Extruder arrangement, and method for generating a texturate

Abstract

The invention relates to an extruder arrangement, comprising a mixer / extruder (1) having an inlet zone for supplying a base mixture which contains at least one protein mixture and water, a mixing zone and an ejection zone; wherein the mixer / extruder is designed to produce a multiphase gel from the base mixture across a plurality of zones with a temperature increase up to a maximum temperature of between 110°C and 160°C. Downstream hereof is an ejection nozzle (20) which is designed, during an advancement of the multiphase gel, to treat said gel thermomechanically to form a viscoelastic multiphase and in particular a cohesive gel, and a roller arrangement (30), the gap of which, at least in some sections, is smaller than a thickness of the ejection nozzle, which is designed to exert a pressure on the viscoelastic multiphase gel perpendicular to an advancement direction.

Description

[0001] EXTRUDER ARRANGEMENT AND METHOD FOR PRODUCING A TEXTURATE

[0002] The present invention relates to an extruder arrangement and a method for producing a textured product.

[0003] BACKGROUND

[0004] 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.

[0005] Vegan food products made from plant proteins have the advantage, among other things, that they can be produced from domestically or locally produced raw materials. Pulses in particular, but also other plant substances, have the advantage over soy and others that they can be grown in a more resource-efficient manner. Endemic plant varieties in particular also have the advantage that they are often adapted to the respective climatic conditions, so that they can possibly be grown in a more resource-efficient manner than imported plant varieties. In contrast, there is a growing demand for various plant-based food products.

[0006] 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 specifically referred to as textured products, the final product has a sponge-like structure with no appreciable anisotropy and 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.

[0007] Moist extrusion (HME) is the current technology used by industry to produce fibrous, plant-based protein products. The resulting products often provide a satisfactory base, exhibiting an anisotropic, meat-like structure, texture, and appearance. Such products are manufactured using various technologies but, in particular, have a higher water content of more than 50% by weight compared to the dry extrusion products mentioned above.

[0008] In such a wet extrusion, the mass or dough, after kneading, is 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 outlet) to prevent expansion, which could destroy the fibrous structures produced in the die section.

[0009] 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 the properties of cooked meat. 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.

[0010] It has been shown that the resulting products exhibit fiber-like structures of only short length, whereas real meat consists of longitudinal fibers up to 30 cm long. Depending on the implementation, the fiber length of the plant proteins can be increased somewhat, but the resulting end product is very compact, hard, and exhibits a high degree of elasticity, which does not result in the desired mouthfeel of meat products.

[0011] It has also 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] There is a need to make further changes to conventional technologies in order to achieve improvements in the products.

[0013] SUMMARY OF THE INVENTION

[0014] This need is taken into account by the subject-matter of the independent patent claims.

[0015] It was therefore the object of the present invention to provide an extruder arrangement which does not have the disadvantages mentioned in connection with the prior art and in particular enables the production of meat substitute products which are as close as possible to meat products in terms of fibre structure, fibre length, anisotropy, texture and / or appearance, and which can also be produced cost-effectively and continuously on an industrial scale.

[0016] The present object is achieved by an extruder arrangement according to claim 1 and a method for producing a textured material according to claim 16. Further developments and embodiments of the proposed principle are specified in the subclaims.

[0017] 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 .

[0018] 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 within 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 mass expansion, and unstable behavior besides fiber disruption.

[0019] As a result, many meat products, especially those with long fiber structures, cannot be adequately imitated using this technology. Instead, the products tend to be elastic, with relatively high gel strength or bite resistance. Due to their cohesive structure, these texturates also offer very low water or fat absorption capacity after extrusion, e.g., during cooking, leaving less scope for culinary developments.

[0020] Furthermore, available die technologies can only be used to texture protein-based matrices with very specific properties. Typically, suitable protein sources should exhibit very high gel strength and viscosity after treatment in the screw section of the extruder, as this significantly influences the shear stresses in the die section (low viscosity, low deformation stresses, no fiber formation). This limits the use of many protein resources that could be cheaper, more sustainable, or healthier.

[0021] Definition of textured plant product

[0022] Textured plant products are foods that are predominantly made from plant-based ingredients and exhibit textural anisotropy.

[0023] Definition of protein mixture

[0024] For the purposes of this application, the term "protein mixture" includes 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.

[0025] 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 protein 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. It is conceivable that the term plant protein mixture is always used when the composition of the mixture differs from the original distribution of the respective plant species.

[0026] Similarly, a "pea protein" or a pea-based plant protein is a protein mixture which essentially comprises (or is derived from) peas, pea components or proteins of the pea plant and has been processed accordingly.

[0027] A protein mixture can be obtained from the plant species itself, but can also be the result of a side stream. There are also various side streams, press cakes, and residues that 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).

[0028] Other plant proteins that can be processed as concentrate, isolate (see the definitions there) or 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.

[0029] 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.

[0030] Definition of legume protein

[0031] A legume protein is a protein mixture obtained from legumes. These include peas and broad beans, as well as lentils, mung beans, chickpeas, white beans, and peanuts. Soy also belongs to these, but should optionally be included under the term "legume protein" unless explicitly stated, even though the cultivation of soybeans consumes significantly more resources than other legumes. Here, too, a protein mixture can be obtained either directly from the respective legume or as a sidestream product.

[0032] Definition of other protein mixtures or non-pulse protein

[0033] In addition to protein mixtures from pulses, other protein mixtures can also be produced from other crops. These include wheat and all types of grains in general, or more generally, all types of proteins from cereals, potatoes, rice, hemp, pumpkin seeds, corn, but also rapeseed, sunflowers, and especially proteins from fungal mycelium or fungal fruiting bodies.

[0034] A non-pulse protein in the sense of the present invention is in particular a protein mixture which comprises plant proteins which, however, do not originate from a legume. They are therefore obtained from other crops which are not listed as legumes in the above definition and do not constitute such. In addition to wheat, this includes all other cereals and grains, for example oats, as well as hemp, potatoes, rice, hemp, pumpkin seeds, corn, but also rapeseed and sunflower. Proteins from algae, yeast, fungal mycelium and / or fungal fruiting bodies also fall under the non-pulse proteins. In this context, protein mixtures from these plants are also referred to as other protein mixtures and are thus distinguished from protein mixtures from or with legumes. Other protein mixtures also include the plant proteins mentioned above.

[0035] Definition of concentrate and isolate

[0036] The terms plant protein isolate and plant protein concentrate describe plant protein mixtures that differ in the concentration of their protein content or whose protein content is present in different concentrations. The other components of an isolate or concentrate include 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. The isolate or concentrate also contains a small amount of residual moisture.

[0037] 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% by weight, i.e. above 85 out of 100 parts by weight, for example in the range from 87% to 97% by weight or 87 to 97% by weight. In a (plant) protein concentrate, the weight proportion of the (plant) protein is usually in the range below 80% by weight or even below 70% by weight, for example in the range from 35 or 40% by weight, up to 75% by weight or even up to approx. 80% by weight. There is also a transition area which, depending on the protein mixture, ranges from 75% by weight to 85% by weight and in which, depending on the manufacturer, protein variant or other parameters, the term concentrate or isolate is used.Depending on the processing and manufacturing process, a plant species can be used to obtain a concentrate, particularly a plant protein concentrate, or an isolate, particularly a plant protein isolate. 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.

[0038] 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.

[0039] Definition of other ingredients

[0040] In some aspects, additional functionality in protein composition, taste, textural composition, visual or haptic properties can be created by various other ingredients or at least one additional ingredient. It should be noted here, firstly, that the above-mentioned protein mixtures from the various fruits are mixed both in terms of the different fruits and in terms of concentration. One example would be (among others) 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.

[0041] Other ingredients such as salt, spices, additional starch, sugar, syrup, fats or oils may also be present. These can be added as part of the raw mass at the beginning, or alternatively or additionally during processing. It has surprisingly been found that sugar, oils and salts and / or ingredients containing sugar, salt and / or oil, e.g. grape juice concentrate or soy sauce, can not only adjust the taste but also change the 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. Another possibility is the addition of functional ingredients such as flavorings and / or additional and / or special protein or amino acid sources to adjust certain properties or improve human biocompatibility.In general, the additional mixtures as well as one or more of the above-mentioned substances are referred to as further ingredients or further components.

[0042] Definition of basic mixture

[0043] A base mix is ​​a combination of a protein mixture, be it as a single protein mixture, in particular from one plant species, or mixtures of several plant species, as an isolate, in particular plant protein isolate, concentrate, in particular plant protein concentrate, paste, sidestream product or a combination thereof, and water, which is optionally added before or during processing. Optionally, further protein mixtures and / or at least one other ingredient and / or at least one other component can be added, in particular to produce the base mix.

[0044] When water is added, the mixture created in this way forms a slurry, which is then further processed in an extruder.

[0045] Preferably, the water content of the base mix for extrusion is adjusted to the desired level as needed. This is due to the fact that the protein mixture also added has a different water content depending on the processing stage. For very moist mixes, e.g., 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 in the dough. The dough is then further processed in the extruder.

[0046] Alternatively, the individual components can also be added to the extruder during extrusion. The proportions in the base mix are generally given 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.

[0047] Accordingly, the proportion of individual ingredients in the base mixture usually varies due to the different distribution of the components within the ingredients. In particular, less water usually needs to be added, since the protein mixture or other ingredients also contain water.

