and 12c are designed in a similar manner, so that they too can be lengthened or shortened by adding or removing individual screw elements.

[0117] In particular, the mixing extruder 1 according to the proposed principle comprises two inlet sections 11a with associated screw elements 12b. The inlet sections 11a each have an opening for supplying the protein mixtures and the essentially dry substances as well as water. In detail, in the illustrated embodiment, the protein mixtures and other solid ingredients are fed via a hopper 14 into a first section 11a of the mixing extruder 1. Subsequently, the water is also added via an inlet 15, so that the two first extruder sections 11a primarily serve for initial mixing to form a dough from the water and the supplied basic mixture.

[0118] A number of further sections are connected to the first sections 11a

[0119] Sections 11b, 11c and 11d, in which partially different screw elements 12a are accommodated. As can be seen in the illustration in Figure 1, the screw elements serve on the one hand to propel the dough, but also to knead the dough while increasing

[0120] Pressure and temperature .

[0121] For this purpose, the individual sections are equipped with several heating elements (not shown here) which can be controlled separately and independently of one another. This means that different temperature profiles and thus different temperatures of the propelled dough can be set in the individual sections 11a to 11e. In a thermodynamic equilibrium, i.e. with slow propulsion or a slow temperature rise over a longer length, the material temperature of the dough is the same as the temperature of the individual sections. In addition, heat energy is added to the dough by kneading the material through the thermomechanical treatment, which leads to an increase in temperature. However, this energy contribution is usually too small to achieve the desired material temperature of more than 100 °C, so that additional heating elements are provided.

[0122] Furthermore, the individual screw elements in each section are designed differently. Some screw elements are used to knead the base mixture made up of the protein mixture(s), the added water and, if applicable, other ingredients, in order to produce a dough with a continuous phase. At the same time, the kneading and further forward movement of the added base mixture in these areas increases the pressure to between 8 and 70 bar. Other screw elements can also be provided with inlets for gases, which are used to add a gas to the dough during kneading to loosen it up. The added gas is bound by the pressure in the screw section of the extruder. The supply is controlled and at one or more points during kneading in order to achieve an even distribution of the gas throughout the dough.

[0123] With a simultaneous increase in temperature, or a high temperature, for example, in the range of 110 °C to 160 °C, and a pressure of several bar, polymerization of the protein mixture with the water and the other components occurs, resulting in a gel-like, highly viscous mass. This mass is kneaded in different ways by the individual screw elements 12a and propelled in small pieces to an exit section 11e of the mixing extruder 1.

[0124] The outlet section Ile of the mixing extruder 1 has a slightly conical shape on the outlet side with an ejection zone 13 to which an expansion nozzle 20 according to the proposed principle is connected either directly or via an intermediate piece. For reasons of clarity, however, this is only indicated but is additionally explained in the further figures 3A to 5C in some exemplary embodiments. The dough mass located in this outlet section is thus pressed under high pressure in the range of several bar, for example up to 25 bar, through the ejection zone as extrudate into the expansion nozzle and there is subjected to elongation deformation by uniform propulsion, so that anisotropy is created in the extrudate.

[0125] The expansion nozzle 20 comprises an expansion body 21 with an inlet region 23 and an outlet region 24. The inlet region 23 has a cross-section that is significantly larger than the cross-section of the outlet region 24. The cross-section is understood to be the sectional area when cutting through the nozzle in the inlet region or outlet region.

[0126] The shape of the input area 23 and also the output area 24 can be shaped in different ways, for example as shown in Figures 3A to 5C, circular, rectangular, slit-shaped, oval, but also round-ended or egg-shaped or elongated.

[0127] The inlet region 23 is connected either directly to the discharge zone of the mixing extruder 1 or via a tubular intermediate piece 30 to the discharge zone 13. In the present exemplary embodiment, the expansion nozzle comprises an inner region which is referred to as the expansion section 22 and is characterized by a cross-section which continuously tapers at the same gradient over the length L of the expansion nozzle. In other words, the diameter (or radius) Ri and the respective area in the inlet region 23 are continuously reduced over the length of the expansion nozzle down to the cross-section R2 and the respective area of ​​the outlet section 24. In the cross-sectional view of the nozzle 20 shown here, the tapered part thus forms a parallelogram with the two parallel sides corresponding to the inlet section 23 and the outlet section 24.Viewed three-dimensionally, it is a truncated cone, with the respective base and end surfaces being circular with a conical inlet, as shown.

[0128] The length L of the expansion nozzle is at least 6 to 12 times the diameter Ri in the inlet area. Due to the tapered cross-section here, the flow velocity of the extrudate is continuously increased at a constant mass flow rate as it advances through the expansion nozzle 20. In the exemplary embodiment, the flow velocity also increases uniformly due to the uniformly decreasing cross-section.

[0129] To achieve a constant mass flow, this means that the flow velocity depends on the radius of the inlet and outlet areas, or rather on their respective areas. For example, if the inlet area has an area three times larger than the area of ​​the outlet area, the flow velocity in the outlet area must also be increased by a factor of three to ensure the same mass flow.

[0130] Due to the increasing flow velocity, the extruded extrudate is stretched axially, i.e. parallel to the extension in the direction of advance. As a result, with the continued high pressure of more than 7 bar and the high temperature in the expansion nozzle in the range of more than 100 °C, elongated fiber structures form and anisotropy develops. The uniform taper, which can be controlled in particular by adjusting the length of the expansion nozzle as well as the inlet and outlet cross sections, prevents wall slippage and shear stress, which could lead to tearing of the extruded extrudate. In a further aspect, the coating on the inside of the expansion nozzle can also be provided with a material that has low static or sliding friction, possibly lower than normally used stainless steel.In addition to this, which is used in food production, among other applications, a plastic such as Teflon is also being considered. This material is particularly low-friction, so the extruded material experiences greatly reduced or almost nonexistent shear stress at the edge. This creates long fibers along the extruded material's direction of travel.

[0131] Depending on the proteins used and the base mixture for the extrudate, different elongation stresses are necessary to prevent material breakage. It may also be necessary to allow the extruded extrudate to "rest" for a while after elongation so that the fibers can align. Accordingly, the elongation dies can also be designed differently with multiple sections. Figures 3A and 3B show two such embodiments, in which the elongation die is formed from various rest sections and sections with elongation deformation.

[0132] At the outlet 24 of the expansion nozzle 20, the extrudate leaves the nozzle as a texturized material. The texturized material exits the nozzle, causing a temperature reduction, possibly also with a further pressure loss. This can result in any existing steam condensing back into the texturized material, but depending on the temperature, a portion of the water can also evaporate, so that the heat of vaporization causes the texturized material to cool more quickly.

[0133] The water content in the texturate after exit and a first cooling to temperatures below 100 ° C , e.g. below 70 ° C , is less than 40 % by weight and in particular less than 30 % by weight , so that it is referred to as a dry or semi-moist texturate .

