Meat substitute products

Abstract

The present disclosure relates to a low-moisture extruded composition that comprises wheat gluten and lentil flour and a process for preparing the low-moisture extruded composition. The present disclosure also relates to a meat substitute product that comprises the low-moisture extruded composition and a process for preparing the meat substitute product. A use of lentil flour to prepare a textured wheat gluten-containing ingredient and a use of the ingredient to prepare a meat substitute and meat extender products are also provided herein.

Description

MEAT SUBSTITUTE PRODUCTSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of European Application No. 23207551.5, filed November 2, 2023, which is incorporated by reference herein in its entirety.FIELD OF INVENTION

[0002] This invention relates to the field of extruded plant-based compositions for meat substitute products, such as for example plant-based burger, mince, meatbail, schnitzel, or chicken nugget substitutes, and also to the field of extruded plant-based compositions for meat extender products.BACKGROUND

[0003] Traditionally, meat products have taken an important place in our diet. Meat products are consumed in many different forms as whole muscle or minced pieces of meat that are cooked, grilled, smoked, cured, or fermented in the form of hamburgers, patties, sausages, meat balls, nuggets, and many more.

[0004] There is a growing trend of a shift in diets towards more plant-based foods. Trends include flexitarianism, characterized by only occasionally consuming meat, vegetarianism, characterized by excluding animal-containing food but consuming dairy and egg, and finally veganism, characterized by excluding both animal-containing food and animal by-products (including dairy and egg). Over the last decade, increasing investment has been directed towards creating meat alternative or substitute products or meat extenders with ever closer organoleptic properties to meat.

[0005] Texture, mouthfeel, appearance, flavor, and cooking experience - these are the elements of meat that the plant-based meat alternative manufacturers are trying to capture, with varying degrees of success, using a range of ingredients to achieve these properties.

[0006] Vital wheat gluten (VWG) has been commonly used in making plant-based meat alternatives. Typically, extruding VWG requires processing aids such as tetrasodium pyrophosphate (TSPP). However, consumers are becoming increasingly concerned about chemically modified ingredients in their products, which they cannot understand or which they do not have in their kitchen pantry. Plant-based meat alternative manufacturers are now looking for solutions that will provide wheat gluten-based meat alternatives with the same or improved functionalities (such as sensory attributes including mouthfeel, appearance, taste, smell, but also physical attributes such as texture, springiness, resilience, water absorption, and retention capacities etc.), whilst offering what is perceived by consumers as a cleaner label.SUMMARY

[0007] The present disclosure provides a low-moisture (or also referred to as “dry”) extruded composition that comprises or essentially consists of:• 25-75wt%, preferably 30-73 wt% of wheat gluten;• 25-75 wt%, preferably 27-70 wt% of lentil flour; and• Optionally a process aiding agent, such as a base,

[0008] based on the total weight of the composition on an as is basis, and preferably wherein the composition has a water absorption capacity of at least 2.5 times, preferably 3.0 times its weight, more preferably 3.0-4.0 times its weight.

[0009] The composition optionally contains a base, such as sodium carbonate, sodium bicarbonate, or sodium hydroxide.

[0010] Such a composition can also be referred to as a textured composition.

[0011] The present disclosure also provides a process for preparing a low-moisture (or also referred to as “dry”) extruded composition that comprises the step of extruding a blend of vital wheat gluten and lentil flour optionally in the presence of a base, such as sodium carbonate, sodium bicarbonate, or sodium hydroxide, at an extrusion temperature of 30 to 180°C, preferably of from 40 to 160 °C, to obtain the low-moisture (or also referred to as “dry”) extruded composition. Water is added to the extruding step in an amount sufficient to cook the composition and such that after extrusion and drying the final moisture content of the composition is preferably not more than 15wt%, or not more than 12wt%, or not more than 10wt%, preferably less than 9wt%, preferably less than 8wt%, preferably less than 7wt%.

[0012] The present disclosure also provides a meat substitute product that comprises the low- moisture (or also referred to as “dry”) extruded composition of the present invention.

[0013] The present disclosure also provides a process for preparing a meat substitute product that comprises the steps of: (a) blending the low-moisture extruded composition of the present invention with one or more ingredients of methylcellulose, plant proteins, fat(s) and / or oil(s), flavoring agents, coloring agents, hydrocolloids, food texturizers, preservatives and salts, to form a mixture; (b) forming the mixture into individual portions of the meat substitute product; (c) optionally coating the meat substitute product with battering agents and coating agents to form a coated meat substitute product; and (d) optionally cooking the coated meat substitute product to form a cooked meat substitute product.

[0014] The present disclosure also provides a use of vital wheat gluten and lentil flour in the preparation of a low-moisture (also known as dry) extruded composition.

[0015] The present disclosure also provides a use of vital wheat gluten and lentil flour in the preparation of a textured composition.

[0016] The present disclosure further provides a use of the low-moisture (also known as dry) extruded composition of the present invention to prepare a meat substitute product or a meat extender product.DETAILED DESCRIPTION

[0017] Reference will now be made in detail to certain aspects of the disclosed subject matter. While the disclosed subject matter will be described in conjunction with the enumerated claims, it will be understood that the exemplified subject matter is not intended to limit the claims to the disclosed subject matter.