[0048] 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.

[0049] The base mix is ​​alternatively given in % by weight, based on the added ingredients. A base mix of 50% by weight protein mix and 50% by weight water is therefore created by mixing equal parts by weight of protein mix and water. However, the total water content in the base mix is ​​slightly greater than 50% because the protein mix itself contains some residual moisture. The same applies to salts, sugars and fats added to the base mix, as these are also present in the protein mix in varying quantities. Accordingly, the individual components in the base mix are slightly offset in terms of the added proportions. This is particularly true with regard to the water content, which is usually somewhat higher in the dough than the pure added water due to the residual moisture in the protein mix, but can be lower in the finished texturate because some water has evaporated.

[0050] Definition of extrudate

[0051] In the following, the dough mass produced or processed in the extruder by kneading or other mechanical processing, which is subsequently stretch-formed or formed at the extruder exit, particularly at the end of the screw section, is referred to as the extrudate or also as viscous, viscoelastic and / or highly viscous mass. The texturate then corresponds to the finished stretch-formed and otherwise processed extrudate.

[0052] Definition of texturing

[0053] 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 the implementation, but usually only afterward through additional means and measures.

[0054] Definition of anisotropy

[0055] 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.

[0056] 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 sample in the direction orthogonal to the fibers to the force required in the direction parallel to the fibers. An anisotropic product has an anisotropy index that is not equal to one, but greater than one.

[0057] The anisotropy index can be determined in various ways, including with 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, these two types of meat have somewhat higher anisotropy indices. Definition of fiber

[0058] 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.

[0059] 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.

[0060] Definition pieces

[0061] Cohesive parts of the textured vegetable product with a thickness of more than 2 mm and dimensions (length and width) of more than 10 mm.

[0062] Definition of thermomechanical treatment

[0063] 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.

[0064] Definition of axial and transverse strain

[0065] 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.

[0066] Definition of material temperature

[0067] The temperature reached by the protein mixture during thermomechanical treatment in the extrusion process. Unless otherwise stated, the temperatures given refer to the material temperature.

[0068] Definition of online and offline cutting

[0069] Cutting methods that are applied either immediately as the product exits the extruder ( online ) or after a delay after extrusion ( offline ).

[0070] The inventor has recognized that during the production process of an extrudate, this is formed into a multi-phase gel structure by the mixing extruder itself. In this process, a multi-phase gel structure with at least two immiscible components is produced by the extrusion, for example a protein-protein mixture, a protein-polysaccharide mixture and a liquid or oily phase. By kneading and simultaneously heating these components with water in the mixing extruder, a multi-phase biopolymer mass is formed, the protein interaction of which is then further intensified by an ejection nozzle. This produces a coherent, i.e. cohesive, multi-phase and viscoelastic gel, which is also referred to below as the extrudate.

[0071] Although the shape and design of the ejection nozzle already leads to an improvement in the protein-protein interaction or the protein-polysaccharide interaction, the inventor has recognized that a decoupling between the extrusion part and a subsequent texturing leads to a significant improvement in flexibility with regard to possible process parameters, selection of raw materials and the various textures. As a result, various texturates based on plant proteins can be produced, which otherwise can only be processed with significantly greater effort. The improved result is achieved by first creating a cohesive, multi-phase and viscoelastic gel from the individual components of a base mixture with water and then

[0072] The extrudate is subjected to further compression deformation. The deformation of the dispersed phase of the extrudate leads, among other things, to a fracture of the gel structure in a preferred direction determined by the compression and forward direction, thereby creating anisotropy in the gel and thus layer formation.

[0073] In this way, not only the strength of the anisotropy formed can be adjusted over a wide range, but also other parameters such as a change in the hardness of the multi-phase viscoelastic gel, a fiber length, and others. Accordingly, the mass can be textured largely independently of the process parameters during extrusion and the materials used in the base mixture. In particular, it is possible to adjust the vector of deformation, i.e. both the strength of the applied pressure or stress and the direction, over a wide range independently of the actual extrusion. This leads to an increase in the anisotropy of the extrudate and thus to the desired adjustable fiber formation.

[0074] Several experiments have shown that the proposed principle also allows for the texturing of extrudates formed with different ejection nozzles, i.e., with different nozzle geometries. This increases flexibility and also allows the use of nozzle geometries in which anisotropy formation does not occur, but is only generated later through deformation. Overall, the formation of different anisotropies and the associated layer or fiber formation is possible with different plant proteins, thus creating meat-like or fish-like products both in terms of their texture and mouthfeel.

[0075] The deformation of the dispersed phase and also the fracture of the multi-phase extrudate to form and shape anisotropy is achieved by exerting pressure, for example by a roller system, which exerts a pressure on the viscoelastic mass that is essentially perpendicular to the direction of advance. At the same time, the mass is allowed to deviate in the other direction perpendicular to the direction of advance, which contributes to the formation of anisotropy. The various properties of the anisotropy in the finished texturate can be adjusted by the operating parameters of the roller device, for example the gap between the upper and lower rollers, the type of rollers, their size, the entry angle, the roller speed and others.

[0076] In one aspect, a mixing extruder has an inlet zone for feeding a base mixture, wherein the base mixture contains at least one protein mixture and water. The mixing extruder further comprises a mixing zone and an output zone and is designed to produce a multi-phase gel from the base mixture and the water across a plurality of zones with a temperature increase up to a maximum temperature of between 110°C and 160°C. This gel comprises, inter alia, two immiscible components which, for example, include protein-protein components, protein-polysaccharide components or oil mixtures. The terms extrudate and gel are used synonymously for the purposes of this application.

[0077] Connected to the mixing extruder is an ejection nozzle which is designed to treat the multiphase gel thermomechanically as it is being pushed forward to form a viscoelastic multiphase and in particular cohesive gel. An extrudate is therefore present at the outlet of this ejection nozzle. The terms extrudate and viscoelastic multiphase and optionally cohesive gel are used synonymously for the purposes of this application. It is to be understood, however, that even in the mixing extruder an interaction takes place between individual proteins and protein polysaccharides as well as other components as a result of the kneading and mixing process, which leads to a certain viscoelasticity. The terms multiphase gel or extrudate are therefore also used to describe the position of the protein-containing mass in the arrangement.The extrusion arrangement according to the invention also comprises a roller arrangement whose gap is, at least in some sections, smaller than the thickness of the ejection nozzle. This ensures that the gap of the roller arrangement is smaller than the thickness of the extrudate discharged through the ejection nozzle. The roller arrangement is also designed to exert pressure on the viscoelastic multiphase gel or extrudate perpendicular to a direction of advance, thus causing the anisotropy of the extrudate through deformation.

[0078] In some aspects it is intended to increase the anisotropy of the texturate. To do this, a second axial and / or transverse stretch is exerted on the already stretched texturate by the roller arrangement. Likewise, in some aspects the anisotropy in the texturate can also be frozen by rolling. By “frozen” we mean that the texturate hardly relaxes 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 increased anisotropy should in principle be irreversible as a result of the additional step. In principle it is conceivable that this combination of measures could impart an anisotropy to the texturate which can be adjusted over a range from 1 to approx. 1.8 and higher, so that the anisotropy of pork or beef is in the range from 1.2 to greater than 1.7, e.g.up to 2 can be simulated. At the same time, not only can directional fibers be created, but their length can also be adjusted up to 20 cm and more.

[0079] The roller arrangement is preferably designed in such a way that the anisotropy index of the gel guided through the roller arrangement or of the texturate emerging from the ejection nozzle is increased by more than 20% and preferably more than 40% and particularly preferably more than 60%. The gel emerging from the ejection nozzle is also referred to in the present description as extrudate or texturate. It is conceivable that with a moisture content between 65% and 75% the anisotropy index of the texturate is more than 1.25 and in particular more than 1.4 and in particular between 1.5 and 2. The term "gap" of the roller arrangement in the sense of the present invention means in particular the minimum distance which two opposite layers transverse to the transport direction of the texturate

[0080] Pair of roller elements, such as rollers or belts, to one another, in particular while the textured product to be rolled moves through the pair of roller elements during rolling. The gap width is in particular constant or variable over its length. It is conceivable that the gap is narrower on one side than on the opposite side along the main extent of the gap. In this way, the inhomogeneity in the textured product is advantageously increased further during rolling and thus a greater similarity to meat products is created. This can be helpful, for example, in the production of steak-like meat substitutes.

[0081] 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.

[0082] This allows the production of a fibrous texture, whereby the anisotropy generated by deformation can be adjusted via the parameters of the roller arrangement. In particular, a texture with longitudinally oriented fibers can be produced even from a protein mixture that is inherently difficult to extrude.

[0083] Some aspects deal with the roller arrangement and the resulting pressure build-up or deformation of the extrudate or the cohesive viscoelastic and multiphase gel. In some aspects, the roller arrangement comprises at least two rows of rollers, which are each arranged opposite one another, in particular transversely to the main transport direction. The viscoelastic multiphase gel is fed from the ejection nozzle as extrudate to the two rows of rollers, which then exert a corresponding pressing pressure perpendicular to the direction of advance through the selected slot spacing between the rollers and thus lead to deformation. Each of these rows of rollers comprises several rollers arranged in the forward direction. The extrudate or texturate is transported through the gap between the two rollers.