[0134] The possible pressure loss and the falling temperature (the expansion nozzle would be heated or at least at a temperature close to or above 100 °C) can, depending on the feed mixture, i.e. depending on the pulse protein mixture used, lead to a slight pore formation due to a so-called "flash expansion" of the re-condensing water vapor in the texturate. For this reason, a cylinder or roller 3 is connected downstream of the expansion nozzle 20, which compresses the texturate again in order to collapse the resulting pores and further increase the existing anisotropy.

[0135] This increases the fiber length or stabilizes the orientation and length of the fibers already formed by the stretching nozzle. Depending on the protein used and the design of the extrudate parameters and the stretching nozzle, the strength of the anisotropy, the anisotropy index, and the fiber length can be adjusted. This allows compact fibrous textures with a fiber length of more than 10 cm to be produced.

[0136] In the present embodiment, the roller and roll assembly 3 additionally comprises heating elements (not yet shown) to enable the temperature of the textured material to be controlled even during the rolling process. The roll can be designed as a single or double roll in the form of a simple smooth roll, but also as a corrugated roll, needle roll, or forming roll. If necessary, a multi-stage rolling process with gradual gap reduction can lead to the desired result.

[0137] The rolling or pressing process is designed so that additional stretching forces are exerted on the textured material. Stretching forces from the rollers or rolls can also point in a different, particularly orthogonal, direction compared to the stretching stresses in the stretching nozzle. Put simply, the textured material is slightly stretched transversely and axially in the roller 3. This can be achieved, for example, by increasing the shear forces orthogonal to the transport direction.

[0138] In addition to the rolling process described here, the textured material can also be rolled, tapped, or pressed. All of these mechanical measures generate additional shear forces on the textured material which, when suitably designed, point in a different direction, i.e., in particular, orthogonal to the tensile stresses previously exerted in the direction of advance. In contrast to conventional solutions, however, in the solution presented here the respective forces are exerted on the textured material at different times, temperatures, and pressures, thus achieving better control and increasing the stabilization of an already imposed anisotropy.

[0139] After cutting in a corresponding machine 5, the resulting product 4 essentially comprises strip-shaped pieces of equal length. The cut strips have, in some aspects, a length which essentially corresponds to the length of the fibers of the textured material and, in addition, have a pronounced anisotropy of greater than 1. The anisotropy is measured with a texture analyzer, e.g. with a TA (XTPLUSC CONNECT TEXTURE ANALYZER from Winopal) using a fixed cutting blade (e.g. LIGHT KNIFE BLADE A / LKB from Winopal).

[0140] The anisotropy is greater the more the fibrous structure is aligned in a preferred direction. In particular, the anisotropy can be adapted to the anisotropy of existing meat products, resulting in the same or very similar mouthfeel and bite sensation for the consumer.

[0141] In a further aspect, further air drying is performed by a corresponding air dryer 6, so that the total water content in the texturate 4 is further reduced. At the end of the process, the total water content in the texturate is less than 25% by weight, but in particular also less than 15% by weight. The now air-dried texturate can now be packaged and further processed.

[0142] In an alternative embodiment, the extruder arrangement also comprises a deep fryer or an atomizer in which the air-dried texturate can be fried or dusted. This dusting with a powder, or also the coating with an emulsion layer in device number 7, can take place both during air drying and afterwards. It is also possible to roll the texturate pieces in a powder or emulsion in a roller drum and coat them in this way. In the extruder arrangement in Figure 1, the individual components 3, 5, 6 and 7 can also be combined or swapped with one another in order to produce a certain consistency, appearance and shape for the desired end product 8. It is thus possible to add additional colorants during the drying step in order to change the color of the texturate. In addition, smoke flavorings or the like can also be added.

[0143] After the outlet 24 of the stretching nozzle 20 or after rolling in the roller arrangement 3, the texturate 4 comprises an average fiber length that lies in the range between 15 cm and 25 cm. The maximum fiber length, however, is significantly longer and amounts to up to 30 cm. In addition, the distribution of the individual lengths can be changed and adapted to the desired end products by suitable measures. In particular, it is possible to reduce the standard deviation with regard to the fiber length to 1.5 cm to 2.5 cm, so that the fibers are essentially the same length or have a narrow distribution.

[0144] Figures 2A to 2D show the results of such a process using the proposed method. Figures 2A and 2B are texturates with a wheat protein of approximately 55%, a faba protein of 35% by weight, and sugar of 10% by weight, each based on the dry matter. Figure 2A shows the texturate after rolling, cutting, and frying. It exhibits a high visual similarity to beef. The mouthfeel and firmness are also similar to beef products. Figure 2B shows the texturate after rolling but before cutting and frying.

[0145] In both embodiments, the meat-like anisotropic structure and consistency are clearly visible. Furthermore, the textured piece in Figure 2B has been slightly stretched to reveal the fibrous longitudinal structure, which has an average length of more than 6 cm. The fibers are formed along the textured piece, an aspect caused by the stretching of the extrudate at the high temperature in the stretching die. The meat-like structure in the textured piece obtained in this way is rolled by the rollers 3 so that the anisotropy is reinforced and stabilized. The product can then be converted into the final product by further measures such as air-drying, deep-frying, or similar.

[0146] Figures 2D and 2E show a texturate made from an oat milk side stream with more than 50% by weight, a wheat protein with 30% by weight, and a pea protein with 20% by weight, each based on dry matter. The texturate is hydrated and then fried (Figure 2D); Figure 2E shows the product after rolling but before hydration and frying.

[0147] Hydration loosens the texture and clearly reveals the fibrous structure. The bevels are longitudinal and essentially correspond to the size of the pieces. The cut edge runs perpendicular to the orientation of the fibers. The pieces are also rolled to open the fibers as shown. The rolling direction is parallel to the direction of advance (e.g., from right to left in Figure 2C), i.e., also along the cut edges.

[0148] Figure 3A shows an embodiment of an expansion nozzle 20 with a nozzle body 21, which has a round inlet area 23 on the inlet side and a correspondingly round outlet cross-section 24 on the outlet side. In this embodiment, the diameter Ri of the inlet cross-section is approximately four times as large as the diameter R2 of the outlet cross-section 23. This results in the area of ​​the inlet section being given by Ri 2 n = ( 8R2 ) 2 n is therefore approximately 16 times the area of ​​the outlet section. It follows that the flow velocity at the outlet must also be approximately 16 times that at the inlet of the expansion nozzle in order to ensure the same mass flow.

[0149] The expansion nozzle of Figure 3A comprises several sections in its interior region. On the inlet side, a first section 25d is provided which is essentially cylindrical and in which the inlet cross section remains constant over the length of section 25d. Connected to this is a first expansion section 25a, in which the inlet cross section Ri is reduced to an outlet cross section R3. In this first expansion section, the flow velocity thus increases while the mass flow remains constant, and the extruded extrudate is subjected to a first expansion stress. The area in the inlet region of the first expansion section is approximately M the area of ​​the inlet region 23; the flow velocity will therefore accelerate fourfold.

[0150] Subsequently, the extrudate, which has been stretched in this way, is advanced over a second cylindrical section 25c. In this section, the diameter and thus also the cross-sectional area and thus the flow velocity are again constant, so that the extrudate undergoes a certain rest phase during the advance.