[0018] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one skilled in the art to which this invention belongs. As used herein, each of the following terms has the meaning associated with it as defined below.

[0019] Unless expressly stated, ppm (parts per million), percentage, and ratios are on a by weight basis. Percentage on a by weight basis is also referred to as wt% below.

[0020] The term “for example,” “for instance,” “such as,” or “including” as used herein is meant to introduce examples that further clarify more general subject matter. Unless otherwise specified, these examples are provided only as an aid for understanding the applications illustrated in the present disclosure and are not meant to be limiting in any fashion.

[0021] In the methods described herein, the acts can be carried out in any order without departing from the principles of the disclosure, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0022] As used herein, the term “room temperature” or “RT” refers to a temperature between 20°C and 25°C.Low-moisture extruded composition

[0023] The present disclosure relates to a low-moisture extruded composition (or also referred to as “dry extruded composition”) suitable for making a meat substitute product. The extruded composition consists essentially of wheat gluten and lentil flour.

[0024] The wheat gluten that is used to make the low-moisture extruded composition is also known as vital wheat gluten or wheat protein. The protein content of the wheat protein or wheatgluten can, preferably, be in a range of 70 to 99 wt%, or 75 to 95 wt%, or 80 to 90 wt%, or 80 to 85 wt% on a dry basis.

[0025] Protein content of lentil flour can, preferably, be at least 20 wt%, at least 24 wt%, or at least 26 wt%, or at least 28 wt% on a dry basis.

[0026] The weight ratio of wheat gluten to lentil flour present in the low-moisture extruded composition can be in a range of from 30:70 to 75:25, or from 30:70 to 71 :29, or from 30:70 to 72:28, or from 35:65 to 75:25, or from 40:60 to 55:45, or from 40:60 to 54:46, or from 45:55 to 51 :49, or around 35:65, or around 50:50, or around 51 :49, or around 52:48, or around 71 :29, or around 72:28 .

[0027] The low-moisture extruded composition of present invention can, preferably, include at least 30 wt%, or at least 35 wt%, or at least 40 wt %, or at least 45 wt %, or at least 48 wt %, or at least 50 wt %, or at least 55 wt %, or at least 60 wt %, or at least 70wt % wheat gluten based on the total weight of the composition. Wheat gluten may be present in the composition up to at most 75wt%, based on the total weight of the composition. Preferably, wheat gluten is present in the composition in a range of from 25 to 75 wt%, or from 35 to 60 wt%, or from 35 to 55 wt%, or from 40 to 54 wt%, or from 45 wt% to 53 wt%, or around 70 wt%, or around 71wt%, or around 50wt%, or around 51wt%, or around 35wt%, based on the total weight of the composition.

[0028] The low-moisture extruded composition of the present invention can, preferably, include at least 25wt%, or at least 30 wt%, or at least 35 wt%, or at least 40 wt%, or at least 45 wt%, or at least 46 wt %, or at least 47 wt %, or at least 50 wt %, or at least 55 wt %, or at least 60 wt % lentil flour based on the total weight of the composition. Lentil flour may be present in the composition up to at most 75 wt%. Preferably, lentil flour is present in the composition in a range of from 25 to 75 wt%, or from 30 to 70 wt%, or from 40 to 65 wt%, or from 45 to 65 wt%, or from 46 to 65 wt%, or from 47 to 60 wt%, or around 28wt%, or around 30 wt%, or around 48wt%, or around 50wt%, or around 65wt%, based on the total weight of the composition.

[0029] Preferably, the low-moisture extruded composition may comprise:• 25 to 75 wt%, or from 35 to 60 wt%, or from 35 to 55 wt%, or from 40 to 54 wt%, or from45 wt% to 53 wt%, or around 70 wt%, or around 71wt%, or around 50wt%, or around 51wt%, or around 35wt% wheat gluten and• 25 to 75 wt%, or from 30 to 70 wt%, or from 40 to 65 wt%, or from 45 to 65 wt%, or from46 to 65 wt%, or from 47 to 60 wt%, or around 28wt%, or around 30 wt%, or around 48wt%, or around 50wt%, or around 65wt% lentil flour, based on the total weight of the composition.

[0030] The low-moisture extruded composition of the present invention may or may not contain one or more process aiding agent(s), like a pyrophosphate, such as tetrasodium pyrophosphate(TSPP) or tetrapotassium pyrophosphate (TKPP). However, in search of cleaner label alternatives, manufacturers are looking to replace such pyrophosphates with more label friendly alternatives, with bases, such as sodium carbonate, sodium bicarbonate, or sodium hydroxide.

[0031] The term “process aiding agent”, as used herein, refers to a substance that helps to ensure a smooth and complete processing of a plant protein in preparation of a meat substitute product (e.g., extrusion). For example, in preparing an extruded ingredient for meat substitutes, process aiding agents are added to ensure extrusion of plant proteins, in particular wheat gluten, are successfully and completely carried out. It can be present of from 0.1 to 5wt% based on the total weight of the composition, preferably of from 0.5 to 3wt% or more preferably of from 0.5 to 1.5wt% or most preferably around lwt%.