[0084] In another aspect, instead of the roller rollers, oppositely arranged belt rollers are provided. These comprise materials approved for the food industry, with the belt rollers each comprising a roller belt tensioned and driven by at least two rollers. This belt is also driven by the rollers and is preferably designed as an endless belt that runs on the rollers. For this purpose, the roller belt can be structured accordingly and, for example, be designed with a toothed ring into which the at least two rollers engage. In addition to the two rollers, further rollers can be provided which, due to their arrangement, exert pressure on the roller belt in the direction of the viscoelastic multiphase gel. In other words, the belt rollers create a deformation of the viscoelastic multiphase gel, thus generating anisotropy through the deformation of the dispersed phase and the disruption of the multiphase structure.

[0085] In a further aspect, a belt roller is provided with a roller belt that is clamped and driven by at least two rollers. On the other side, and arranged at a distance therefrom, is a row of one or more rollers. As the extrudate is advanced through the roller belt, these rollers exert additional pressure on it, thus causing a deformation that leads to the desired anisotropy and thus to the formation of the fibrous structure.

[0086] The different roller arrangements can be combined as desired to create the desired anisotropy in the extrudate. For example, it is possible to first provide belt rollers followed by two rows of roller rolls to direct the anisotropy in a desired direction. It is also possible to specify different roller arrangements in which the pressure and the resulting deformation occur in different directions perpendicular to the feed direction.

[0087] In one aspect, the adjacent rollers of both the rows of rollers and the rollers of the belt roller can have a spacing that is less than a diameter or less than a radius of the roller or roller. In other words, the pressure and thus the strength of the deformation on the extrudate is adjusted by the spacing between the adjacent rollers. In some aspects, this spacing between opposing rollers can be varied, thus enabling a further flexible design.

[0088] It is also conceivable to adjust not only the distance between two adjacent rollers in a row, but also the distance between two opposing rollers in order to create a further degree of freedom. This makes it possible, for example, to use different distances to generate different levels of pressure on the viscoelastic multiphase gel or the extrudate as it is pushed forward through the roller arrangement, in order to thus create pressure sections and rest sections as the rollers move forward through the roller arrangement. In some aspects, it can be provided that the individual rollers are not directly opposite one another, but slightly offset, i.e. with a "gap". This may result in more even deformation of the extrudate from both sides.

[0089] In some aspects it is provided for this purpose that at least two adjacent roller rollers have a different diameter. Alternatively, as previously described, the position of the roller rollers perpendicular to the direction of advance can also be different. In some aspects it is particularly provided that a roller roller which is arranged downstream in the direction of advance has a larger diameter than a roller roller arranged upstream of this roller roller in the direction of advance. In other words, the diameters of the roller rollers become larger in the direction of advance, so that the gap between opposing roller rollers or between the roller rollers and the roller belt of a belt roller increasingly decreases in the direction of advance. In the same way, the distance between the two opposing roller belts can also decrease in the direction of advance.In an alternative embodiment, it is also possible for the rollers to be arranged at a different distance from one another or at a different distance perpendicular to the direction of advance.

[0090] In a further aspect, the gap of the roller arrangement, i.e., the distance between two opposing roller rolls or opposing belt rollers, can decrease continuously or in sections. In some further aspects, it is provided in this context that the gap of the roller arrangement remains essentially constant in the advancing direction, at least in sections. This allows, for example, compression or deformation sections and rest sections to be defined during the advancing movement through the roller arrangement.

[0091] Another possibility for generating anisotropy in the multiphase viscoelastic and cohesive gel is achieved by varying the rotational speed of the rollers. For example, it is possible for rollers positioned downstream in the direction of advance to have a higher rotational speed than rollers positioned upstream in the direction of advance. In other words, in this exemplary embodiment, the rotational speed of the individual rollers increases the further the extrudate is advanced in the roller arrangement.

[0092] In another aspect, for example, rollers in one row can have a different rotational speed than the rollers in another row. Accordingly, it is also possible for the oppositely arranged belt rollers to have different speeds, so that in this way an upper side of the extrudate experiences a different tension as it is pushed through the arrangement than the underside of the extrudate. This allows the shear forces to be varied; however, with a suitable arrangement it is also possible to change the stretching forces, so that a high degree of flexibility is achieved. In a further aspect, it can also be provided that the roller belt moves at a different speed than the individual rollers.

[0093] All the above-mentioned aspects of the roller rolls or belt rolls can be combined with each other so that a different anisotropy can be achieved depending on the desired texture and parameters used, such as the composition of the base mixture, the parameters of the extrudate and also the geometric parameters of the ejection nozzle.

[0094] In a further aspect, it can also be provided that the surface of the roller roll or the surface of the belt rollers is structured in order to imprint a track on the viscoelastic and multi-phase gel as it is driven forward.

[0095] Another aspect concerns the expansion and temperature processing by the roller arrangement. During the ejection phase, i.e., during the exit of the multiphase viscoelastic and cohesive gel from the ejection nozzle, further expansion can occur in some aspects, during which any water or moisture still present within the gel evaporates due to the pressure drop, thus loosening the mass. In this context, it can therefore be advantageous to design the roller arrangement so that it can be temperature-controlled and, in particular, heated or cooled, in order to thus also obtain a further degree of freedom.

[0096] In this context it was also found, among other things, that the deformation caused by the roller arrangement is at least partially reversible under certain parameters, i.e. the viscoelastic mass partially returns to its original shape even after pressure has been applied. Accordingly, it is intended to make the deformation irreversible by adjusting the strength of the pressure, the duration of advance by the roller arrangement, the slot thickness, as well as other geometric and mechanical parameters and a temperature setting. The term irreversible also means, among other things, that the multi-phase component fractures, resulting in the formation of layers.

[0097] A permanent and essentially irreversible anisotropy can be directly induced, among other things, by the roller arrangement, for example, by the applied pressure exceeding a threshold value or a threshold range. In another embodiment, this can additionally be combined with a temperature change during propulsion and in particular during deformation or shortly thereafter. Thus, it has surprisingly been found that anisotropy is retained even if the anisotropy is generated at a higher temperature and the thus-treated mass is subsequently cooled before the onset of regression.

[0098] Another aspect concerns the design of the ejection nozzle and the differences between the ejection nozzle and the roller arrangement. In the area of ​​the ejection nozzle, it is expedient to generate a transverse or longitudinal tensile stress without additional shear forces, since the latter contribute to the destruction of possible fiber formation or to a reduction of anisotropy possibly already generated by the ejection nozzle. Accordingly, it is expedient to reduce adhesion between the surface of the ejection nozzle and the propelled mass, i.e., the multiphase gel.

[0099] In some embodiments, therefore, an inner side of the ejection nozzle is coated with a fluoropolymer and in particular Teflon. Alternatively, it can also be provided that an inner side of a first section of the ejection nozzle has a first material and an inner side of a subsequent second section of the ejection nozzle comprises a second material and a material that is different from the first material. In this context, the material of the ejection nozzle or its surface quality can in particular be designed differently than the material of the roller arrangement or its surface quality. In some aspects, it is expedient in this context for a material of the ejection nozzle to have, at least in sections, a lower coefficient of static and / or sliding friction than a material of the roller arrangement. In other words, the surface of the roller arrangement generally has a higher friction than the surface of the ejection nozzle.Accordingly, the extruder arrangement is designed in such a way that static friction in the ejection nozzle is as low as possible, but is greater in the roller arrangement to produce the anisotropy.

[0100] In some aspects, the ejection nozzle comprises at least one section in which a decrease in diameter along a first direction perpendicular to the forward direction is greater than a decrease along a second direction perpendicular to the first direction and the advance direction. Thus, the ejection nozzle is designed as a transverse expansion nozzle in which the mass produced in the mixing extruder is subjected to an expansion stress transverse to the advance direction.

[0101] Alternatively, the ejection nozzle can also have at least one section in which the diameter increases along a direction perpendicular to the propulsion direction. In this embodiment, too, expansion forces are generated perpendicular to the propulsion direction. An inlet cross-section of the ejection nozzle can, in some aspects, be larger than an outlet cross-section. Accordingly, with constant mass transport through the ejection nozzle, the change in the cross-section leads to the propelled mass being expanded in one direction, for example, transverse to the propulsion direction.

[0102] In another aspect, however, a longitudinal expansion nozzle may also be provided, in which, for example, the cross-section of the nozzle decreases along the propulsion direction without changing the ratio of the length to width of the nozzle. Thus, the cross-section of the nozzle decreases while maintaining its shape over the length of the nozzle.

[0103] In a further aspect, the ejection nozzle comprises different sections, at least some of which have a constant cross-section. Accordingly, the ejection nozzle can therefore have sections in which the propelled mass is subjected to a transverse or also a longitudinal extension (or a combination thereof), as well as further sections connected thereto, which are characterized as rest zones and in which the mass is merely propelled but is essentially not subjected to any further extension stress. In a further aspect, transverse and longitudinal stresses can be realized simultaneously by an appropriate geometry of the ejection nozzle or its cross-section.

[0104] The nozzle can thus be designed as a slot nozzle, a square or rectangular nozzle, or even as an oval, round, or Couette nozzle, each with a shorter or longer length. In some aspects, the nozzle is longer than its corresponding inlet or outlet cross-section. However, this is not absolutely necessary; it is also possible for the outlet cross-section to be larger in one direction (e.g., in width) than the length of the nozzle.