[0151] Connected to this is a second expansion section 25a, in which the inlet side area of ​​cross section R3 is reduced again to the outlet side area of ​​cross section R4. This reduction is somewhat smaller, so that the flow velocity does not increase as much as in the first expansion section, but only by twice as much, for example. Also connected to this is a further rest section 25c, which in turn is followed by a final expansion section 25a. In this, the inlet side area of ​​cross section R4 is now narrowed to the outlet side area of ​​cross section R2, and the flow velocity increases again slightly while the mass flow remains the same.

[0152] On the outlet side, a further rest section 25e of the expansion nozzle 20 is arranged, in which the extruded, stretch-formed material is extruded again. Section 25e forms the end section, at whose outlet 24 the now produced textured material exits the nozzle.

[0153] The expansion sections 25a present here are each designed with a different gradient, with the first expansion section on the left having the greatest reduction in cross-sectional area (from Ri to R3). Accordingly, the flow velocity increases particularly sharply here, while it increases somewhat less in the following expansion sections (e.g. by a factor of 4 in the first expansion section, and then by twice as much in each case). The different sections 25d, 25c and the exit section 25e primarily serve to ensure that the extruded extrudate can rest between the individual expansion sections and that no further expansion stress is exerted on it.

[0154] In this context, it may be advisable to coat the inside of the expansion sections with a suitable material to further reduce friction and adhesion of the extrudate to the inside of the expansion sections. This further reduces potential shear forces, particularly in the area of ​​the tapered sections, so that the extruded extrudate is only subjected to the tensile stress due to the decreasing cross-section.

[0155] Figure 3B shows a further embodiment of such an arrangement in which the expansion sections are significantly longer than the rest sections, in contrast to the embodiment in Figure 3A. In the embodiment, the inlet region 23 and also the outlet region 24 of the expansion nozzle are no longer circular, but rectangular. However, other inlet cross-sectional shapes and outlet cross-sectional shapes are also possible in this context; moreover, the shape of the inlet cross-section can also be selected to be different from the shape of the outlet cross-section, so that during the expansion sections or also the rest sections the shape changes accordingly. This change is designed in such a way that as little shear force as possible is exerted on the extrudate as a result of the change in shape as it is being pushed forward, but rather the extrudate is mainly subjected to expansion deformation.

[0156] The inlet section 25d of the expansion nozzle 20 in Figure 3B is followed by a conically tapered and narrowing first expansion section 25b. In this section, the outlet diameter R3 is approximately one third as large as the inlet diameter Ri. The first expansion section 25b is designed with a continuous taper in the direction of the outlet region 24 and has a length LI that is greater than the first rest section 25d in the inlet region of the expansion nozzle and also a second rest region 25c adjoining the outlet of the first expansion section. This second rest region 25c is short, with only one fifth to one quarter of the length of the expansion section 25b and then merges into a second, shorter expansion section 25b. On the outlet side, this expansion is in turn connected to a further rest section 25e, which simultaneously forms the outlet region 24.

[0157] Figures 4A to 4C address a further aspect, namely that the inlet cross-section does not reduce uniformly (albeit in sections), but the inlet reduces in one preferred direction, whilst in the other direction it actually increases in size relative to the outlet. Figure 4A shows an embodiment in this regard in which the inlet 23 with its area A1 relative to the outlet region 24 with its area A2 remains essentially the same, but its shape is changed. In particular, a square inlet region is provided in Figure 4A. By constantly reducing the height and simultaneously widening the width, this results in an elongated, narrow transverse slot in the outlet region 24 which is approximately twice as wide as the inlet. Its height has, however, reduced by more than half.

[0158] The expansion nozzle therefore leads to a decreasing height / width ratio over the length of the expansion nozzle. For example, the width can increase by a factor of 3 while the height H decreases by the same factor. However, other factors are also possible in this context, whereby the cross-sectional area of ​​the outlet region 24 also decreases compared to the inlet region 23. In the present example in Figure 4A, the height of the nozzle at the outlet decreases significantly more than the width increases. As a result, the overall area of ​​the outlet is smaller than the cross-sectional area at the inlet. Accordingly, in this exemplary embodiment, there is not only a transverse flow velocity and thus an expansion of the mass perpendicular to the forward direction, but also a longitudinal expansion.

[0159] Figures 4B and 4C show two further designs, this time with round and oval inlet cross-sections, respectively. While in Figure 4B this oval shape in the inlet area 23 is transformed into a rectangular shape with clear corners in the outlet 24, in Figure 4C the edges are rounded and thus retain at least roughly the same shape as in the inlet area 23. In the design in Figure 4B the areas of the inlet and the outlet are the same, so that here only a transverse flow occurs, but no or only a very slight longitudinal flow. Accordingly, the extrudate is deformed primarily transversely to the direction of advance. In Figure 4C the areas are again different, so that here too, in addition to a transverse stretching of the extrudate, a longitudinal stretching is also generated.

[0160] In all of these arrangements, a decrease or change occurs along a first direction (e.g. width of the nozzle) perpendicular to the direction of advance and differently along a second direction perpendicular to the direction of advance (e.g. height H). Accordingly, the unequal decrease in the two different spatial directions not only causes longitudinal expansion, i.e. along the length of the expansion nozzle, but also transverse expansion, i.e. along the width B or the height H. The transverse expansions are in turn different due to the different heights and widths. This design makes it possible to bring about longitudinal as well as transverse expansion in the extrudate in a targeted manner, the intensity of which is controlled by the geometry of the expansion nozzle.

[0161] Figure 5 shows an embodiment of a roller and roll arrangement 3, each with two belt rollers 31, 32. Each belt roller comprises a roller belt 300 and several rollers 310 and 311 provided for driving the roller belt. The diameter of the rollers 310 and 311 is designed to be the same size, so that the belts running on them are stretched essentially flat.

[0162] However, the belt roller 32 is planar, i.e. approximately parallel to the direction of ejection of the texturate, and the belt roller 31, in contrast, is provided with an incline. In this respect, the planar belt roller 32 can also be used as a transport means and can be extended accordingly, so that the texturate coming from the ejection nozzle is transported along the belt roller 32 to the start of the second upper roller belt. This results in a gap between the two belt rollers 31 and 32 that decreases in the forward direction with the second belt roller 31. This means that the texturate is pressed more and more strongly with further advance, with the increase occurring gradually. This results in both an axial or longitudinal stretching, i.e. a stretching in the advance direction and a stretching in the direction perpendicular to this, in which the texturate can at least partially escape. Shear forces can also occur here.

[0163] In addition, some rollers 311 are provided with a temperature control device, so that the propelled mass can be subjected to additional heating or cooling in successive steps. This allows for an additional degree of freedom, allowing the temperature of the propelled mass to be adjusted during the amplification and stabilization of the anisotropy and also during deformation.

