Plant-based cheese products and methods for producing plant-based cheese products

Abstract

A plant-based cheese product is provided. The plant-based cheese product has similar appearance, cold texture, and melting characteristics to dairy-based cheese. The cheese product includes a vegetable protein, at least a first starch and a second starch, a fat component, and an acidulant. The first starch includes a hydrophobic starch. The second starch includes a modified starch. The fat component has a solid fat content ranging from 30% to about 60% at 50°F and 0% to about 10% at 92°F. A softening agent may also be included.

Description

[Technical field]

[0001] This application relates generally to plant-based cheese products. [Background technology]

[0002] Some commercially available plant-based cheese products can replicate the color and texture of dairy-based cheese products at refrigeration temperatures. However, these typical plant-based cheese products often do not have other functional properties expected of dairy-based cheese, including melting properties at cooking temperatures. In fact, some plant-based cheese products do not melt uniformly at high temperatures, such as when making foods such as grilled cheese or pizza. For example, currently available shredded plant-based cheese products often maintain a shredded appearance even after being exposed to cooking temperatures. These plant-based cheese products are poorly accepted by consumers who expect a cooking and eating experience that replicates dairy-based cheese. [Brief description of the drawings]

[0003] [Figure 1] FIG. 1 is a black and white reproduction of an original color photograph of a grilled cheese type product, exemplified by a melted vegetable-based cheese product. [Diagram 2] FIG. 1 is a black and white reproduction of an original color photograph of another grilled cheese type product, illustrative of another melted plant-based cheese product.

[0004] Elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the size and / or relative location of some elements in the figures may be exaggerated relative to other elements to aid in understanding various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in commercially feasible embodiments are often not depicted to make these various embodiments of the present invention easier to view. Although certain actions and / or steps may be described or illustrated in a particular order of occurrence, those skilled in the art will understand that such specificity with respect to the order is not actually required. The terms and expressions used in this specification have the ordinary technical meanings as given to such terms and expressions by those skilled in the art of the art described above, unless a specific meaning is otherwise set forth herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0005] A plant-based cheese product is described herein. For purposes of this specification, the term "plant-based cheese product" refers to a cheese analog or cheese substitute prepared with non-dairy proteins. The plant-based cheese product has an appearance, cold texture, and melting properties similar to dairy-based cheese. The dairy proteins of dairy-based cheese form a network and structure that results in the cold texture and hot / melt texture of dairy-based cheese. Because the plant-based cheese products disclosed herein can be dairy protein-free, they cannot rely on dairy proteins to produce the desired cold texture and melting properties, such as meltability at conventional cooking temperatures and texture upon melting. Rather unexpectedly, it has been found that a plant-based cheese product with properties consistent with consumer expectations for dairy-based cheese can be obtained by using a combination of a plant protein, a fat component, a hydrophobic starch, and a modified starch. In some embodiments, a plant-based cheese product with properties consistent with consumer expectations for dairy-based cheese can be obtained by using a combination of a plant protein, a fat component, a hydrophobic starch, a modified starch, and a softening agent.

[0006] In one approach, the plant-based cheese product comprises a vegetable protein; at least a first and a second starch, where the first starch comprises a hydrophobic starch and the second starch comprises a modified starch; a softening agent; a fat component having a solid fat content in the range of 30% to about 60% at 50° F. and about 0% to about 10% at 92° F.; and an acidulant in an amount effective to provide a pH of the plant-based cheese product of about 4.5 to about 5.7.

[0007] The plant-based cheese products disclosed herein can be formed into any desired shape. In some examples, the plant-based cheese products are in the form of cheese blocks, sliced ​​cheese, diced cheese, or shredded cheese. In some approaches, the plant-based cheese products can be in the form of oil-in-water emulsions.

[0008] Plant-based cheese products include plant proteins. For simplicity and purposes herein, the term "plant protein" includes any non-dairy and non-animal protein. The term "plant protein" also specifically includes fungal-based proteins or proteins produced via microbial fermentation, even if those proteins are not derived from plants.