[0105] The proposed principle creates texture and anisotropy in the extrudate discharged from the ejection nozzle. The roller assembly deforms the extrudate during propulsion, thus creating a fracture in the multiphase gel. However, it is not necessary for the roller assembly to be directly adjacent to the ejection nozzle; additional arrangements for processing the ejected extrudate can be provided.

[0106] In some aspects, this is, for example, a cutting arrangement arranged between the ejection nozzle and the roller arrangement. The cutting arrangement can be designed to divide the mass exiting the ejection nozzle perpendicular to the direction of advance into portions, in particular portions of equal length. In another aspect, the cutting arrangement is designed to cut and divide the mass exiting the ejection nozzle along the direction of advance.

[0107] In this way, the roller assembly is fed not as a continuous extrudate, but as individual pieces or strips. It is possible that these pieces or strips are irregularly gripped by the roller assembly, for example, because they fall into the roller assembly from above. This creates different anisotropy for each piece, with gel fracture or deformation occurring both in the direction (i.e., along a strip and across it).

[0108] According to a further preferred embodiment, it is provided that the cutting device separates individual strips from the gel emerging from the ejection nozzle, wherein the extruder arrangement has an alignment unit which changes the orientation of the strips separated by the cutting arrangement relative to their main transport direction and in particular rotates the strips such that their main extent is oriented perpendicular or almost perpendicular to the main transport direction before the strips pass through the roller arrangement. The alignment unit is therefore arranged between the cutting device and the roller arrangement in order to change the orientation of the strips separated by means of the cutting arrangement.

[0109] It is particularly conceivable that the severed strips each have an elongated extension in the main transport direction when they leave the cutting arrangement, and that the orientation of the strips is changed by means of the alignment unit in such a way that the elongated extension is then oriented perpendicular or almost perpendicular to the main transport direction. This has the advantage that the strips are not guided into the roller arrangement in the longitudinal direction, but perpendicular or almost perpendicular to the main transport direction, which advantageously further increases the inhomogeneity during rolling. In other words: the strips are rotated by means of the alignment unit. It is conceivable that when they leave the alignment unit, the elongated extension of the strips is oriented in particular at an angle of between 50 and 130 degrees, preferably between 70 and 110 degrees and particularly preferably between 80 and 100 degrees to the main transport direction.The alignment unit preferably comprises two conveyor belts that are arranged perpendicularly or nearly perpendicularly to one another, whereby the alignment of the strips with respect to their respective main conveying direction changes upon transition from one conveyor belt to the subsequent conveyor belt. It would also be conceivable to provide a single belt conveyor as the alignment unit, which has an inclined stop for the strips on one side, whereby a torque is exerted on the strips as they pass through said stop, thereby changing their alignment with respect to the main transport direction.

[0110] In a further aspect, a rest zone can also be provided, which is arranged between the ejection nozzle and the roller arrangement. This is designed, among other things, to transport the viscoelastic multiphase gel or extrudate from the ejection nozzle to the roller arrangement while changing its moisture content. The moisture content can decrease in the process, but can also increase slightly through spraying or other measures. The rest zone can also be temperature-controlled. Likewise, further measures such as dusting or coating with an emulsion can be provided in this.

[0111] The cutting arrangement presented here, as well as the rest zone, are arranged downstream of the roller arrangement in some aspects. Furthermore, it is possible to provide a cooling device downstream of the roller arrangement, in which the viscoelastic multiphase mass, now endowed with anisotropy, is rapidly cooled, thus preserving the anisotropy and thus creating an irreversible process.

[0112] Another aspect relates to a method for producing a texturate. In this method, a base mixture is provided which comprises at least a first protein mixture with a weight proportion of between 40% and 90% by weight, based on a base mixture. The protein mixture can, as already explained above, be made up of a single protein mixture or a combination of different protein mixtures, both as concentrates and as isolates. Oils, starch, flavorings and other substances are either present in the concentrates or, in some aspects, are also added. Likewise, water is added to the protein mixture, which water has a weight proportion of between 10% and 50% by weight, based on the base mixture, to form a slurry. The slurry is then kneaded and mixed to produce a multi-phase gel at a maximum temperature of between 110°C and 160°C.Depending on its composition, this gel also exhibits viscoelasticity. Due to the low water content in the base mixture, this is referred to as dry or semi-dry extrusion. During the mixing and kneading process, the higher pressure of several bar and the elevated temperature also cause interaction between the individual components of the mass, for example, between the proteins themselves or between the starch and the proteins. Following the kneading process, the gel may contain various phases, some of which are present in separate areas.

[0113] The resulting multiphase gel is then subjected to a first thermomechanical treatment to further enhance its viscoelasticity, resulting in the viscoelastic multiphase gel in the form of an extrudate. The first treatment is carried out at a temperature above 100 °C and a high pressure of several bar, so that vapor transfer of the water present in the mass, which would cause expansion of the viscoelastic multiphase gel, is excluded during the first thermomechanical treatment.

[0114] In particular, the mechanical treatment is designed in such a way that expansion of the multiphase gel is restricted in both directions perpendicular to the forward direction. The term “restriction of expansion” means that the multiphase gel can only expand slightly in one of the two directions perpendicular to the forward direction and that this expansion is restricted. In other words, the first thermomechanical treatment is carried out in such a way that mass flow is constant during this treatment and the flow velocity of the multiphase gel either remains the same or is increased during the treatment to increase the viscoelasticity. In the first case, the volume flow is not changed; in the second case, the volume flow is restricted so that an increased flow velocity results with a constant mass flow.Subsequently, in order to develop anisotropy in the viscoelastic multiphase gel treated in this way, deformation is effected by exerting pressure on it in a direction perpendicular to the forward direction with simultaneous essentially unrestricted expansion in the other direction perpendicular to the forward direction. The development of anisotropy breaks up the structure of the viscoelastic multiphase gel or extrudate and, in particular, deforms the dispersed phase. In this respect, it can also be said that the dispersed phase of the extrudate is deformed and a fracture is produced in the extrudate, whereby a layered and fibrous structure is formed or an existing one is strengthened. By appropriate control of various parameters, the strength of the anisotropy as well as its direction and structure can be adjusted over a wide range.

[0115] In some aspects, the viscoelastic multiphase gel or extrudate to be treated is a cohesive gel. The cohesion remains even after deformation and the creation or enhancement of anisotropy, i.e., the textured material forms a coherent structure.

[0116] The shaping or reinforcement of anisotropy is achieved, among other things, by rolling the viscoelastic multiphase gel, for example, through two rows of opposing rollers. These rollers exert propulsion on the multiphase viscoelastic gel through rotation and simultaneously generate a pressure perpendicular to it. The rollers also allow expansion in the second direction perpendicular to the forward direction.

[0117] Alternatively, this anisotropy can also be achieved by rolling the treated viscoelastic multiphase gel through two opposing belt rollers. In this case, the roller belts are each tensioned by at least two rollers and are driven by these. Of course, several rollers are also possible, so that the pressure on the viscoelastic multiphase mass remains as constant as possible during propulsion or can be adjusted section by section via the different rollers across the roller belt. In a further aspect, the treated viscoelastic multiphase gel is rolled over a roller belt that is tensioned and driven by at least two rollers and opposite which a row of several rollers is arranged.

[0118] In some aspects, the anisotropy is formed by breaking the viscoelastic multiphase gel or extrudate into at least two phases of different viscosity and / or consistency. One phase can have a higher proportion of water or an oil or fat than the other. In some aspects, the anisotropy can also be formed by section-wise or continuous compression of the treated viscoelastic multiphase gel or extrudate during extrusion. In some aspects, the anisotropy of the treated viscoelastic gel or extrudate can be formed or reinforced by rolling using rollers of different sizes. Alternatively, it is also possible to form or reinforce the anisotropy by rolling at different rotational speeds. In this context, the anisotropy is formed by compressing the extrudate.At the same time, the extrudate is advanced. In some cases, rollers rotating at different speeds can be used for this purpose. Likewise, the individual belt rollers can have different speeds.

[0119] In some aspects, during the formation of the anisotropy of the treated viscoelastic multiphase gel, structuring is also performed, which particularly comprises imprinting the surface of the extrudate. The imprinting is at least partially irreversible, so that the imprinted structure is retained thereafter.

[0120] As a result of the rolling process, the thickness of the extrudate is initially greater and then less after the application or reinforcement of an existing anisotropy. In order to prevent a revision of the generated anisotropy, i.e. a "shrinkage" or "change" of shape caused by the viscoelasticity, in some aspects a heat treatment or even heating or cooling is provided during or shortly after the formation of the anisotropy. In some aspects the treated viscoelastic multiphase gel is cut before rolling, for example perpendicular to the direction of advance. In other words, in this aspect several individual pieces or strips of the viscoelastic multiphase gel or extrudate are subjected to compression or rolling. This rolling can take place both along the main direction of the individual extrudate pieces or strips or transversely to this.

[0121] It is furthermore preferably provided that the orientation of the gel cut into pieces or strips is changed before rolling, in particular with the alignment unit described above. It is conceivable that the strips are rotated in particular such that their main extension is oriented perpendicular to the main transport direction through the roller arrangement.