[0032] In this case, the inventors have found that preferably a base, preferably sodium carbonate, sodium bicarbonate, or sodium hydroxide, can be used to achieve the desired texture of the final composition. Therefore, pyrophosphates such as TSPP and TKPP can be avoided. The base can be present of from 0.1 to 5wt% based on the total weight of the composition, preferably of from 0.5 to 3wt% or more preferably of from 0.5 to 1.5wt% or most preferably around lwt%.

[0033] The low-moisture extruded composition of the present invention may have a protein content of at least 40 wt%, or at least 45 wt%, or at least 50 wt%, or at least 55 wt%, or at least 60 wt%, or up to at most 68 wt%, or up to at most 65 wt% on a dry basis. The low-moisture extruded composition of the present invention may have a protein content of from 40wt% to 68wt%, or of from 41wt% to 67%, or of from 42wt% or 65wt%.

[0034] Protein digestibility corrected amino acid score (PDCAAS) refers to a method for evaluating protein value in human nutrition. The method compares the amino acid profile of the specific food protein against a standard amino acid profile with the highest possible score being a 1.0, in which a 1.0 score means that the specific food protein provides per unit of protein 100% or more of the indispensable amino acids required for human nutrition (See, for example, Food and Agriculture Organization of the United Nations (FAO) / World Health Organization (WHO) / United Nations University (UNU) Expert Consultation 1985). Thus, the higher the value of PDCAAS of a food product is, the higher the protein quality the food product has. In one aspect, the low-moisture extruded composition may have a PDCAAS of at least 0.25, or of at least 0.30, or of at least 0.35.

[0035] The moisture content of the low-moisture extruded composition is preferably not more than 15wt%, preferably not more than 12wt%, more preferably not more than 10wt%, most preferably not more than 8wt%, or even not more than 5wt%. Moisture content can be measured using a moisture meter.

[0036] The low-moisture extruded composition can have particle sizes of from 1 to 15mm. Depending on the intended application the composition can have particles sizes of from 1 to 4mm, alternatively of from 4 to 7mm, alternatively of from 7 to 15mm. The desired range of particle size can also be achieved by sieving. Particle size range of the composition can be measured by sieving.

[0037] The low-moisture extruded composition can have a bulk density of from 0.15 to 0.5 g / ml, preferably 0.18 to 0.40 g / ml, more preferably 0.2 to 0.35 g / ml. Bulk density is measured by the following method:1. Thoroughly mix the sample to obtain a uniform particle distribution.2. Tare a measuring cup of known volume.3. Overfill the cup with sample.4. Gently shake the cup from side to side over the waste container to remove voids within the cup.5. Scrape the top of the cup with the ruler, removing excess material. Ensure the cup is filled completely without voids, flush with the top edge of the cup.6. Record the weight (g).7. Calculate the bulk density: divide the weight by the volume to obtain the bulk density as g / ml.

[0038] The low-moisture extruded composition can have a water absorption capacity of from 2.5 to 5.0, preferably from 3.0 to 5.0 g of water per g of composition, more preferably from 3.0 to 4.0 g / g. Water absorption capacity is measured by the following method:1. Weigh 50.0 g of sample (C).2. Measure 250 ml of cold tap water (A).3. Pour water and sample into 600 ml beaker.4. Allow sample to stand for 20 minutes for the samples having a protein content of 53wt%, or 30minutes for the samples having a protein content of 65wt% (dry basis).5. Insert strainer into dry plastic graduated cylinder.6. Pour contents into strainer funnel and allow to stand for 5 minutes.7. Read the cylinder with the drained contents to the nearest 5 ml (B) and record the value.8. Calculate the water absorption capacity: (A-B) / C, i.e., original water volume (A) minus the drained contents (B), divided by original sample weight (C).

[0039] The low-moisture extruded composition preferably has a pH in the range of 7.0 to 7.5 or preferably 7.35 to 7.50, measured by measuring the pH at a concentration of 5% at room temperature.

[0040] If the composition has a protein content of about 45 to 55wt% and a particle size range of from about 1 to 4mm:• The bulk density is preferably 0.2 to 0.4 g / ml, more preferably 0.25 to 0.35 g / ml,• And / or the water absorption capacity is preferably 3.0 to 4.0 g / g, more preferably 3.2 to 3.8 g / g,• And / or the pH is preferably in the range of from 7.0 to 7.5.

[0041] If the composition has a protein content of about 45 to 55wt% and a particle size range of from about 4 to 7mm:• The bulk density is preferably 0.25 to 0.35 g / ml, more preferably 0.27 to 0.33 g / ml,• And / or the water absorption capacity is preferably 2.5 to 4.5 g / g, more preferably 3.0 to 4.0 g / g,• And / or the pH is preferably in the range of from 7.0 to 7.5.

[0042] If the composition has a protein content of about 45 to 55wt% and a particle size range of from about 7 to 15mm:• The bulk density is preferably 0.15 to 0.25 g / ml, more preferably 0.17 to 0.23 g / ml,• And / or the water absorption capacity is preferably 3.5 to 5.0 g / g, more preferably 4.0 to 4.5 g / g,• And / or the pH is preferably in the range of from 7.0 to 7.5.