[0009] Any suitable vegetable protein may be used in the vegetable cheese product. In some embodiments, the vegetable protein comprises one or more of chickpea protein, broad bean protein, soy protein, mung bean protein, pea protein, canola protein, and lentil protein. In some approaches, the vegetable protein may be in the form of an isolate, concentrate, or flour, although the exact form of the vegetable protein is not considered to be particularly limited. In one embodiment, the vegetable protein comprises chickpea protein. In some examples, the fungal protein comprises mycoprotein.

[0010] As mentioned above, the vegetable protein may be of microbial origin.For example, proteins generally derived from dairy products, such as casein or whey, may be obtained by microbial fermentation.When produced by a microorganism using a non-dairy-based substrate and a fermentation medium, the obtained protein will be considered as vegetable protein for the purposes of this specification.

[0011] In some embodiments, the plant protein is the only protein source in the plant-based cheese product. In this regard, in some embodiments, the plant-based cheese product is free of animal proteins, including, for example, casein and whey. Additionally or alternatively, the product may be a vegan cheese product (i.e., the cheese product does not contain any animal-derived ingredients of any kind).

[0012] In one approach, the vegetable protein is present in an amount ranging from about 1% to about 25% crude protein by weight based on the total weight of the vegetable cheese product. In another approach, the vegetable protein is present in an amount ranging from about 2% to about 20%, about 2% to about 15%, about 4% to about 15%, or 4% to about 10% crude protein by weight based on the total weight of the vegetable cheese product. The amount of crude protein in the vegetable protein source may depend on the form of the source (e.g., whether the source is in the form of an isolate, concentrate, or flour). Thus, for purposes herein, vegetable protein refers to the crude protein content, i.e., the amount of protein contributed by the source that delivers the vegetable protein. For example, commercially available ARTESA® chickpea protein products contain about 60% protein components and 40% non-protein components. If a plant-based cheese product contains about 13% by weight ARTESA® chickpea protein product, then the plant-based cheese product will contain about 8% by weight vegetable protein, for percentage purposes herein.

[0013] In some approaches, it has been found that a small average particle size of the vegetable protein is advantageous to allow for good dispersion of the protein within the fat component. For example, the use of vegetable proteins having an average particle size of less than about 15 microns may be beneficial. In another embodiment, the use of vegetable proteins having an average particle size in the range of about 6 to about 15 microns, and in another embodiment, about 8 to about 11 microns may be beneficial. In some examples, the average particle size of the protein may be determined using dynamic light scattering. As an example, a Zetasizer Ultra-DLS (Malvern) may be used to measure the average particle size using dynamic light scattering.

[0014] In some approaches, the inclusion of chickpea protein and the small average particle size described herein has surprisingly been found to provide significant benefits in preventing the "oiling off" problem that can occur in dairy-based cheese products if not stored at refrigeration temperatures. Oiling off refers to the separation of oil from other ingredients, which results in the product leaching during manufacturing, at room temperature or when heated.

[0015] The plant-based cheese product further comprises a combination of at least two starches to achieve desired properties. The plant-based cheese product comprises at least a first starch and a second starch. As described above, the combination of the first starch and the second starch can provide the plant-based cheese product with a desired cold texture and hot / melting texture.

[0016] In one embodiment, the first starch is a hydrophobic starch. The hydrophobic starch can function as an emulsifier during the manufacturing process and in the plant-based cheese product. The hydrophobic starch can also provide moisture management to the plant-based cheese product.

[0017] Any suitable hydrophobic starch may be used. In some examples, the hydrophobic starch may be octenyl succinic anhydride (OSA) starch. Examples of suitable hydrophobic starches include, for example, ACCUBIND® starch (Cargill) or STA-MIST® starch (Tate & Lyle), both of which are OSA modified dent corn starches. It is currently believed that hydrophobic starches act as emulsifiers. In some examples, lipid droplet size distribution may be measured by Bruker Time Domain Nuclear Magnetic Resonance (TD-NMR).