[0164] In addition, the individual rollers 310 and 311 are designed with an additional toothed ring which engages with the corresponding roller belts 300. This enables an intimate connection and prevents slipping on the individual rollers when pressure is exerted on the mass 40. By using several rollers 310, 311 per roller belt 300, i.e. more than two, continuous pressure can also be exerted on the propelled mass along the entire propulsion path. This is particularly useful if the overall propulsion path is somewhat longer or if the roller belt itself is designed to be elastic. In addition, the inclination of the upper belt roller 32 is adjustable. By designing and arranging the individual rollers and the roller belts relative to one another, a defined pressure can be exerted on the texturate in order to achieve the desired anisotropy and fiber length.

[0165] In contrast to the ejection nozzle 20, where static friction and thus the buildup of potential shear stress should be low, static friction is deliberately created between the roller belts 300 and the advancing material in the roller arrangement in order to reliably transport the texturized material despite deformation and counterpressure. The rollers usually comprise Teflon or a polymer with very low adhesion. This allows an existing anisotropy to be intensified and / or generated in the form of gel fracture and thus layer formation.

[0166] Figure 6 shows a further combination of a roller and roll arrangement in which different belt rollers 31, 32 and 32' are used. The lower planar belt roller 31 comprises a roller belt 300' which is provided with a surface structuring which is impressed onto the surface of the textured material as it is pushed forward over the roller arrangement. The two upper belt rollers 32, 32' in this exemplary embodiment comprise a plurality of rollers 313 with a smaller diameter than the rollers 310 of the belt roller 31. In addition, one of the two belt rollers 32, 32' is arranged parallel to the belt roller 31 so that the distance between them does not change or changes only insignificantly during the push. This does cause propulsion, but without further significant deformation, so that this section can also be referred to as a rest section.It serves to stabilize an imposed anisotropy and freezes the length of the fibers by largely preventing relaxation.

[0167] The second belt roller 32' is again inclined relative to the lower belt roller 31, so that a wider inlet zone and a narrower outlet zone are formed, the distance between which corresponds to the distance between the belt roller 32 and the belt roller 31. Furthermore, it is also possible to provide individual rollers with different diameters in order to thereby reduce the thickness of the propelled mass.

[0168] Figures 5C and 5D show two further embodiments of a belt roller. In the embodiment of Figure 5C, a roller belt 300 is provided, on which the textured material lies and is moved forward by it. Several individual rollers or cylinders 310 (three shown here, but there can also be more or fewer) with the same diameters are arranged above the roller belt 300. The distance of the individual rollers 310 to the roller belt is the same, but it can also change and become smaller with further advance. The roller belt 300 has a relatively high

[0169] Friction, the rollers, on the other hand, are made of Teflon or another material with low friction. It is also possible to change the diameter of the individual rollers and cylinders 310 in order to vary the distance. The rotation speed is adapted to the speed of the belt. This exerts a stretch on the texturate being passed through, so that the fibers of the texturate are stretched and aligned along the direction of advance. This increases the anisotropy. By using multiple rollers, the fiber length can be adjusted and stabilized.

[0170] Figure 5D shows a further embodiment in which several belts 300 are provided to transport the textured material forward. Between the belts are two parallel rollers 310, the distance between which decreases after each pass. The textured material is rolled between the two rollers and thus stretched in the longitudinal direction.

[0171] Figure 5E shows further embodiments, in which the rollers are arranged vertically, so that the textured pieces are moved downward between them and a stationary area. Here, too, the distance between the roller and the stationary wall decreases with each pass. In the other embodiment, it is similar, but the textured material is transported downward by two opposing pairs of rollers 310.

[0172] Figure 4D shows a modification. Here, too, the textured material is driven by a roller belt. However, the deformation is achieved by pairs of opposing rollers 310, which are spaced a defined distance apart. A further belt is arranged between two pairs. Here, too, the rotation speeds of the rollers are adapted to those of the belts.

[0173] If the texturate has a lower viscosity, it is advisable to taper the cross-section over a longer distance and thus subject the exhibit to only low tensile stresses so that the extruded dough does not tear off and lead, for example, to wall slippage or warping. Matrices made from dough with a higher viscosity, on the other hand, can be stretched to a greater extent without wall slippage occurring. Accordingly, shorter stretching sections or stretching sections with a greater taper could be provided here so that the flow velocity is increased while the mass flow remains the same. Rest sections between individual stretching sections serve to relax the extruded dough somewhat and thus prevent the dough from tearing off and the production of shorter fibers.

[0174] In some aspects, the material should be output as a texturate, whereby the texturate as a single strand should only have a small volume at each exit. This is particularly the case when the material tears with too large a volume and corresponding tensile stress, thus leading to wall slippage or warping. This can occur if the tensile deformation is large at the edge of the stretching nozzle, but is still too small inside the propelled dough mass. With the laminar flows present here, shear forces can occur particularly in the interior, which impair long fiber formation.

[0175] Figure 6A shows a first embodiment of the proposed method. In step S1, a protein mixture is provided. This comprises a protein isolate from wheat and a protein isolate from pea protein. The proportion of proteins in the respective isolates is approximately 85% by weight based on the dry mass, with a residual moisture content in the range of approximately 5% by weight and other components. In this embodiment, plant fibers are hardly present in the isolates. The two isolates are mixed in a ratio of 80% wheat protein to 20% pea protein. This mixture corresponds to approximately 60% of the basic mixture, resulting in a dry mass of 0.95 * 0.6 = 57% in the basic mixture. The pure protein content in the basic mixture is again 0.85 * 0.6 = 51%. In step S2, water is now added to the basic mixture, namely 35% based on the total mass of the basic mixture.This results in a total moisture content of 0.6*0.05+0.35 = 38%. The base mix thus comprises 38% moisture by weight and 51% pure protein by weight. The remaining portion of approximately 11% by weight is divided among the other components of the protein isolate, i.e., sugar, salts, and oils. In addition, some flavorings, starch, and oils are added, amounting to around 5% dry matter by weight, based on the mass of the base mix.

[0176] The resulting dough is then kneaded in an extruder under pressure and at elevated temperature in step S3. The dough is kneaded in sections and then extruded slightly. In the first sections, the temperature is rapidly increased from room temperature to over 100 °C, and then maintained at around 135 °C for the remaining kneading and extrusion steps.

[0177] In the discharge zone of the mixing extruder, the mass is transferred directly into an expansion die. The expansion die comprises a short inlet section, in which the cross-section remains essentially constant, an elongated expansion section, and an outlet section.

[0178] In this embodiment, in step S4 the extrudate is subjected to longitudinal stretching at a temperature of approximately 125°C, the stress of which results from a continuous reduction in the area of ​​the inlet cross-section to the area of ​​the outlet cross-section. The area of ​​the inlet cross-section is 8 times larger than the area of ​​the outlet cross-section. The stretching takes place over a distance which is 5 to 6 times larger than the maximum diameter of the inlet cross-section. Therefore, due to the constant mass flow, the flow velocity over this distance also changes by a factor of 8, as a result of which the dough is stretched primarily lengthwise. In the middle section of the stretching nozzle, the static friction is reduced by a suitable coating, so that the resulting texture does not get stuck and no major shear forces occur that could lead to wall slippage or breakage of the dough.