[0043] If the composition has a protein content of about 55 to 65wt% and a particle size range of from about 1 to 4mm:• The bulk density is preferably 0.35 to 0.45 g / ml, more preferably 0.35 to 0.40 g / ml,• And / or the water absorption capacity is preferably 2.5 to 3.5 g / g, more preferably 0.35 to 0.4 g / g,• And / or the pH is preferably in the range of from 7.0 to 7.5.

[0044] If the composition has a protein content of about 55 to 65wt% and a particle size range of from about 4 to 7mm:• The bulk density is preferably 0.30 to 0.53 g / ml, more preferably 0.33 to 0.50 g / ml,• And / or the water absorption capacity is preferably, more preferably 3.0 to 4.5 g / g, more preferably 3.1 to 4.0 g / g,• And / or the pH is preferably in the range of from 7.0 to 7.5.Process for preparing low-moisture extruded composition

[0045] The low-moisture extrusion of the composition of the present invention can be prepared using a standard low-moisture extruder, for instance a commercially available co-rotating doublescrew extruder. The barrel of the extruder can, for instance, contain 12 zones, each with its own temperature setting. The die is a standard die used in the art.

[0046] A pre-conditioning step (to humidify and / or pre-heat the composition) may or may not be applied to the composition prior to extruding. It was surprisingly found by the inventors that no pre-conditioning step is required.

[0047] The low-moisture extruded composition of the present invention can be prepared by a process, which comprises the step of extruding wheat gluten and lentil flour at an extrusion temperature of from 30 to 180°C, preferably 40 to 165 °C to form the low-moisture extruded composition. The temperature increases from room temperature at the beginning of the extruder to the maximum temperature at the end of the extruder.

[0048] Preferably, extrusion occurs under low moisture conditions. This is also referred to in the literature as dry extrusion. Sufficient water is added during the extrusion process to allow for proper cooking of the composition and for the desired end moisture content.

[0049] The composition can be extruded and cut such that the particle sizes are from 1 to 15mm. Depending on the intended application the composition, it can be extruded and cut such that the particles sizes will be from 1 to 4mm, alternatively of from 4 to 7mm, or alternatively of from 7 to 15mm. Alternatively, the desired range of particle size can also be achieved by milling and / or sieving.

[0050] After exiting the die, the composition is dried to achieve a maximum moisture content of 15wt%, preferably 12wt%, most preferably 10wt%. Drying can be done by any known means, but preferably in a single-belt dryer or a fluid bed dryer, most preferably a single-belt dryer.Meat substitute product or meat extender products

[0051] Meat substitute products also refer to meat alternative products, meat analogue products, meat mimicking products, meat replacement products, meat replica products and the like. By “meat” it is meant herein not only substitutes for red meats (from Bovidae), such as beef, lamb, bison, goat, and mutton, but any animal meat, including poultry (e.g., chicken, turkey, duck, ostrich, pigeon), fish (e.g., whether farmed or wild-caught), and shellfish (e.g., shrimp, prawns, crab, crayfish, lobster, scallops).

[0052] Alternatively, the meat substitute product of the present invention is a pet food. The term “pet food” means any food composition intended to be consumed by a pet. A pet may be any domestic or tamed animal kept for companionship or pleasure. The pet can, preferably, be an avian, bovine, canine, equine, feline, hircine, lupine, murine, ovine, or porcine animal. Preferably, the pet is a dog or a cat.

[0053] Preferred meat substitute products are vegetarian or vegan burger patties, sausages, coldcuts, nuggets, crumbles, or meat-like toppings (e.g., for dishes such as pizzas, pies, flans, quiche, and the like), seafood alternatives, poultry alternatives, breakfast meat alternatives, and minced meat alternatives. By minced meat it is included herein also toppings for dishes such as pizzas, pies, flans, quiche, and the like. Preferably, the meat substitute product can be a plant-based red- meat substitute product (e.g., plant-based burger, meatballs or minced meat) or a plant-based schnitzel substitute product or a plant-based chicken nugget substitute product.

[0054] As used herein, by “vegetarian” it is meant not comprising any animal meat products, including bovid meats, poultry, fish, crustaceans, mollusks, game, and the like.

[0055] As used herein, by “vegan” it is meant not comprising any animal meat products, nor any animal by-products, the latter referring to products such as eggs, honey, and dairy products.

[0056] Also disclosed herein are meat extender food products comprising the low-moisture extruded composition and meat or meat-derived ingredients. Meat extender products are products wherein a portion of the meat or meat-derived ingredients are replaced with plant-based ingredients. The present disclosure therefore also comprises the use of low-moisture extruded compositions as described above in a meat extender food product further comprising meat or meat- derived ingredients. Preferred meat extender food products are burger patties, sausages, schnitzels, cold-cuts, nuggets, crumbles, or meat toppings (e.g., for dishes such as pizzas, pies, flans, quiche, and the like), seafood alternatives, poultry alternatives, breakfast meat alternatives, and minced meat alternatives. By minced meat it is included herein also toppings for dishes such as pizzas, pies, flans, quiche, and the like.