[0018] In one approach, the first starch is present in an amount ranging from about 0.5% to about 15% by weight, in another embodiment from about 1% to about 13% by weight, and in another embodiment from about 5% to about 15% by weight, based on the total weight of the plant-based cheese product.

[0019] The second starch is a modified starch different from the first starch. In one approach, any suitable modified waxy starch may be used. In some examples, the modified waxy starch may be a waxy (non-amylose-containing starch) starch that is crosslinked, substituted, or both crosslinked and substituted. The modified waxy starch is selected to manage viscosity and moisture when the cheese product is at high temperatures, either during the manufacturing process or upon heating by the consumer. For example, the modified starch may be REZISTA® starch (Tate & Lyle) and / or SHUR-FIL® 677 modified starch (Tate & Lyle). SHUR-FIL® 677 modified starch may provide a thickening effect at high temperatures, such as 100-150°F. In some examples, the modified starch may be dent corn starch that forms a thermoreversible gel.

[0020] In another approach, the second starch may be selected from hydrolyzed amylose-containing starches. In one exemplary approach, the starch may be an acid-thinned starch. For example, the acid-thinned starch may be THINGUM® starch (Tate & Lyle). The hydrolyzed amylose-containing starch is selected to provide the plant-based cheese product with firmness upon cooling, low hot viscosity, and ease of slicing.

[0021] It has been found that in at least some embodiments, it is advantageous to include a combination of modified starches (i.e., both modified waxy starch and hydrolyzed amylose-containing starch) along with the first hydrophobic starch. The relative amounts of modified starches are selected to provide the desired properties to the cheese product. The second starch combination can provide the desired physical properties at both high and low temperatures (such as firmness upon cooling and a desired viscosity at high temperatures), thereby better replicating the properties of dairy-based cheese and meeting consumer expectations.

[0022] In one approach, the second starch is present in an amount ranging from about 0.5 to about 10% by weight, and in another embodiment from about 1% to about 5% by weight, based on the total weight of the plant-based cheese product. The ranges herein are applicable to the modified waxy starch and hydrolyzed amylose-containing starch present individually, or to a combination of modified waxy starch and hydrolyzed amylose-containing starch.

[0023] In one approach, the modified waxy starch and hydrolyzed amylose-containing starch may be included in a ratio of about 10:1 to about 1:10, in another aspect about 5:1 to about 1:5, and in yet another aspect about 3:1 to about 1:3.

[0024] Water is also included in an amount of about 30% to about 60% by weight, in another embodiment about 37% to about 55% by weight, and in another embodiment about 42% to about 55% by weight, based on the total weight of the plant-based cheese product.

[0025] The plant-based cheese product may further include a softening agent that reduces the brittleness and / or stiffness of the cheese product. For example, the softening agent may function as a bulking agent. Additionally or alternatively, the softening agent may contribute to the softness of the plant-based cheese product. The softening agent may be a polysaccharide, a gum, or a hydrocolloid. Suitable softening agents include, for example, one or more of instant starch, xanthan gum, guar gum, locust bean gum, cellulose gum, fenugreek gum, konjac gum, agar, gellan gum, propylene glycol alginate (PGA), alginates, microcrystalline cellulose (MCC), carboxymethyl cellulose (CMC), konjac glucomannan, carrageenan, and pectin. In some examples, the softening agent includes one or more of carrageenan and pectin.

[0026] In general, the cold and hot melt properties and texture of the plant-based cheese product can be manipulated by adjusting the relative amounts of hydrophobic starch and modified starch, as well as the amount of total starch relative to the protein content of the plant-based cheese product. Additionally, additional starch may be included, if desired. In general, as the amount of protein in the plant-based cheese is reduced, additional starch is required to provide the desired texture and functionality.

[0027] In one approach, the softening agent is present in an amount ranging from about 0.1% to about 20% by weight, based on the total weight of the plant-based cheese product. In another approach, the softening agent is present in an amount ranging from about 0.1 to about 15%, about 0.1 to about 12%, about 0.2 to about 12%, about 1% to about 15%, about 1% to about 12%, about 2% to about 10%, about 2% to about 5%, or about 5% to about 10% by weight, based on the total weight of the plant-based cheese product.