[0122] It is also possible to further reduce the moisture content before or after rolling, for example, by a longer resting phase followed by heat treatment, so that the remaining moisture evaporates or evaporates. In some cases, the surface of the resulting textured material can be coated with a spice, salt, or emulsion layer after rolling.

[0123] 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.

[0124] In some other aspects, a gas is added during kneading, i.e. in the screw section of the extruder, in order to loosen 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 various 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 exited 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.

[0125] 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.

[0126] BRIEF DESCRIPTION OF THE DRAWINGS

[0127] Further aspects and embodiments according to the proposed principle will become apparent with reference to the various embodiments and examples which will be described in detail in conjunction with the accompanying drawings.

[0128] Figure 1 shows an embodiment of an extruder arrangement with a mixing extruder, as can be used for the proposed method according to the proposed principle;

[0129] Figure 2 shows a first embodiment of a roller arrangement in cross-sectional view according to the proposed principle;

[0130] Figure 3 shows a further embodiment of a roller arrangement according to the proposed principle; Figure 4 shows a further embodiment of a roller arrangement according to the proposed principle in cross-sectional view;

[0131] Figure 5 shows a fourth embodiment of a roller arrangement in cross-sectional view according to the proposed principle;

[0132] Figure 6 shows a fifth embodiment of a roller arrangement in cross-sectional view according to the proposed principle;

[0133] Figure 7 shows a further embodiment of a roller arrangement according to the proposed principle;

[0134] Figure 8 shows a further embodiment of an extruder arrangement according to the proposed principle,

[0135] Figure 9 shows an embodiment of an ejection nozzle with a transversely varying cross-section to illustrate some aspects of the proposed principle;

[0136] Figures 10A and 10B show two simulations of a transverse expansion nozzle as it can be used in an extruder arrangement according to the proposed principle;

[0137] Figure 11 is an example of a method for producing a texture;

[0138] Figures 12A to 12B show a further embodiment of an extruder arrangement according to the proposed principle with corresponding images of a texture after each roller;

[0139] Figure 13 shows sectional views of the texture of Figure 12B;

[0140] Figures 14 to 16 show further embodiments of a roller arrangement as can be used in the method and in the extruder arrangement according to the proposed principle; Figure 17 shows further different examples of possible rollers in a roller arrangement.

[0141] Figure 18 shows a schematic representation of an extruder arrangement according to the invention according to a further embodiment.

[0142] DETAILED DESCRIPTION

[0143] 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 can 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 be combined with one another without thereby impairing the inventive principle. Some aspects have a regular structure or shape. It should be noted that in practice slight deviations from the ideal shape can occur without, however, contradicting the inventive idea.

[0144] 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.

[0145] Figure 1 shows part of an extruder assembly according to the proposed principle. The extruder assembly is designed with a mixing extruder 1 with a twin worm gear, in which the supplied mass is kneaded by means of two worm gears and driven forward toward 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.

[0146] 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.

[0147] 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 have an opening for supplying the base mixture or water. In detail, in the illustrated embodiment, the base mixture is introduced into a first section 11a of the mixing extruder 1 via a hopper 14. 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 slurry from the water and the supplied base mixture.

[0148] Connected to the first sections 11a are a plurality of further sections 11b, 11c, and 11d, some of which are filled with different screw elements 12a. As can be seen in Figure 1, the screw elements serve both to advance the dough and to knead the dough while increasing the pressure and temperature.

[0149] 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 therefore different temperatures of the dough being forced forward can be set in the individual sections 11a to 11e. Furthermore, the individual screw elements in the respective sections are also designed differently. Some screw elements are used to knead the mass from the base mixture and the added water in order to produce a dough with a continuous phase. At the same time, the pressure in these areas is increased to between 15 bar and 20 bar through the kneading and further forward movement of the fed base mixture.

[0150] With a simultaneous increase in temperature, or a high temperature, for example, in the range of 120 °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.

[0151] The outlet section 11e of the mixing extruder 1 has a slightly conical shape on the outlet side with an ejection zone 13, to which an ejection nozzle is connected either directly or via an intermediate piece. This nozzle is explained below by way of example with reference to Figure 9. The ejection nozzle is designed not only to promote propulsion but also to enhance further interaction between proteins and proteins and polysaccharides.

[0152] In this embodiment, the ejection nozzle 20 is designed with a constant cross-section and propels the mass at a temperature of over 100°C and a pressure of greater than 10 bar. Upon exit, the mass expands and is transported to a roller arrangement 30 via a short conveyor.

[0153] The roller arrangement creates or reinforces an anisotropy of the extrudate that has already formed in the ejection nozzle, so that a desired structure is created at the outlet. The term anisotropy describes, for example, a fiber or layer formation of the extrudate. Figure 2 shows a possible embodiment of a roller arrangement to explain some aspects of producing a textured product with a longitudinal anisotropy. In this case, the roller arrangement comprises two opposing belt rollers 31 and 32. These are arranged opposite one another. In this case, the two roller belts 300 of the belt rollers 31, 32 are not aligned parallel, but rather V-shaped as shown in the cross-sectional view in Figure 1, with a wider inlet and a thinner outlet. In other words, the distance between the two roller belts 300 decreases in the forward direction, i.e.towards the outlet of the roller arrangement.

[0154] Each roller belt 300 is driven by a plurality of rotating rollers 310, with the rotation direction of the rollers being counterclockwise for the upper roller belt 300 and clockwise for the lower roller belt 31. This results in a uniform forward speed of the two roller belts 300 for the belt rollers 31 and 32, respectively.

[0155] The viscoelastic mass provided by the mixing extruder and the ejection nozzle 20 is now fed to the inlet area of ​​the roller arrangement 30. The mass is gripped by the two roller belts 300 of the belt rollers and propelled forward due to the existing static friction. The rotation speed of the two roller belts 300 can be somewhat greater than that given by the mass flow of the ejection nozzle 20. The static friction between the viscoelastic mass of the extrudate 40 and the roller belts 300 results in an elongation stress which, with a simultaneous reduction in the thickness or the distance between the two roller belts 300, creates an anisotropy in the forward direction. As a result, the dispersed phase of the coherent multi-phase and viscoelastic mass is deformed and the individual protein-protein or protein-polysaccharide chains are aligned with one another and along the direction of advance.Due to the pressure exerted on the mass, the individual phases are subjected to varying degrees of stress or tension. This leads to a localized application of shear or tensile stress and, subsequently, to the formation of layers, which is also referred to as gel fracture.

[0156] In contrast to the ejection nozzle 20, in which the static friction and thus the build-up of a possible shear stress should be low, in the roller arrangement 30 a static friction is deliberately brought about between the roller belts 300 and the material being driven forward in order to subject the individual phases to a shear and / or tensile stress and thus to reinforce an already existing anisotropy and / or to generate this in the form of gel fracture and thus layer formation.

[0157] Figure 3 shows a further embodiment, with two belt rollers 31, 32 each with a roller belt 300 and several rollers 310 and 311 provided for driving the roller belt. Similar to Figure 2, the diameter of the individual rollers 310 and 311 is the same.

[0158] In contrast to the previous example, however, the belt roller 32 is planar 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 mass 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. In addition, some roller 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 a further degree of freedom, so that the temperature of the propelled mass can be adjusted during the generation of the gel fracture and the deformation.

[0159] 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 section. This is particularly useful if the overall propulsion section is somewhat longer or if the roller belt itself is designed to be elastic. By designing and arranging the individual rollers and the roller belts relative to one another, a defined pressure can be exerted on the viscoelastic mass in order to achieve the desired gel fracture and thus the desired anisotropy.

[0160] Figure 4 shows a further embodiment of the proposed principle of a roller arrangement 30. In this case, the roller arrangement comprises a planar belt roller, opposite which a plurality of rotating individual roller rolls are arranged. In contrast to the previous exemplary embodiments, the necessary pressure and the corresponding tension are not generated by a roller belt per se, but by a plurality of rotating rollers 33 arranged one behind the other. The distance between the individual rollers 33 and the roller belt 300 decreases with increasing direction of advance.

[0161] The distance between the individual rollers is significantly smaller than the corresponding diameter or radius of these individual rollers, so that when the compressed mass is transferred between the individual roller belts, there is no significant recovery and thus no dissolution of the generated anisotropy. In other words, this also ensures that the existing gel fracture created by the compression in the roller arrangement 30 does not heal again.

[0162] In the previous embodiments, the individual rollers are directly aligned with one another, i.e. they lie directly opposite one another. At the same time, the rollers are also the same size. However, both aspects are not necessary and can be varied. For example, it is possible (not shown here) to align the individual rollers with a gap between them and thus not directly opposite one another. Instead, one roller is arranged in its extension in the middle of two adjacent, opposite rollers. The rollers in the belt roller can also be aligned in this way. Such a "gap" design can, among other things, lead to improved pressure application and thus to more continuous tension generation and deformation of the propelled mass.

[0163] Figure 5 shows a further embodiment in which a belt roller 31 is designed with a plurality of rollers for generating a propulsion speed of the roller belt 300. A plurality of further roller rollers 312 are arranged opposite the roller belt 300, the diameter of these roller rollers 312 being significantly different from the roller roller 310 and, in particular, being smaller. Smaller roller rollers that are arranged closer together have the advantage that they exert a uniform force on the extrudate and thus produce improved anisotropy and irreversibility. In this exemplary embodiment of the roller arrangement too, the distance between the individual roller rollers 312 from the belt roller 31 decreases as the propulsion distance increases, down to a defined exit gap.