[0057] The meat substitute products or meat extender food products can be frozen, fresh, or canned. The meat substitute products can be sold cooked, pre-cooked, or raw. The meat substitute products can undergo heating / cooking step(s), for instance by frying, baking, steaming, boiling, grilling, or roasting, to make the product fully cooked and ready to eat.

[0058] The meat substitute product or meat extender food product of the present disclosure comprises the low-moisture extruded composition as described above.Process for preparing meat substitute product

[0059] The present disclosure also provides a process for preparing a meat substitute product as described above. The process comprises the steps of: (a) blending a low-moisture extruded composition as described above with one or more ingredients of methylcellulose, plant proteins, fat(s) and / or oil(s), flavors (including salts), hydrocolloids, dietary fibers, food texturizers, preservatives (including acids, e.g. vinegar or citric acid) in water to form a mixture; (b). forming the mixture into individual portions of the meat substitute product; (c). optionally coating the meatsubstitute product with battering agents and coating agents to form a coated meat substitute product; and (d). optionally cooking the (coated) meat substituted product to form a cooked meat substitute product.

[0060] In one aspect, the meat substitute product may comprise, based on the total weight of the meat substitute product:

[0061] (i). the low-moisture extruded composition in an amount of from 5 to 30 wt%, preferably from 10 to 25 wt%;

[0062] (ii). water in an amount of from 50 to 75 wt%, preferably from 55 to 65 wt%;

[0063] (iii). methylcellulose in an amount of from 0.5 to 1.5 wt%, preferably from 0.8 to 1.2 wt%;

[0064] (iv). plant protein powder (e.g. vital wheat gluten, pea protein, or soy protein etc. - nontexturized), in an amount of from 1 to 6 wt%, preferably from 2 to 4 wt%;

[0065] (v). fat(s) and / or oil(s) (e.g. canola oil, sunflower etc.) in an amount of from 5 to 15 wt%, preferably from 7 to 10 wt%;

[0066] (vi). Flavoring agents (e.g. salt, pepper) in an amount of from 1 to 5 wt%, preferably from 1.5 to 2.5 wt%;

[0067] (vii). Hydrocolloids (e.g. carrageenan, konjac) in an amount of from 0.5 to 3 wt%, preferably from 1 to 2.5 wt%;

[0068] (viii). Food texturizers (e.g. modified starch) in an amount of from 1 to 3 wt%, preferably from 1.5 to 2.5 wt%; and

[0069] (ix). Dietary fibers (e.g. citrus fibers) in an amount of from 0.5 to 2 wt%, preferably from 0.5 to 1.5 wt%.Examples

[0070] The invention is further described in detail by reference to the following experimental examples. These examples are provided for purposes of illustration only and are not intended to be limiting unless otherwise specified. Thus, the invention should in no way be construed as being limited to the following examples, but rather should be construed to encompass any and all variations which become evident as a result of the teaching provided herein.Example 1 - Low-moisture extruded compositions1.1 Recipes of low-moisture extruded compositions

[0071] A study was carried out to compare the physiochemical properties and attributes of vital wheat gluten and lentil flour-based low-moisture extruded compositions. Wheat gluten was blended with lentil flour and process aiding agent, sodium carbonate. Table 1 shows recipes oftwo wheat gluten and lentil flour blends having different overall protein content. Amounts of the ingredients are measured in wt% of the total weight of the corresponding recipes.Table 1. Recipes of blends1.2 Process for preparing low-moisture extruded compositions

[0072] Following steps were taken to prepare the low-moisture extruded compositions using the recipes as shown in Table 1 with recipe-specific process conditions as shown in Table 2.

[0073] The dry ingredients of vital wheat gluten, lentil flour, and sodium carbonate were dry blended and then added to an extruder barrel.

[0074] An extruder shaft speed was set to approximately 400 rpm with no steam being added. The extruder was set to run at around 169 kg / h capacity.

[0075] All the dry ingredients were mixed and hydrated in an initial zone in the extruder barrel at an extrusion temperature around 40°C. The water feeding rate was between 42 L / h to 75L / h depending on the desired particle size range and protein content.Table 2. Recipe-specific process conditions

[0076] The mixed ingredients were conveyed into a heating zone by extruder screws within the extruder barrel, with the extrusion temperature increasing from zone to zone from 40°C to around 165°C as shown in Table 3. The average pressure was 20bar.Table 3. Extrusion temperatures across zones

[0077] The heated ingredients were conveyed out of the extruder barrel through a die with a die temperature of 120°C. The moisture at the die was at about 22.70wt%. The extruded composition was further cooled down in a cooling die at a cooling temperature of 28 to 30°C with a conehead pressure from 62 to 81 bar to obtain the low-moisture extruded compositions. The composition was dried after the die in a single-belt dryer at 120°C, such that the final product moisture was at a maximum 10wt%.

[0078] The low-moisture extruded compositions were cut into desired sizes e.g. 7- 15mm, 4-7mm, and l-4mm and stored in a refrigerator.1.3 Attribute evaluation

[0079] Bulk density, water absorption capacity, hydration time, and pH were measured on all the samples. Measurement methods were as described above.Table 4. Water absorption capacity1.4 Conclusion

[0080] It is known in the art that process aiding agents, such as TKPP and TSPP, are typically required when extruding wheat gluten to adjust pH for expansion of wheat gluten during dry extrusion. As observed from the results, it has surprisingly been found that by adding lentil flour to wheat gluten, the resulting wheat gluten / lentil flour blends can be successfully extruded without the use of TSPP or TKPP. Instead, the use of sodium carbonate as the process aiding agent leads to surprisingly well-textured ingredients suitable for use in meat alternative and meat extender products.