[0028] In some embodiments, the combination of starches (and optional flexibility enhancers) is present in an amount effective to achieve a complex viscosity of the plant-based cheese product in the range of about 20 Pa·s to about 200 Pa·s at a frequency of 10 rad / s and a temperature of 80° C. In some embodiments, the combination of starches (and optional flexibility enhancers) is present in an amount effective to achieve a complex viscosity of the plant-based cheese product in the range of about 20 Pa·s to about 180 Pa·s, about 20 Pa·s to about 150 Pa·s, about 20 Pa·s to about 120 Pa·s, about 20 Pa·s to about 100 Pa·s, about 20 Pa·s to about 80 Pa·s, about 20 Pa·s to about 50 Pa·s, about 50 Pa·s to about 200 Pa·s, about 8 ... The complex viscosity of the plant-based cheese product is present in an amount effective to achieve a complex viscosity of the plant-based cheese product in the range of about 100 Pa·s to about 200 Pa·s, about 120 Pa·s to about 200 Pa·s, about 150 Pa·s to about 200 Pa·s, about 180 Pa·s to about 200 Pa·s, about 50 Pa·s to about 180 Pa·s, about 80 Pa·s to about 180 Pa·s, or about 100 Pa·s to about 150 Pa·s. As discussed in more detail below, some products may be shear thinning, such that the complex viscosity may be lower than the zero shear viscosity.

[0029] In any of these embodiments, the complex viscosity may be measured after the mixture (or second mixture) or combination of plant-based cheese product ingredients is heated to a temperature of about 80° C. Additionally or alternatively, the complex viscosity may be measured prior to cooling the heated mixture or combination to form the plant-based cheese product.

[0030] As used herein, complex viscosity is the viscosity estimated from dynamic rheology experiments. It is the flow property of a material as a response to a sinusoidal wave applied stress / strain. In some approaches, shear thinning can occur through the addition of flexibility enhancers. The stiffness of a product is proportional to the molar concentration of intermolecular bonds. It is expressed as the shear modulus G, given by G=nRT, where "n" represents the molar concentration of bonds. Stiffness is calculated by G', G' values ​​considering the viscoelastic behavior of the material. For all these materials, G'>>G'', so G (shear modulus or stiffness) is approximately the same as G'. Relaxation time is a measure of how fast a material relaxes to an equilibrium state after releasing an applied stress / strain. For example, a viscous liquid relaxes faster due to dissipation of energy by flow, resulting in a relaxation time of zero. An elastic solid takes longer to stretch itself and reach equilibrium. Thus, a material with a short relaxation time will stick to a surface when subjected to a uniform strain. Relaxation time is inversely proportional to tan delta. At any temperature, materials with longer relaxation times or lower tan delta values ​​can be expected to have improved stability or resistance to changes in viscoelastic properties. Tan delta is the ratio of the energy dissipated to the energy stored in a viscoelastic material when it is subjected to stress or strain. The apparent zero shear viscosity is the product of the stiffness (shear modulus) and the relaxation time. It is a material property related to the internal structure of the material and is independent of the applied strain rate. Complex viscosity is the viscosity estimated from dynamic rheology experiments. It is the flow property of a material as a response to a sinusoidally applied stress or strain. In this study, it was measured at a frequency of 10 rad / s. Some materials may be shear thinning, and therefore the complex viscosity at 10 rad / s may be lower than the zero shear viscosity.

[0031] For example, the complex viscosity of an oil-in-water emulsion product can be measured over a temperature ramp range of 5-80 °C using a DHR rheometer equipped with a parallel plate attachment (25 mm cross-hatched parallel top plate and 60 mm cross-hatched bottom plate with a 1 mm gap between the plates). Specifically, the temperature was ramped at 2 °C / min, the applied stress was 10 Pa, and the frequency was 10 rad / s. The processing conditions have a significant impact on the viscosity of the resulting product, as smaller emulsion droplets produce a more viscous product, and therefore more stable against creaming forces.