[0164] Figure 6 shows a further combination 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 extrudate as the mass is propelled 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 propulsion. This does cause propulsion, but without further significant deformation, so that this section can also be referred to as the rest section.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 .

[0165] It is also possible to provide individual rollers with different diameters in order to reduce the thickness of the propelled mass. Figure 7 shows such an embodiment in which a first roller arrangement 320 is located opposite a belt roller 31. The first roller arrangement 320 is inclined with respect to the belt roller 31 and comprises a plurality of individual rollers 312, 313, 314 and 315 arranged one behind the other, which in turn have an increasing diameter in the forward direction. As a result, the distance is reduced during the propulsion of the viscoelastic mass and the extrudate is deformed to produce the anisotropy. Further propulsion then takes place via a roller belt 32, the propulsion rollers 311 of which are each temperature-controlled. In this way, the anisotropy produced by the arrangement 320 can be frozen in the textured material so that it is irreversible.

[0166] The roller arrangements presented here allow for the imposition of additional anisotropy on an otherwise isotropic extrudate. Likewise, any existing anisotropy can be enhanced. Accordingly, they can also be used to texture protein mixtures whose extrudate exhibits little or only minimal structure when propelled through a suitable nozzle.

[0167] According to the proposed principle, the roller arrangement can be combined with various ejection nozzles, including a special stretching nozzle, in which a transverse or longitudinal stretching stress (or a combination thereof) is also exerted on the extrudate and the propelled mass.

[0168] Figure 8 shows such an embodiment, which also provides a cutting arrangement 41. The mixing extruder in the proposed arrangement corresponds to the mixing extruder in the embodiment of Figure 1. A special expansion nozzle 20 is connected to the outlet area 13 of the mixing extruder. This is designed as a transverse expansion nozzle and is explained in more detail below in Figure 9. The protein mixture kneaded in the mixing extruder and mixed with water is further processed through the expansion nozzle 20. The transverse and / or longitudinal expansion stress present in the expansion nozzle 20 leads to increased molecular interaction of the protein-protein and protein-polysaccharide chains during propulsion, which creates a slight anisotropy when a corresponding protein mixture is selected.

[0169] After being ejected through the nozzle 20, the extrudate is fed to a cutting machine 41. This machine has one or more blades 401 arranged perpendicular to the feed direction, which cut the extrudate into strips of substantially equal length. Additional blades can also further cut the extrudate strips lengthwise, making them narrower. The pieces are then fed to the roller arrangement.

[0170] In these designs, the roller arrangement is essentially planar, i.e. the extrudate is fed flat to the roller arrangement. This is not necessary, however; rather, the extrudate or extrudate strips can fall into the roller arrangement and be gripped and propelled by the roller belt or rollers. This may be useful for strips or extrudate pieces, i.e. if the size is already determined by cutting the extrudate into strips or pieces. It is also useful if an anisotropy is already predetermined, or if this can be easily enhanced or created by the roller arrangement. The cutting arrangement 41 can also be a rest arrangement and suitably temperature-controlled to improve the imprinting of the anisotropy.

[0171] The nozzle in Figure 9 addresses another aspect that can contribute to gel formation: the inlet cross-section does not decrease uniformly along the length of the nozzle (this is one possible design), but rather the inlet reduces in one preferred direction, while in the other direction it actually increases relative to the outlet. This creates an outlet that forms a slot, whereby the width-to-height ratio and the shape of the side surfaces can vary.

[0172] In this regard, Figure 9 shows an embodiment in which the entrance 23, with its area A1, remains essentially the same relative to the exit area 24, with its area A2, but its shape is changed. In particular, Figure 9 shows a square entrance area. A steady decrease in height, with a simultaneous widening of the width, results in an elongated, narrow transverse slot in the exit area 24, which is approximately twice as wide as the entrance. Its height, however, has decreased by more than half.

[0173] The expansion nozzle therefore leads to a decreasing ratio of H / B 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 9, 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.

[0174] Figure 10, in the upper part A, shows a simulation of the tensile stresses that occur with adhesion and friction effects along the inside. The direction of propulsion is now along the Y-axis, the Z-axis corresponds to the width B of the nozzle in part 10. Due to friction, the speed at the edge only increases insignificantly over the length shown here, but a broadening of the speed profile in the width can be seen, since the height of the nozzle also decreases continuously in the X-direction. However, due to friction, the maximum speed increase occurs more in the middle of the width (since only half the nozzle is shown here, this has to be included for reasons of symmetry).

[0175] The lower part B of Figure 10 shows the simulation through the nozzle without friction on the inner walls. Here, a significant increase in speed occurs at the edge, i.e. in the Z-direction, which

[0176] Tensile stresses are caused. The individual elements of the roller arrangement shown here in the various designs can be combined as desired with regard to their individual sections, geometries, structure, and wall coatings in order to control the anisotropy and fiber formation and prepare them for the desired end product. In particular, a combination of ejection nozzle and roller arrangement can achieve a high degree of flexibility with regard to the strength, direction, and shape of the anisotropy.

[0177] Figures 14, 15 and 16 show further embodiments of a corresponding roller arrangement. In Figure 14, a plate element 150 is provided which is stationary and at the same time arranged at an angle relative to a belt roller 31, so that a gap present in the advancing direction becomes increasingly smaller. The angle between the roller belt 300 and the plate can be adjusted in some aspects. The extrudate mass is driven forward by the belt roller 31 with a roller belt 300 in the direction of the outlet, so that a very thin, but wide-pressed strip is pressed out there. The plate element 350 is designed with heating or cooling elements so that the temperature of the texturate can be adjusted. In addition, the surface of the plate 350 can comprise different materials in order to adjust static friction and / or sliding friction between the extrudate and the plate 350.In this embodiment, the plate 350 achieves a uniform and continuous linear reduction of the extrudate towards the exit.

[0178] Figure 15, on the other hand, shows a slightly different embodiment in which a plurality of height-adjustable plate elements 355 are arranged one behind the other. The two plate elements 355a following the first plate element 355 each have a bevelled or curved surface facing the inlet, followed by a surface running parallel to the roller belt. Accordingly, a transition from a first distance to a second distance through these curved regions is essentially continuous and uniform, i.e. occurs without major breakage. In this exemplary embodiment too, the distance between the belt roller 31 with its roller belt 300 and the undersides of the height-adjustable plate elements 355 is reduced, as a result of which the extrudate is subjected to transverse and longitudinal tension, thus producing the desired texturing.

[0179] The adjustable height elements 355 and 355a make it possible to exert different transverse and longitudinal stresses on the extrudate, thus allowing adjustments to be made in the event of a change in the recipe and achieving the desired text control. Furthermore, the plate shapes shown here can also be designed differently, for example, with different gradients, and not, as shown here, with a curved entry area, where a surface parallel to the roller belt 300 is positioned.

[0180] Compared to Figure 14, Figure 16 shows a kinematically reversed embodiment in which the plate element 350 is arranged straight and the belt roller 31 with its roller belt is arranged at an angle due to differently sized roller rollers 312, 313 and 314. This likewise leads to a reduction in the distance between the roller belt 300 and the underside of the plate 350, with the propulsion again being achieved by the rotation of the belt roller. However, due to the different geometry between Figures 14 and 16, a different texturing can occur, so that flexible texturing is ensured by the geometric arrangement and design between the plate element and the belt roller.

[0181] In addition to the roller rolls 310, 312, 313 and 314 shown here in different sizes, other designs and in particular other shapes of rollers are also possible. Figure 17 shows various designs in this regard which, due to their different geometries, do not exert uniform pressure, but rather a different pressure on a roller belt or on the extrudate depending on the rotational position. This makes it possible to achieve a flexible design with different pressure profiles for producing a textured product. Accordingly, the different shapes of roller rolls shown can also be combined with round roller rolls without this detracting from the inventive concept. Accordingly, the individual roller arrangements with the various elements can also be combined with one another and adapted to the respective recipe.

[0182] Figures 12A to 12C show a further exemplary embodiment. Here, the extruder arrangement downstream of the expansion nozzle comprises a number of rollers arranged one behind the other, which together form a roller arrangement according to the proposed principle. The individual rollers are labeled 1 to 5, with the first roller 1 being the roller closest to the expansion nozzle. The numbering serves, among other things, to show the effect of the respective rollers on the extrudate in Figures 12B and 12C. For this purpose, the viscoelastic multiphase gel emerging from the expansion nozzle is labeled 0. Pressure is then exerted by the individual rollers perpendicular to the direction of advance, with the thickness of the gel strand simultaneously becoming increasingly smaller, i.e. the distance between two opposing rollers decreases as described above.

[0183] Figure 12B shows a top view of several strands and their surface texture after each roll. Figure 13 shows the same strands in a cross-section for each roll. The increase in fibrous consistency across the different rolls is clearly visible. This consistency is evident both in the surface and in the cross-section. The fibrous structure runs along the strands and its length corresponds to the length of the strands. The roll arrangement thus allows transverse and longitudinal tension to be generated by adjusting the number of rolls and the pressure exerted by them. This tension textures the extrudate and gives it a long, fibrous structure. The dispersion between the individual phases is broken up in this way and, in the present example, flat, fibrous textures are produced from the round pieces.