[0179] The axial and longitudinal stretching structures the extrudate, forming longitudinal fibers with an average length of between 10 mm and 20 mm. This also leads to anisotropy, as the fibers have a preferred direction. The temperature does not change significantly during the stretching process, i.e. the texturized material has a temperature of approximately 125 °C at the end of the stretching die. At the die outlet, the trapped water recondenses, resulting in rapid cooling. At the same time, the fibrous structure created is not destroyed.

[0180] In step S5, the still warm and moist texturate is rolled using a roller that generates tensile stress in the direction of advance, so that the existing anisotropy is reinforced and the fiber length increases even further. At the same time, the strength of the texturate is reduced by the pressing and rolling process because, in addition to the tensile stress, a shear stress is also generated orthogonal to the direction of advance or transport of the texturate. The temperature here is approximately 55 °C to 70 °C. The rolled product is then cut into smaller pieces in step S6, resulting in texturate pieces 5 cm to 10 cm long whose fibrous structure extends over the entire length of the piece.

[0181] In step S7, the pieces produced in this way are placed in a herb, salt, and spice mixture to form a thin coating resembling marinated pork or beef. This mixture can contain appropriate flavorings. It also increases shelf life and flavor. The remaining moisture can be used to adhere this mixture. Alternatively, the textured pieces can be sprayed beforehand, for example, with an oil-water mixture, a sugar- or starch-containing liquid, a marinade, or something similar, to improve adhesion.

[0182] In another process example, shown in Figure 6B, a wheat protein isolate is used, with a proportion of approximately 25% of the basic mixture (without water), whereby the protein proportion is approximately 92% by weight of the dry matter. The remainder consists of other substances and a small residual moisture content of 3%. In addition, an oat milk side stream product is used in this embodiment, the pure moisture content of which is approximately 50%. The remaining 50% by weight corresponds to the dry matter, whereby the protein proportion in the dry matter is approximately 45% by weight. The remaining components of the dry matter are sugar, oils and fats, but above all also dietary fiber. The sugar component is approximately 18% by weight for this side stream product. For the basic mixture, these two components are then mixed in a ratio of 75% oat milk side stream to 25% wheat protein mixture.

[0183] The resulting base mix then has a total water content of 0.75*0.5+0.25*0.03=38%. The remaining ingredients in the base mix account for 62% by weight of the base mix (corresponding to the dry matter of the base mix), with the protein content of the dry matter being: 0.45*0.5*0.75+0.92*0.25 = approximately 40%. It has been shown that further addition of water is unnecessary here, and instead, the sidestream product can be used directly and immediately.

[0184] The mixture prepared in step S1 is then blended into a dough in step S2 and fed into an extruder. The subsequent steps S3 and S4, in particular kneading into a dough and extruding through a die, are carried out at various pressures and temperatures to obtain a longitudinally fibrous structure. For this purpose, a die according to the embodiment shown in Figure 3B is used, the length of which is approximately five times greater than the initial cross-section.

[0185] After leaving the nozzle, the texturate is first cooled and then, in step S5', cut into elongated pieces more than 60 mm long and approximately 25 mm wide. The thickness of these pieces is approximately 1.5 cm. In step S6', the pieces are placed in a roller arrangement as shown in Figure 5D, where their thickness is reduced to approximately 1 cm in several pressing and rolling steps. At the same time, the pieces are slightly stretched so that their length is now more than 70 mm. The rolling and pressing process makes the texturate less firm and greater anisotropy develops in the longitudinal direction, with the fiber length roughly corresponding to the length of the pieces. Subsequently, in step S7', the pieces are hydrated so that their water content is approximately 60% and then seasoned. Their consistency and mouthfeel roughly correspond to pork with an anisotropy index value of approximately 1.35 to 1.5.

[0186] In the following , further recipes are presented which can be textured by combining the various elements , in particular by adapting the exit nozzle with a suitable downstream roller arrangement into texturates with an anisotropy greater than 1 and elongated fibers in a wide range of adjustable lengths .

[0187] Example group 1

[0188] In a first example, a protein mixture based on wheat protein is combined with a pulse protein mixture. Peas or broad beans were used as the pulses, with the proportion of pure pulse protein being lower than that of pure wheat protein. The respective mixtures are either concentrates or isolates, so they each contain a certain proportion of carbohydrates, starch, and various sugars. In addition, salts and oils or fats are also components of the mixtures.

[0189] Additional flavorings are added to adjust the taste. The mixtures are blended with water to produce a dough with a total moisture content between 35% and 50% by weight.

[0190] The material temperature in the extruder during extrusion ranges between 130 °C and 145 °C, although higher material temperatures of up to 160 °C are also possible. At the extruder outlet, the extrudate is directly subjected to axial and transverse tensile stress. This is achieved by an expansion die whose square cross-section tapers along its length and features an elongated slit at the outlet. The outlet temperature is approximately 100 °C at the outlet of the expansion die.

[0191] The finished textured material already possesses a pronounced anisotropy in the longitudinal direction due to the axial stretching. It has been determined that an average fiber length in the textured material can be adjusted within a certain range by adjusting or changing the propulsion speed. Overall, fiber lengths from over 20 mm up to a length of approximately 200 mm are achievable.

[0192] Example group 2

[0193] In a second example group, a protein mixture based on wheat protein is combined with a pea protein mixture. In this embodiment, however, the proportion of pure pea protein is in the range of that of pure wheat protein or even exceeds it. Here, too, the respective mixtures comprise concentrates or isolates, with proportions of carbohydrates, starch and various sugars in the range of 10% to 20% by weight, as well as salt in the range of 3% by weight and oils and fats between 3% and 10% by weight. No further flavorings were added. Because of the slightly changed protein mixtures, the total amount of water added also changes. However, the total moisture content of the dough is in the range of 25% to 45% by weight.

[0194] The resulting dough is kneaded and extruded in an extruder at increasing temperatures up to a material temperature of between 120 ° C and 150 ° C. At the extruder outlet, a dilatation die is arranged, the inlet cross-section of which tapers along its length to a slot perpendicular to the forward direction. The temperature at the outlet of the dilatation die is over 100 ° C.

[0195] The texturate emerging at the outlet cools down quickly due to evaporation and recondensation. As water and moisture evaporate, the water content of the texturate continues to decrease, so that when cooled it is less than 40% by weight. The texturate is cut while warm into oblong pieces that are approximately 5 cm wide and 15 to 20 cm long. These pieces are then rolled again while warm at approx. 50 °C to 60 °C so that the elongated fiber structure and thus the existing anisotropy and strength adapt. The average fiber length is between 8 cm and 15 cm and is therefore somewhat shorter than the length of the individual pieces. Due to the additional rolling, the anisotropy index is somewhat less than 2, i.e. the force applied to cut the pieces across the fiber direction is significantly greater than the force along the fiber direction.

[0196] Example group 3

[0197] A third example group also uses a protein mixture based on wheat protein. However, this is combined with a sidestream product that arises during the production of oat milk. In addition to proteins, the oat milk sidestream also contains other components such as sugar and starch, or carbohydrates and salts.