[0081] Another advantage lentil flour brings is the reduction in a noticeable film or “sliminess” that wheat flour creates when the product is hydrated. Upon hydration, wheat gluten alone is much less firm and much more “slimy” which would greatly impact mouthfeel and the impression of mushiness and chewiness. However, wheat gluten / lentil flour blends can maintain texture, firmness, and shape with no noticeable exterior film. Differences in chemical composition between lentil flour and wheat flour play a role in this observed physical difference and lentil flour shows positive improvement in comparison to other flours used commercially.

[0082] Further, the wheat gluten / lentil flour blends have surprisingly been found to improve firmness of the resulting compositions. The created fibrous structure can more closely mimic meaty, mince-like textures.

[0083] Advantageously, the low-moisture extruded compositions of the instant invention (i.e., made from wheat gluten + lentil flour blends) have an improved protein content and / or protein quality as compared to compositions made from other wheat gluten blends (e.g., wheat gluten / wheat flour blends).Example 2 - Meat substitute products2.1 Application of low-moisture extruded composition - minced meat burger substitute

[0084] Low-moisture extruded compositions made from the wheat gluten / lentil flour blends of the instant invention, as described in Table 1 above, can be used to prepare a minced meat burger substitute using particle sizes as described in Table 4. A formulation of a burger substitute is shown in Table 5. Amounts of the ingredients are measured in wt% of the total weight of the burger substitute.Table 5. Formulation of minced meat burger substitute

[0085] Following steps were taken to prepare the burger substitute with the formulation as described in Table 5.(1). The water (at 4°C) (for hydration of the extruded wheat gluten and lentil flour composition) was weighed out and mixed with the coloring agents, flavorings, spices, salt and frozen onion and garlic to obtain a homogeneous color and taste.(2). A methylcellulose emulsion was made by:(i) adding weighed sunflower oil for the emulsion to a mixer,(ii) adding the methylcellulose on top,(iii) mixing for 1.5min to ensure good dispersion at slow speed,(iv) adding starch (Simpure 99600) and wheat protein (Gluvital 21020) and vinegar,(v) adding weighed water for pre-emulsion and ice for pre-emulsion while the mixer is running and then mixing at high speed until a stable emulsion was formed (about 2min),(vi) and storing the emulsion at 2-4°C.(3). The extruded wheat gluten and lentil flour composition (1c) were hydrated with the water (from step 1) containing the coloring agents, flavorings, spices, salt, frozen onion and garlic. The Composition (1c) was hydrated at a ratio of 1 : 1 and mixed for a duration of 15min.(4). At the end of the hydration the hydrated mix was kneaded in a reverse direction in a mixer. The temperature was kept at 2-4°C.(5). Citripure was added and then mixed for 30 seconds. Then the emulsion kept at 2-4°C from step (2) was added on top of the cooled (at 2-4°C) mixture in the mixer at slow speed and then mixed at high speed until a stable structure was formed.(6). The coconut fat was weighed out, then added and then mixed at high speed in the mixer for 2min.(7). The dough was rested overnight and then given shape and cooked like a minced meat burger.2.2 Application of low-moisture extruded composition - minced meat burger substitute

[0086] Table 6 shows another formulation of a minced meat burger substitute that uses the low- moisture extruded compositions made from the wheat gluten / lentil flour blends of the instant invention as described in Table 1 above, using particle sizes as described in Table 4. Amounts of the ingredients are measured in wt% of the total weight of the burger substitute.Table 6. Formulation of minced meat burger substitute

[0087] Following steps were taken to prepare the burger substitute with the formulation as described in Table 5.(1). The water (at 4°C) (for hydration of the extruded wheat gluten and lentil flour composition) was weighed out and mixed with the coloring agents, flavoring agents, frozen shallots, dark pepper, cumin, salt, and garlic to obtain a homogeneous color and taste.(2). A methylcellulose emulsion was made by:(i) adding weighed sunflower oil for the emulsion to a mixer,(ii) adding the methylcellulose on top,(iii) mixing for 1.5min to ensure good dispersion at slow speed,(iv) adding citrus fiber, maize fiber, and vital wheat gluten, and vinegar,(v) adding weighed water for pre-emulsion and ice for pre-emulsion while the mixer is running and then mixing at high speed until a stable emulsion was formed (about 2min),(vi) and storing the emulsion at 2-4°C.(3). The extruded wheat gluten and lentil flour composition (1c) were hydrated with the water (from step 1) containing the coloring agents, flavoring agents, frozen shallots, dark pepper, cumin, salt, and garlic. The Composition (1c) was hydrated at a ratio of 1 : 1 and mixed for a duration of 40 min.(4). At the end of the hydration the hydrated mix was kneaded in a reverse direction in a mixer. The temperature was kept at 2-4°C.(5). The emulsion kept at 2-4°C from step (2) was added on top of the cooled (at 2-4°C) mixture in the mixer at slow speed and then mixed at high speed until a stable structure was formed.(6). The coconut oil was weighed out, added, and then mixed at high speed in the mixer for 2 min.(7). The dough was rested overnight at 4°C and then given shape and cooked like a minced meat burger.Clauses describing the invention

[0088] The following clauses also cover aspects of the invention.