[0184] Figure 11 shows an example of the steps in a process for producing a texturate according to the proposed principle, as can be produced using one of the mixing extruders with a downstream roller arrangement shown in the explanations. The process takes advantage of the fact that a dough mix with a lower water content leads to increased interaction between the individual proteins and polymers during kneading of the dough in the extruder arrangement, so that the resulting dough has a significantly increased viscosity while at the same time retaining elasticity. By adding sugar and salt and by means of a suitable two-stage thermo-mechanical treatment using the proposed extruder arrangement (e.g.The viscoelasticity is first adjusted (using a two-axis screw drive) and then used with the downstream roller arrangement to impose a defined deformation and thus anisotropy on the multiphase system or the extrudate. This involves specifically deforming the dispersed phases of the extrudate and deliberately causing the extrudate to fracture, resulting in the desired anisotropy in the form of layers and / or fibers.

[0185] In step S1, a protein mixture is provided. This comprises a protein concentrate from wheat and a protein concentrate from pea protein. The proportion of proteins in the respective concentrates is approximately 45% by weight, with a residual moisture content in the range of approximately 25% by weight and other components such as starch, oils and others. In this embodiment, vegetable fibers are also present in the concentrates. The two concentrates are mixed in roughly equal proportions and make up approximately 70% by weight of the basic mixture. 10% by weight of vegetable oil is also added to the mixture, as well as salt in the range of 1% by weight and sugar in the range of 5% by weight. Flavorings and spices are in the range of 2% by weight. The solid and oily components therefore make up 88% by weight, with the residual moisture in this mixture being approximately . 17.5% by weight (0.70% * 0.25%).

[0186] In step S2, water is added to the mixture in a concentration of approximately 12% by weight and mixed to a light slurry. This results in approximately 30% by weight of water in the resulting slurry.

[0187] The slurry is then kneaded into a dough in step S3 under pressure and at an increased temperature. The dough is kneaded in sections and then slightly advanced. In the first sections, the temperature is rapidly increased from room temperature to over 100 °C, and then maintained at around 130 °C for the remaining kneading and advance steps. The pressure during this process is between 5 and 6 bar.

[0188] 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.

[0189] In this embodiment, in step S4, the mass is subjected to transverse expansion at a temperature of approximately 125°C. The expansion stress in this expansion zone results from a change in the width of the die while the die shrinks at the same time. In this configuration, only the shape of the inlet changes with respect to the outlet; however, their areas are the same, so that the mass flow through the die is also constant. In the center section of the expansion die, a suitable coating reduces static friction, so that the dough being forced forward does not get stuck and no major shear forces occur that could lead to wall slippage or dough breakage.

[0190] The temperature does not change significantly during the expansion deformation, i.e., at the end of the expansion die, the extrudate has a temperature of approximately 125 °C. Rapid expansion occurs at the outlet due to the pressure drop. This creates a porous structure in the extrudate without destroying any existing structure caused by the expansion stress.

[0191] The extrudate is then fed in step S5 to a roller arrangement which has two opposing belt rollers. The belts grip the extrudate and push it forward due to their static friction. The rotation speed of the belt rollers and the decreasing gap between them exerts vertical pressure with simultaneous forward propulsion. Due to the static friction, strong forces are created in the material. The protein-protein interaction and protein-polysaccharide interaction during kneading and the ejection nozzle form elongated fibers and a layer-like structure. The stretching which occurs here leads to a splitting of this possibly isotropic structure (any existing anisotropy can also be increased in this way) and to anisotropy. This is at least partially reversible due to the above-mentioned interaction, provided the pressure and duration are not too great.The roller assembly now exerts pressure of sufficient intensity and duration to maintain the anisotropy applied within the roller assembly. The finished textured product.

[0192] Another example of a method for producing a textured article with a fibrous structure whose length may be greater than 10 cm is shown below, again with reference to Figure 11.

[0193] In step S1, a protein mixture is also prepared. In the example, this comprises a protein concentrate from a vegetable protein. The pure protein content in the concentrate is in the range of 55% by weight. The remaining 45% by weight in the concentrate is divided into a residual moisture content of 15% by weight, vegetable oils and fats at approximately 10% by weight and starch in the range of 10% by weight. The remaining 10% by weight are fibers and other residual vegetable components, such as

[0194] Salts and minerals .

[0195] For the base mix, the protein concentrate is mixed at a weight ratio of 75% with water at 25%. No other components are added in this example. This results in the following proportions for the base mix: 41% pure protein, 36% water, 7.5% oils and fats, 7.5% starch, and approximately 7.5% fiber.

[0196] In step S2, this essentially dry mixture is fed into a mixing extruder and the water is slowly added in successive stages under pressure and at an increased temperature. In other words, the water is not added all at once, but in several parts during the kneading process. The water is heated during addition, so that there is no or only a slight temperature gradient and the dough is kept at a high or increasing temperature during the kneading process. The maximum temperature during the kneading process is in the region of approximately 145°C.

[0197] In step S3, the kneaded matrix, as a viscoelastic gel, is subjected to tensile stress. The dough mass is propelled forward in sections without tensile stress and then stretched in sections. The latter occurs when the flow velocity of the dough is increased at the same mass flow. The stretching deformation in sections and the resting sections create a reversible structuring so that only slight anisotropy develops. The length of the propulsion, in which the flow velocity is increased in sections, is significantly greater than the diameter of the inlet cross section. Furthermore, in this design the increase in flow velocity in the tapered sections of the stretching nozzle is different. In particular, the flow velocity is only increased slightly at the beginning, but increases further during the propulsion. This prevents the fiber formation from breaking.

[0198] In section S4 the product is suddenly released at the outlet. At the same time the temperature does not drop suddenly but slowly to below 100 °C. This causes some of the water bound in the matrix to evaporate, which leads to pore formation. The extrudate is then cut into several longitudinal strips and then fall into a roller arrangement in step S5. The roller arrangement comprises two oppositely arranged belt rollers, each of which has several rollers with gaps. The extrudate strips are conveyed towards the belt rollers by gravity until they are gripped by a roller belt. The two roller belts exert a strong pressure perpendicular to the force of gravity and convey the extrudate strips further due to static friction. The roller belts are open at the sides, i.e.The mass of the extrudate strips can deflect perpendicularly to the direction of advance and to the direction of compression during the advance, so that a tensile stress is exerted in this direction and in the forward direction, which leads to anisotropy and layering of the mass.

[0199] In another alternative example not shown in the figures, a protein mixture is produced from a broad bean concentrate and a soy protein isolate by mixing them in proportions of 60% to 40% by weight. The broad bean concentrate contains, in addition to a protein content of 45% by weight, starch and sugar at 25% by weight, residual moisture of 10% by weight, and fibers, oils, and other components totaling 20% ​​by weight. The soy protein isolate has a protein content of 93%, 3% by weight is residual moisture, 2% by weight is starch, and the rest is oils and fats.

[0200] The mixture specified above results in protein contents in the range of 64.2% by weight, sugar and starch in the range of 16% by weight, a residual moisture content of 7.2% by weight, and 13% by weight of remaining components.

[0201] This mass can then be mixed with water, for example, to create the base mixture, with 20 parts water being added to 80% by weight of this mixture. This results in a total of 51.4% by weight of proteins and approximately 27% by weight of water. The remainder, approximately 22% by weight, is made up of starch and sugar, along with the other components. This base mixture can be further processed using the proposed method.

[0202] The processes specified here produce an extrudate as an intermediate product whose moisture content is lower than the water content in the base mix during kneading of the dough. The reason for this is the water loss during expansion at the outlet of the expansion die after the stretching step, particularly when the temperature of the dough and the pressure are kept above the vapor pressure of the water at this temperature. Figure 18 shows a schematic representation of an extruder arrangement according to the invention according to a further embodiment of the present invention.

[0203] This further embodiment builds on the embodiment explained with reference to Figure 1, so that the above statements also apply to the embodiment shown in Figure 18. However, the embodiment according to Figure 18 additionally has an alignment unit

[0204] 180 which is functionally arranged between the cutting device 41 and the roller arrangement 30.

[0205] It is schematically shown how the cutting device 41 separates strips from the gel or textured material emerging from the ejection nozzle 20. The strips are firstly fed one after the other onto a first conveyor belt

[0206] 181 from the cutting device 41 to a second conveyor belt 182. The strips are aligned on the first conveyor belt 181 such that their main extent is oriented parallel to the main conveying direction (indicated by the thick arrow). The second conveyor belt 182 is at an angle of between 50 and 130 degrees to the first conveyor belt 181, preferably between 70 and 110 degrees and particularly preferably between 80 and 100 degrees. In the present case, the two conveyor belts 181, 182 are, for example, perpendicular to one another (an angle of 90 degrees). This means that the strips are transported on the second conveyor belt 181 along a main conveying direction which runs perpendicular to their main extent. The strips are therefore rotated by the alignment unit 180 by approximately 90 degrees relative to the main conveying direction.

[0207] The strips are thus conveyed transversely into the subsequent roller arrangement 30 and rolled there across their entire width, thereby promoting the formation and, in particular, the freezing of the anisotropies. Advantageously, the anisotropy index of the textured material conveyed through the roller arrangement is increased by more than 20%, preferably more than 40%, and particularly preferably more than 60%.