[0198] In this embodiment, the side stream is also aqueous, i.e., its water content is in the range of 50% to 70% by weight. This means that no additional water needs to be added to prepare the dough and the base mix. Instead, "dry" wheat protein is added until the water or moisture content is in the desired range in the example group, between 35% and 47%.

[0199] The direct use of sidestream products reduces process costs because they do not require energy-intensive dewatering. Transportation costs can also be reduced accordingly. In this case, sugar and other ingredients are already included, so they no longer need to be added.

[0200] The dry content of the oat milk side stream is between 10% and 90% by weight, in this example between approximately 40% and 70% by weight, with the pure protein content in turn being between 40% and 80%.

[0201] The dough is extruded in an extruder at material temperatures between 110°C and 160°C, and in particular between 130°C and 150°C. The extrudate is then forced through a die, although due to a slightly modified die geometry and the boundary conditions, only a slightly pronounced anisotropy occurs. For this reason, a belt roller with several rollers is arranged downstream of the die outlet. The vertical distance between the roller belt and the individual rollers decreases slightly over the lateral transport section, so that the extrudate is slightly compressed with each pass and stretched due to the continuous transport.

[0202] It has been shown in this group of examples that the shape, number and speed of the rollers can not only enhance texture but also create it in an extrudate. This effect can be observed in all example groups, with the roller devices shown in this application reinforcing, stabilising or even creating an existing anisotropy depending on the extrudate composition. It has also been shown that subsequent rolling reduces the strength of the fibrous anisotropic texturate. This not only slightly enhances the anisotropy but also results in a better mouthfeel more similar to pork or beef.

[0203] Example group 4

[0204] A further variation of example group 3 involves combining several different protein mixtures with additional side stream products. For example, a wheat protein mixture can be blended with a field bean or pea protein mixture, with another side stream product being added. The side stream product can have the largest proportion of the total dry matter, for example in the range between 40% and 70% by weight. In this case, the proportion of the wheat protein mixture and the other pulse protein mixture is lower and is, for example, between 10% and 50% by weight of the dry matter.

[0205] In the experiments for these examples, it was determined that it is possible to directly use various sidestream products and combine them with different protein mixtures, which can be present as isolates or concentrates. The individual amounts of pure protein can vary depending on the ingredients, so that different haptic, olfactory, and sensory properties can be achieved. However, the overall protein content is selected so that it lies between 40% and 70% by weight of the dry matter in the base mixture and thus also in the texturate.

[0206] The mixture, which also contains salt components, is extruded in an extruder at a material temperature of approximately 130 °C to approximately 150 °C. A wider temperature range of 110 °C to 160 °C is possible. The extrudate is then pressed through an expansion die, the cross-section of which tapers rapidly over a shorter length (i.e. approximately 3 to 4 times the cross-section). To reduce sliding or static friction, the inside of the die is coated with Teflon. The emerging strand of the slightly anisotropic texturate is rolled several times and thus formed into a transverse and longitudinal strip approximately 5 mm thick and several cm wide.

[0207] It is then cut and dried until the water content is approximately 30%. The resulting pieces are approximately 5 to 7.5 mm thick and have a width of approximately 5 to 7.5 cm and a length of up to 10 cm. They have a chip-like structure in terms of their fiber orientation and fiber length.

[0208] Example group 5

[0209] In the last example group, a beer leavener is used as an additional source of proteins and other ingredients instead of an oat milk side stream. The proportion of the beer leavener is lower than the proportion of at least one of the other proteins and is, for example, between 5% by weight and 40% by weight based on the dry matter of the base mix, in particular between 10% by weight and 20% by weight. Further protein sources in this example group are both a pulse protein mix and a wheat protein mix. The beer leavener has a reduced moisture content of less than 20%, so that additional water is added to the base mix until the total moisture content is between 25% by weight and 55% by weight, in particular below 50% by weight, e.g. between 35% by weight and 47% by weight. Processing takes place in the temperature ranges mentioned above.Depending on the amount of beer driver, a varying degree of anisotropy forms at the outlet of a normal stretching nozzle, as described here. The anisotropy and also the fiber length seem to decrease the larger the amount of beer driver. However, a downstream rolling step increases the anisotropy, reduces the strength and increases the fiber length to at least double. For this purpose, the texturate is passed through several rollers arranged one behind the other. The rotation speed of these rollers is not too high, so that a longitudinal stretch is exerted on the texturate over a longer distance.

[0210] In the various group examples, the protein contents are present in varying amounts. For each example, several tests were carried out, which are shown in the table below. Surprisingly, it has been found that, in addition to isolates and concentrates, flours, i.e. protein mixtures with even lower protein contents, i.e. less than 60% based on the dry matter, can be produced in the desired shape and fiber length. This aspect makes it possible to produce meat-like anisotropic texturates and products with long, aligned fibers and a water content of less than 40% of the total mass. Nevertheless, the protein content can be adjusted over a wide range, e.g. up to 60% by weight based on the dry matter and beyond, whereby the texturate retains many of its sensory properties.

[0211] The potential use of sidestream products, whose protein content often fluctuates or is lower than in concentrates, allows for more cost-effective production. The proposed downstream rolling step not only enhances existing anisotropy, but also reduces the strength of the texturate through rolling. This means that the texturate can be pulled apart more easily, thus becoming even more similar to the fibrous structure of various meat products made from pork, beef, or veal. The following presents processes, protein-containing texturates, and a vegan meat substitute that implement some aspects of the proposed principle:

[0212] 1. A method for producing a texturate, comprising the steps of: providing a protein mixture which comprises at least one non-pulse protein mixture, in particular a wheat protein mixture, with a weight proportion of between 8% by weight and 72% by weight based on a base mixture;

[0213] Providing sugar or starch in a weight proportion of between 0.1% and 25% by weight based on the basic mixture and salt in a weight proportion of between 0.05% and 5% by weight based on the basic mixture;

[0214] Adding water in a proportion of between 25% and 50% by weight based on the basic mixture to form a slurry;

[0215] Extruding the slurry at a maximum temperature between 110 ° C and 160 ° C to form an extrudate; longitudinally and / or transversely stretching the extrudate at a temperature greater than 100 ° C by propelling the extrudate through an expansion die, an inlet of the expansion die having a different shape or cross-sectional area than an outlet of the expansion die.