[0089] Clause 1. A low-moisture extruded composition, comprising: a. wheat gluten; b. lentil flour; and c. optionally a process aiding agent, such as a base; wherein the wheat gluten and the lentil flour are in a weight ratio of wheat gluten to lentil flour of from 30:70 to 75:25, or from 30:70 to 71 :28, or from 35:65 to 75:25, or from 40:60 to 55:45, or from 40:60 to 54:46, or from 45:55 to 51 :49, or around 35:65, or around 50:50, or around 51 :49, or around 52:48, or around 71 :29, or around 72:28; wherein the composition has a water absorption capacity of at least 2.5 times, preferably 3.0 times its weight, more preferably 3.0-4.0 times its weight.

[0090] Clause 2. The low-moisture extruded composition of clause 1, wherein the composition comprises or essentially consists of, based on the total weight of the composition:• 25 to 75 wt%, preferably 30 to 73 wt%, or 50 to 71 wt%, or 51 to 70 wt%, or 30 to 60 wt% of wheat gluten,• 25 to 75 wt%, preferably 27 to 70 wt%, or 28 to 48 wt%, or 30 to 50 wt% of lentil flour, and• optionally 0.1 to 5 wt% of a process aiding agent

[0091] Clause 3. The low-moisture extruded composition of clause 1 or 2, wherein the process aiding agent is a base, preferably selected from the group consisting of sodium carbonate, sodium bicarbonate, and sodium hydroxide.

[0092] Clause 4. The low-moisture extruded composition of any of the preceding clauses, wherein the composition has a bulk density of from of from 0.15 to 0.5 g / ml, or from 0.15 to 0.45 g / ml.

[0093] Clause 5. The low-moisture extruded composition of any of the preceding clauses, wherein the particle sizes of the composition range from 1 to 15mm, preferably 1 to 4mm, or 4 to 7mm, or 7 to 15mm.

[0094] Clause 6. The low-moisture extruded composition of any of the preceding clauses, having a protein content of at least 40 wt%, or at least 50 wt%, or at least 60 wt%, or at least 65 wt%, and preferably not more than 75wt%.

[0095] Clause 7. A process for preparing a low-moisture extruded composition according to any one of clauses 1 to 6, comprising the step of: a. extruding vital wheat gluten and lentil flour at an extrusion temperature of from 30 to 180°C, preferably of from 40 to 160 °C, to obtain the low-moisture extruded composition; and b. optionally in the presence of a process aiding agent, preferably a base such as sodium carbonate, sodium bicarbonate or sodium hydroxide, wherein vital wheat gluten and lentil flour are in a dry weight ratio of, vital wheat gluten to lentil flour, of from 30:70 to 75:25, or from 30:70 to 71 :29, or from or from 30:70 to 72:28, or from 35:65 to 75:25, or from 40:60 to 55:45, or from 40:60 to 54:46, or from 45:55 to 51 :49, or around 35:65, or around 50:50, or around 51 :49, or around 52:48, or around 71 :29, or around 72:28.

[0096] Clause 8. A meat substitute product or meat extender product comprising the low-moisture extruded composition of any one of clauses 1 to 6.

[0097] Clause 9. A process for preparing a meat substitute product or a meat extender product, comprising the steps of: a. blending the low-moisture extruded composition of any one of clauses 1 to 6 with one or more ingredients of methylcellulose (preferably in emulsion form), plant proteins, fat(s) and / or oil(s), flavoring agents, coloring agents, hydrocolloids, food texturizers, preservatives, dietary fibers and salts in water to form a mixture; b. forming the mixture into individual portions of the meat substitute or meat extender product;c. optionally coating the meat substitute or meat extender product with battering agents and coating agents to form a coated meat substitute or coated meat extender product; and d. optionally cooking the coated meat substitute or coated meat extender product to form a cooked meat substitute or cooked meat extender product.

[0098] Clause 10. The process of clause 9, wherein the meat substitute product is a plant-based burger, plant-based meatbail, plant-based minced meat substitute, plant-based schnitzel substitute, or plant-based nugget substitute.

[0099] Clause 11. Use of lentil flour in the preparation of a low-moisture extruded wheat gluten- containing composition.

[0100] Clause 12. The use of clause 11, wherein the composition is prepared without and / or does not comprise any process aiding agent(s) selected from the group consisting of tetrasodium pyrophosphate (TSPP) and tetrapotassium pyrophosphate (TKPP).

[0101] Clause 13. The use of clause 11 or 12, wherein the composition is prepared without and / or does not comprise any process aiding agent(s) selected from the group consisting of TSPP and TKPP and is prepared with and / or comprises a process aiding agent selected from a base selected from one or more of the list consisting of sodium carbonate, sodium bicarbonate, and sodium hydroxide.