Claims

PATENT CLAIMS 1. Extruder arrangement, comprising: a mixing extruder (1) with an inlet zone for supplying a base mixture which contains at least one protein mixture and water, a mixing zone and an ejection zone; wherein the mixing extruder (1) is designed to produce a multi-phase gel from the base mixture across several zones with a temperature increase up to a maximum temperature between 110°C and 170°C; an ejection nozzle (20) which is connected to the ejection zone and is designed to treat the multi-phase gel thermomechanically during an advance of the multi-phase gel to form a viscoelastic multi-phase and in particular cohesive gel; a roller arrangement (30) whose gap is at least partially smaller than a thickness of the ejection nozzle (20), which is designed to exert a pressure on the viscoelastic multi-phase gel perpendicular to an advance direction.

2. Extruder arrangement according to claim 1, wherein the roller arrangement (30) is designed such that the anisotropy index of the gel guided through the roller arrangement (30) is increased by more than 20% and preferably more than 40% and particularly preferably more than 60%.

3. Extruder assembly according to claim 1, wherein the roller assembly (30) comprises at least one of the following elements: - two rows of rollers (310, 311, 312, 313, 314, 315) facing each other, each row comprising a plurality of rollers arranged in the forward direction; - two oppositely arranged belt rollers (31, 32), each comprising a roller belt (300) tensioned and driven by at least two rollers (310, 311); - a belt roller (31, 32), a roller belt (300) tensioned and driven by at least two rollers (310, 311) and a row of at least one roller roller (310, 311, 312, 313, 314, 315) opposite the roller belt (300).

4. Extruder arrangement according to claim 2, wherein a distance between two adjacent roller rollers (310, 311, 312, 313, 314, 315) of a row is less than a diameter and in particular less than a radius of the roller rollers.

5. Extruder arrangement according to one of claims 2 to 3, in which at least two adjacent roller rollers (310, 311, 312, 313, 314, 315) have a different diameter, wherein in particular one roller roller has a smaller diameter than a roller roller arranged downstream of this roller roller in the direction of advance.

6. Extruder arrangement according to one of claims 2 to 4, in which the roller arrangement (30) is designed to effect different rotational speeds of the roller rollers (310, 311, 312, 313, 314, 315); and in particular, to effect a lower rotational speed for a roller roller in a row than for a roller roller in the row arranged downstream of this roller roller in the direction of advance.

7. Extruder arrangement according to one of claims 2 to 5, wherein the roller arrangement (30) is designed to effect a different speed between the oppositely arranged rows of roller rollers (310, 311, 312, 313, 314, 315); or to effect a different speed between the oppositely arranged belt rollers (31, 32) or between the belt roller (300) and the oppositely arranged roller roller (310, 311, 312, 313, 314, 315).

8. Extruder arrangement according to one of claims 2 to 6, in which a surface of the roller rollers (310, 311, 312, 313, 314, 315) facing the viscoelastic multiphase gel or a surface of the roller belt facing the viscoelastic multiphase gel is structured, in particular has an embossed surface.

9. Extruder arrangement according to one of the preceding claims, wherein an input-side gap of the roller arrangement (30) is larger than an output-side gap.

10. Extruder arrangement according to one of the preceding claims, in which the gap of the roller arrangement (30) decreases at least in sections in the advancing direction.

11. Extruder arrangement according to one of the preceding claims, in which the gap of the roller arrangement (30) remains substantially constant in the advancing direction, at least in sections.

12. Extruder arrangement according to one of the preceding claims, in which the roller arrangement (30) is designed to be temperature-controlled, in particular heatable, in particular designed so that the roller rollers (310, 311, 312, 313, 314, 315) and / or the roller belts (31, 32) can be temperature-controlled separately.

13. Extruder arrangement according to one of the preceding claims, wherein an inner side of the ejection nozzle (20) is coated with a fluoropolymer, in particular Teflon; or an inner side of a first section of the ejection nozzle (20) comprises a first material, and an inner side of a subsequent second section of the ejection nozzle (20) comprises a second material different from the first material.

14. Extruder arrangement according to one of the preceding claims, wherein the ejection nozzle (20) has at least one section in which a decrease in diameter along a first direction perpendicular to the advancing direction is greater than a decrease along a second direction perpendicular to the first direction and advancing direction; and / or the ejection nozzle (20) has at least one section in which an increase in diameter takes place along a direction perpendicular to the advancing direction, wherein an inlet cross section of the Ejection nozzle (20) is larger than an output cross-section of the ejection nozzle; the ejection nozzle (20) has at least a first section with a constant cross-section, at least a second section with a decreasing cross-section, and at least a third section with a constant cross-section; and / or optionally, a material of a section with a constant cross-section is different from a material of a section with a decreasing cross-section.

15. Extruder arrangement according to one of the preceding claims, in which a material of the ejection nozzle (20) which is in contact with the multiphase gel is at least partially different from a material of the roller arrangement (30) which is in contact with the viscoelastic multiphase gel; and / or in which a material of the ejection nozzle (20) has, at least partially, a lower coefficient of static friction than a material of the roller arrangement (30).

16. Extruder assembly according to one of the preceding claims, further comprising: a cutting assembly (41) arranged between the ejection nozzle (20) and the roller assembly (20); and / or a rest zone arranged between the ejection nozzle (20) and the roller assembly (30) and configured to transport the viscoelastic multiphase gel while reducing a moisture content.

17. Extruder arrangement according to one of the preceding claims, wherein the cutting device (41) separates individual strips from the gel emerging from the ejection nozzle (20), wherein the extruder arrangement has an alignment unit (180) which determines the alignment of the strips separated by the cutting device (41) relative to their main transport direction and in particular rotates the strips in such a way that their main extension is oriented perpendicular or nearly perpendicular to the main transport direction before the strips pass through the roller arrangement .

18. A method for producing a textured article, comprising the steps of: Providing a protein mixture comprising at least a first protein mixture with a weight proportion of between 40% by weight and 90% by weight based on a base mixture; adding water with a weight proportion of between 10% by weight and 50% by weight based on the base mixture to form a slurry; Extruding the slurry to form a viscoelastic multiphase gel at a maximum temperature between 110 ° C and 160 ° C ; applying a first thermomechanical treatment to the viscoelastic multiphase gel, in particular at a temperature above 100 ° C, wherein expansion of the viscoelastic multiphase gel is restricted in both directions perpendicular to the forward direction; Inducing anisotropy in the treated viscoelastic multiphase gel by exerting a pressure on the treated viscoelastic multiphase gel in one direction perpendicular to the forward direction while allowing substantially unrestricted expansion of the treated viscoelastic multiphase gel in the other direction perpendicular to the forward direction . 19 . The method of claim 18 , wherein the treated viscoelastic multiphase gel is a cohesive gel after subjecting it to a first thermomechanical treatment.

20. A method according to any one of claims 18 to 19, wherein the formation of anisotropy comprises breaking the viscoelastic multiphase gel into at least two phases of different viscosity.

21. A method according to any one of claims 18 to 1800, wherein forming an anisotropy of the treated viscoelastic multiphase gel comprises intermittently or continuously compressing the treated viscoelastic multiphase gel during propulsion.

22. The method according to any one of claims 18 to 21, wherein the step of forming anisotropy is carried out by rolling the treated viscoelastic multiphase gel through two rows of opposing rollers; and / or rolling the treated viscoelastic multiphase gel through two oppositely arranged belt rollers (31, 32), each comprising a roller belt tensioned and driven by at least two rollers; rolling the treated viscoelastic multiphase gel through a belt roller (31, 32) which comprises a roller belt (300) tensioned and driven by at least two rollers and a row of at least one roller roller (310, 311, 312, 313, 314, 315) opposite the roller belt (300).

23. The method according to any one of claims 18 to 22, wherein forming an anisotropy of the treated viscoelastic multiphase gel comprises rolling the treated viscoelastic multiphase gel with rollers of different sizes; and / or rolling the treated viscoelastic multiphase gel with rollers having different rotational speeds.

24. The method according to any one of claims 18 to 23, wherein forming an anisotropy of the treated viscoelastic multiphase gel comprises compression, wherein two oppositely arranged rows of roller rolls each have a different speed; or wherein two oppositely arranged belt rollers each have a different speed; or wherein a belt roller and at least one oppositely arranged roller roll (310, 311, 312, 313, 314, 315) have a different speed.

25. Method according to one of claims 18 to 24, wherein the formation of an anisotropy of the treated viscoelastic multiphase gel comprises structuring, in particular embossing, the surface of the treated viscoelastic multiphase gel.

26. The method according to any one of claims 18 to 25, wherein a thickness of the treated viscoelastic multiphase gel is greater than a thickness of the gel after the anisotropy has been formed.

27. A method according to any one of claims 18 to 26, wherein forming anisotropy comprises heating or heat treating the treated viscoelastic multiphase gel. 28 . Method according to one of claims 18 to 27 , further comprising : Cutting the treated viscoelastic multiphase gel substantially perpendicular to the direction of advance; and / or reducing a moisture content of the treated viscoelastic multiphase gel, in particular before generating anisotropy. 29 . Method according to claim 28, wherein the gel is cut into strips and wherein the strips are changed and in particular rotated with regard to their orientation relative to the main transport direction.

30. Method according to one of claims 18 to 29, further comprising treating the surface of the textured product, in particular coating it with a spice, a salt, or an emulsion layer.

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