[0216] 2. The method according to item 1, wherein the step of providing the protein mixture comprises at least one of the following:

[0217] Providing a field bean protein mixture with a weight proportion between 20% and 50% by weight; and / or providing a field bean protein mixture with a weight proportion between 30% and 40% by weight; and / or providing a combination of a field bean protein mixture with a weight proportion between 10% and 35% by weight and another legume protein mixture with a weight proportion between 10% and 45% by weight;

[0218] Providing a legume protein with a weight fraction between 10% and 64% by weight. Process according to one of the preceding objects, wherein the extruding step comprises a step of kneading the supplied protein mixture and water at an increasing temperature up to the maximum temperature, wherein optionally the maximum temperature is in the range from 110°C to 150°C and in particular between 115°C and 135°C and in particular between 120°C and 145°C. Process according to one of the preceding objects, wherein a temperature of the texturate at the outlet of the nozzle is greater than 100°C.Method according to one of the preceding objects, wherein in the step of stretching the flow velocity is increased; and / or in the step of stretching a transverse stretch is produced, in which a width of an inlet of the nozzle increases towards the outlet of the nozzle and at the same time a height of an inlet of the nozzle decreases towards the outlet of the nozzle, wherein optionally the reduction in height is greater than the increase in width; and / or in the step of stretching a transverse stretch is produced, in which a width of an inlet of the nozzle increases towards the outlet of the nozzle, wherein optionally a maximum width of the nozzle corresponds to 0.25 times to 4 times a length of the nozzle.Method according to one of the preceding objects, in which the step of stretching comprises: stretching sectionally at temperatures greater than 100 ° C, in particular by advancing the extrudate so that a flow velocity is increased;.

[0219] Propelling the extrudate at a substantially constant flow velocity, wherein a time at a substantially constant flow velocity is greater than a time during which the flow velocity is increased. Method according to one of the preceding objects, in which the tensile stress is changed in at least two successive sections during the propulsion. Method according to one of the preceding objects, further comprising :

[0220] Cooling the extrudate to a temperature below 100 ° C to form the texturate after the stretch forming step. A method according to any one of the preceding claims, further comprising after the stretch forming step:

[0221] Compressing the deformed textured material, in particular by rolling or rolling, whereby stretching and / or shearing forces are exerted on the textured material;

[0222] Optional separation of the texturate. Method according to one of the preceding objects, in which the step of stretching deformation takes place along a direction of advance of the extrudate, and a subsequent further deformation is effected by shear forces which run along a different stretching deformation direction. Method according to one of the preceding objects, further comprising: deep-frying the texturate; or cooking the texturate; or baking the texturate; or frying the texturate; or microwave-heating the texturate; or air-drying the texturate; or smoking the texturate; or a combination with several of the above. Method according to one of the preceding objects, further comprising a sequence of the above-mentioned steps, namely a

[0223] Extruding through the nozzle, followed by cutting, followed by

[0224] Rehydrate optionally with an emulsion; or

[0225] Extruding through the die, followed by cutting and rolling, followed by rehydration; or

[0226] Extruding through the die, followed by grinding; or Extruding through the die, followed by rehydration, followed by grinding; or

[0227] Extruding through the die, followed by rolling, followed by grinding; or

[0228] Extruding through the die, followed by rolling, followed by rehydrating optionally also with an emulsion, followed by grinding.Protein-containing texturate, comprising: a base mixture with o at least one legume protein mixture, in particular a field bean protein mixture with a proportion of between 0% by weight and 64% by weight based on the base mixture; o a second vegetable protein mixture different from the legume protein mixture, in particular a wheat protein mixture with a proportion of between 8% by weight and 72% by weight based on the base mixture; o sugar or starch with a proportion of between 2% by weight and 25% by weight based on the base mixture; o salt with a proportion of between 0.25% by weight and 3% by weight based on the base mixture; a water content of less than 30% by weight, in particular less than 20% by weight based on the texturate; wherein the texturate has a fiber length along a longitudinal direction of the texturate greater than 10 cm or a fiber length of the texturate is longer than a length of a piece of the texturate.Protein-containing texturate according to item 13, wherein the second vegetable protein mixture comprises at least one of the following:.

[0229] wheat protein;

[0230] pumpkin protein;

[0231] rice protein;

[0232] corn protein;

[0233] Mushroom protein

[0234] Soy protein;

[0235] Rapeseed protein Sunflower protein;

[0236] potato protein;

[0237] fungal mycelium; and

[0238] Mushroom fruit body.

[0239] 15. Protein-containing texturate according to one of the preceding items 13 to 14, wherein fibers of the texturate are pressed, beaten, hammered, rolled, or rolled; and / or wherein the texturate is deep-fried.

[0240] 16. Vegan meat substitute, in particular in the form of a steak or goulash, comprising a texture of the preceding items or produced by a process according to one of the preceding items, in which the vegan meat substitute is sliced ​​and / or rolled; and wherein the vegan meat substitute has a moisture content in the range between 20% by weight and 40% by weight due to rehydration.

[0241] LIST OF REFERENCE SYMBOLS

[0242] 1 extruder arrangement

[0243] 3 rollers, waltz, press machine

[0244] 4 cutters, dismemberers

[0245] 5 pollinators, coaters

[0246] 6 dryers, fryers

[0247] 10 worm gears

[0248] 11a, 11b Extruder section

[0249] 11c, l ld extruder section

[0250] 12a, 12b Screw section

[0251] 12 c screw section

[0252] 14 Inlet mixer

[0253] 15 Water inlet

[0254] 13 Ejection zone

[0255] 20 expansion nozzle

[0256] 21 nozzle body

[0257] 22 Expansion section

[0258] 23 Nozzle inlet

[0259] 24 Nozzle out of gear

[0260] 25a, 25b expansion section

[0261] 25 c, 25d advance section

[0262] 25e advance section

[0263] 30 bodies

[0264] Ri , R2 final cross-section

[0265] R3 r R« internal cross section

[0266] L length

Claims

Patent claims 1. A process for producing an anisotropic vegetable texture, the texture comprising a water content of less than 50% by weight and more than 50% by weight based on the dry mass of non-isotropic ingredients, wherein a protein content comprises more than 30% by weight based on the dry mass, comprising the steps of: Providing at least one protein mixture having at least 50% by weight based on dry matter of ingredients other than soy; Producing a base mixture from the provided protein mixture and water, such that the water content of the base mixture is in the range of 25% to 60% by weight; Producing a dough from the base mixture; Extruding the dough by means of a thermomechanical treatment , whereby the dough reaches a material temperature in the range of 110 to 160 ° C during the extrusion ; Exerting a first axial and / or transverse stretching to the extrudate, in particular in a channel with a changing cross-section to produce a texture; Cutting of the textured material with thicknesses greater than 2 mm and length and width greater than 10 mm.

2. A process according to claim 1, wherein the texturate comprises a protein content of between 35 and 60% protein based on the dry matter.

3. Method according to claim 1 or 2, further comprising: Exerting a second axial and / or transverse stretching to the texturate, in particular by rolling the texturate; and / or enhancing an anisotropy in the texturate by rolling the texturate; and / or pressing and stretching the texturate; and / or shearing the texturate.

4. Method according to one of the preceding claims, in which the exertion of a second axial and / or transverse stretching and / or the strengthening of an anisotropy of the texturate comprises: a section-wise or continuous compression of the texturate during the advance; and / or rolling of the texturate by at least two opposing rollers; and / or rolling with at least one roller which is arranged opposite a roller belt; rolling of the texturate by two oppositely arranged belt rollers, each of which comprises a roller belt tensioned and driven by at least two rollers; and / or rolling of the texturate by a belt roller which comprises a roller belt tensioned and driven by at least two rollers and a row of at least one roller roller opposite the roller belt; and / or rolling of the texturate with rollers of different sizes;and / or rolling the textured material with rollers having different rotational speeds; and / or pressing the textured material together, with two oppositely arranged rows of rollers each having a different speed.