[0102] Clause 14. The use of any one of clauses 11 to 13, wherein the composition comprises or essentially consists of, based on the total weight of the composition:• 25 to 75 wt%, preferably 30 to 73 wt%, or 50 to 71 wt%, or 51 to 70 wt%, or 30 to 60 wt% of wheat gluten,• 25 to 75 wt%, preferably 27 to 70 wt%, or 28 to 48 wt%, or 30 to 50 wt% of lentil flour, and• optionally 0.1 to 5 wt% of a process aiding agent.

[0103] Clause 15. Use of the composition of any one of clauses 1 to 6 to prepare a meat substitute product or a meat extender product.

Claims

CLAIMSWhat is claimed is:

1. A low-moisture extruded composition, comprising: a. wheat gluten; b. lentil flour; and c. optionally a process aiding agent, such as a base; wherein the wheat gluten and the lentil flour are in a weight ratio of wheat gluten to lentil flour of from 30:70 to 75:25, or from 30:70 to 71 :28, or from 35:65 to 75:25, or from 40:60 to 55:45, or from 40:60 to 54:46, or from 45:55 to 51 :49, or around 35:65, or around 50:50, or around 51 :49, or around 52:48, or around 71 :29, or around 72:28; wherein the composition has a water absorption capacity of at least 2.5 times, preferably 3.0 times its weight, more preferably 3.0-4.0 times its weight.

2. The low-moisture extruded composition of claim 1, wherein the composition comprises or essentially consists of, based on the total weight of the composition:• 25 to 75 wt%, preferably 30 to 73 wt%, or 50 to 71 wt%, or 51 to 70 wt%, or 30 to 60 wt% of wheat gluten,• 25 to 75 wt%, preferably 27 to 70 wt%, or 28 to 48 wt%, or 30 to 50 wt% of lentil flour, and• optionally 0.1 to 5 wt% of a process aiding agent.

3. The low-moisture extruded composition of claim 1 or 2, wherein the process aiding agent is a base, preferably selected from the group consisting of sodium carbonate, sodium bicarbonate, and sodium hydroxide.

4. The low-moisture extruded composition of any of the preceding claims, wherein the composition has a bulk density of from of from 0.15 to 0.5 g / ml, or from 0.15 to 0.45 g / ml.

5. The low-moisture extruded composition of any of the preceding claims, wherein the particle sizes of the composition range from 1 to 15mm, preferably 1 to 4mm, or 4 to 7mm, or 7 to 15mm.

6. The low-moisture extruded composition of any of the preceding claims, having a protein content of at least 40 wt%, or at least 50 wt%, or at least 60 wt%, or at least 65 wt%, and preferably not more than 75wt%.

7. A process for preparing a low-moisture extruded composition according to any one of claims1 to 6, comprising the step of: a. extruding vital wheat gluten and lentil flour at an extrusion temperature of from 30 to 180°C, preferably of from 40 to 160 °C, to obtain the low-moisture extruded composition; andb. optionally in the presence of a process aiding agent, preferably a base such as sodium carbonate, sodium bicarbonate or sodium hydroxide, wherein vital wheat gluten and lentil flour are in a dry weight ratio of, vital wheat gluten to lentil flour, of from 30:70 to 75:25, or from 30:70 to 71 :29, or from or from 30:70 to 72:28, or from 35:65 to 75:25, or from 40:60 to 55:45, or from 40:60 to 54:46, or from 45:55 to 51 :49, or around 35:65, or around 50:50, or around 51 :49, or around 52:48, or around 71 :29, or around 72:28.

8. A meat substitute product or meat extender product comprising the low-moisture extruded composition of any one of claims 1 to 6.

9. A process for preparing a meat substitute product or a meat extender product, comprising the steps of: a. blending the low-moisture extruded composition of any one of claims 1 to 6 with one or more ingredients of methylcellulose (preferably in emulsion form), plant proteins, fat(s) and / or oil(s), flavoring agents, coloring agents, hydrocolloids, food texturizers, preservatives, dietary fibers and salts in water to form a mixture; b. forming the mixture into individual portions of the meat substitute or meat extender product; c. optionally coating the meat substitute or meat extender product with battering agents and coating agents to form a coated meat substitute or coated meat extender product; and d. optionally cooking the coated meat substitute or coated meat extender product to form a cooked meat substitute or cooked meat extender product.

10. The process of claim 9, wherein the meat substitute product is a plant-based burger, plantbased meatbail, plant-based minced meat substitute, plant-based schnitzel substitute, or plant-based nugget substitute.

11. Use of lentil flour in the preparation of a low-moisture extruded wheat gluten-containing composition.

12. The use of claim 11, wherein the composition is prepared without and / or does not comprise any process aiding agent(s) selected from the group consisting of tetrasodium pyrophosphate (TSPP) and tetrapotassium pyrophosphate (TKPP).

13. The use of claim 11 or 12, wherein the composition is prepared without and / or does not comprise any process aiding agent(s) selected from the group consisting of TSPP and TKPP and is prepared with and / or comprises a process aiding agent selected from a base selected from one or more of the list consisting of sodium carbonate, sodium bicarbonate, and sodium hydroxide.

14. Use of the composition of any one of claims 1 to 6 to prepare a meat substitute product or a meat extender product.

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