5. Method according to one of the preceding claims, further comprising a rolling step which is designed to reduce a strength of the texturate compared to the strength of the texturate before rolling, in particular to reduce it by 30% to 60%; and / or to increase an average fiber length of the texturate by more than 10 mm and in particular more than 20 mm and in particular more than 30 mm. 6 . Method according to one of the preceding claims, wherein a surface of the channel has at least in sections a lower sliding friction than a surface of the extruder, in particular due to a different surface coating, in particular one made of Teflon and ceramic.

7. Method according to one of the preceding claims, wherein applying a first axial and / or transverse stretch comprises at least one of the following: Increasing a flow velocity of the extrudate within the channel; Creating a transverse stretch in which a width of an entrance of a channel increases towards the exit of the channel and simultaneously a height of an entrance of the channel decreases towards the exit of the channel, optionally wherein the decrease in height is greater than the increase in width; Stretching the extrudate along a first direction perpendicular to the direction of advance more than along the direction of advance and a second direction perpendicular to the direction of advance and the first direction; Increasing a flow velocity in a first direction transverse to the direction of propulsion while remaining the same or decreasing it in another second direction; Generating a longitudinal tensile stress on the extrudate; and generating a transverse strain in which a width of an inlet of the channel increases towards the outlet of the channel, wherein optionally a maximum width of the nozzle corresponds to 0.25 times to 4 times a length of the channel.

8. Method according to one of the preceding claims, further comprising: Drying, in particular air drying, the cut texture to a moisture content of less than 20% by weight and in particular less than 10% by weight.

9. Method according to one of claims 1 to 7 further comprising: Hydrating the texturate to a moisture content of between 40% and 80% by weight, and in particular between 50% and 70% by weight, and in particular between 55% and 75% by weight. 10 . Method according to one of the preceding claims, further comprising, in particular after drying or hydrating one of: Frying the texture; Deep frying the textured product; marinating the textured product; smoking the textured product; coating with an emulsion; or a combination of several of the above.

11. A method according to any one of the preceding claims, wherein the step of providing at least one protein mixture comprises: Providing the protein mixture with a protein content of between 20% by weight and 95% by weight, and in particular between 25% by weight and 80% by weight, and in particular between 30% by weight and 70% by weight, and in particular less than 60% by weight, each based on the dry mass of the protein mixture; and / or providing a combination of a protein mixture of at least one legume protein mixture and a non-legume protein mixture; and / or providing non-protein-containing additional ingredients, in particular one or more of starch, polysaccharides, fats, oils and flavorings.

12. A method according to any one of the preceding claims, wherein the step of producing a base mixture comprises adjusting the moisture content of the base mixture such that a protein content in the base mixture is more than 35% by weight and less than 60% by weight. 13 . Method according to one of the preceding claims, in which the protein mixture provided comprises a combination of a wheat protein mixture and at least one of a legume protein mixture, in particular a pea protein mixture, a field bean protein mixture and an oat milk side stream, wherein a proportion of wheat protein in the dry matter of the protein mixture provided is between 10% by weight and 90% by weight, and in particular between 20% by weight and 70% by weight, and in particular between 40% by weight and 70% by weight, and in particular between 30% by weight and 60% by weight, and in particular between 10% by weight and 50% by weight; a proportion of the other protein in the dry matter of the protein mixture provided is between 35% by weight and 60% by weight, and in particular between 20% by weight and 80% by weight, and in particular between 40% by weight and 70% by weight, and in particular between 10% by weight and 50% by weight.

14. The method according to claim 13, wherein the protein mixture provided further comprises an oat milk side stream or a beer driver, the proportion in the dry matter being between 10% by weight and 90% by weight and in particular between 40% by weight and 70% by weight and in particular between 5% by weight and 40% by weight or between 10% by weight and 20% by weight.

15. A method according to claim 13 or 14, wherein a salt content in the dry matter of the protein mixture is less than 5% by weight and / or wherein a proportion of carbohydrates including starch and sugar in the dry matter is less than 20% by weight. 16 . Method according to one of the preceding claims, in which an anisotropy index of the texturate measured at a moisture content between 65 % and 75 % is more than 1.25 and in particular more than 1.4 and in particular is between 1.5 and 2. 17 . Method according to one of the preceding claims, in which a fiber length is greater than 15 mm and in particular in the range between 15 mm and 25 mm and in particular between 20 mm and 30 mm.

18. Protein-containing texturate, comprising a first protein mixture with a non-legume protein, in particular a wheat protein, with a proportion between 10% by weight and 90% by weight and in particular between 20% by weight and 50% by weight based on the dry matter, a second protein mixture, in particular with a legume protein or a side stream product with a proportion between 10% by weight and 90% by weight and in particular between 20% by weight and 70% by weight and in particular between 20% by weight and 50% by weight based on the dry matter; a moisture content in the range less than 50% by weight and in particular less than 40% by weight; wherein a protein proportion in the texturate has a proportion between 35% by weight and 60% by weight of the dry matter; wherein the textured material comprises fibers with a preferred direction and a length of more than 10 mm and in particular more than 15 mm.

19. Protein-containing texturate according to claim 18, wherein an anisotropy index of the texturate at a moisture content between 65% and 75% is more than 1.25 and in particular more than 1.4 and in particular is between 1.5 and 2.

20. Protein-containing texturate according to claim 18 or 19, wherein the side stream product comprises one of an oat milk side stream, a pea milk side stream and a faba milk side stream, with a dry matter content of between 25% by weight and 80% by weight and in particular between 30% by weight and 75% by weight and in particular between 40% by weight and 70% by weight.

21. Protein-containing texturate according to claim 18, further comprising a third protein mixture from a sidestream product, in particular one from oat milk sidestream, faba milk sidestream, pea milk sidestream and beer driver, with a proportion between 5% by weight and 70% by weight and in particular between 5% by weight and 40% by weight and in particular between 40 % by weight and 70 % by weight and in particular between 10 % by weight and 20 % by weight.

22. Protein-containing texturate according to one of claims 18 to 21, wherein the moisture content is in the range of less than 25% by weight and in particular less than 15% by weight.

23. Protein-containing texturate according to one of claims 18 to 22, wherein the texturate is marinated; and / or cooked, in particular in a marinade; and / or fried; or deep-fried; or coated with an emulsion; or coated with breadcrumbs; or smoked.

24. Protein-containing texturate according to one of claims 18 to 23, in which the anisotropy index of the texturate has a maximum deviation of 10% from an anisotropy index of one of pork, in particular pork schnitzel, minute steaks, pork steaks and pork fillet, beef, in particular beef steak, beef fillet, veal, in particular veal schnitzel and veal fillet.

25. Processed texturate comprising a proteinaceous texturate according to any one of claims 18 to 24, wherein the processed texturate has a moisture content by hydration of between 40% and 110% by weight, and in particular between 45% and 70% by weight, and in particular more than 55% by weight.

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