[0032] The plant-based cheese products further comprise a fat component having a solid fat content ranging from about 30% to about 60% at 50° F., and 0% to about 10% at 92° F. When the fat component has a solid fat content within the specified ranges, it can act similar to butterfat and contribute a flavor profile, cool texture, and melt profile to the plant-based cheese product similar to dairy-based cheeses.

[0033] Any suitable fat component may be used, including one or more solid fats, liquid oils, or combinations thereof, having a solid fat content ranging from about 30% to about 60% at 50° F. and 0% to about 10% at 92° F. In some examples, the fat component includes one or more of coconut oil, palm oil, palm oil fractions, shea butter, and shea olein. In some of these examples, the fat component further includes one or more of soybean oil, sunflower oil, olive oil, canola oil, peanut oil, sesame oil, and corn oil to provide a blend of ingredients to impart the desired solid fat content at the respective temperature. In other examples, the fat component includes coconut oil.

[0034] In one approach, the fat component is present in an amount ranging from about 15 to about 30% by weight, and in another embodiment from about 20% to about 30% by weight, based on the total weight of the plant-based cheese product.

[0035] The plant-based cheese product further comprises an acidulant in an amount effective to provide a pH of the plant-based cheese product of about 4.5 to about 5.7, in another embodiment about 4.8 to about 5.7, in another embodiment about 4.8 to about 5.5, in another embodiment about 4.8 to about 5.0, in another embodiment about 5.0 to about 5.7, and in yet another embodiment about 5.2 to about 5.5. Any suitable acidulant may be used. In one example, the acidulant comprises one or more of citric acid, acetic acid, phosphoric acid, sorbic acid, and lactic acid.

[0036] For example, the plant-based cheese products described herein have acceptable meltability at cooking temperatures, firm texture at refrigeration temperatures, and an overall suitable mouthfeel similar to dairy-based cheese products. The plant-based cheese products maintain their physical integrity at refrigeration temperatures, but melt when exposed to elevated temperatures.

[0037] Antimicrobial agents such as sorbic acid, cultured vinegar, cultured sugar, cultured glucose, etc. may be added to the plant-based cheese product to increase resistance to bacterial and mold growth. In some approaches, the antimicrobial agent may also function as an acidulant.

[0038] The plant-based cheese products may be offered in a variety of flavors, such as American, Swiss, Gouda, Provolone, Cheddar, Colby, Colby Jack, Pepper Jack, or Mozzarella. Flavorings may be added to achieve a desired flavor profile. Colors may be added to achieve a desired color for the plant-based cheese product.

[0039] In another approach, ingredients may be added to achieve the desired flavor profile, for example, herbs, spices, pepper, chilli, garlic, natural or artificial flavours, etc., may be added alone or in combination to provide the desired flavour profile.

[0040] In addition to hydrophobic starch, chemical emulsifiers may be included. Suitable chemical emulsifiers include, for example, orthophosphates (including disodium phosphate, monosodium phosphate, and trisodium phosphate), sodium hexametaphosphate, sodium acid pyrophosphate, trisodium citrate, polyoxyethylene sorbitan monostearate (polysorbate 60), or other emulsifiers, or combinations of emulsifiers. Other approaches do not include chemical emulsifiers.

[0041] In some examples, the plant-based cheese product may further comprise a flavor masking agent. The masking agent may comprise any suitable ingredient effective in reducing the perceived intensity of a particular flavor. In some applications, consumers may perceive non-dairy proteins as contributing off-flavors to cheese-type products (i.e., flavors that are not consistent with consumer expectations for dairy-based cheese). For example, soy may be perceived as imparting an undesirable beany flavor to foods. To reduce the flavor of a particular non-dairy protein, it may be desirable to include a flavor masking agent. For example, the agent may comprise a sweetener (including nutritive and non-nutritive sweeteners), a flavoring, a bitterness blocker, or other suitable additive. Any suitable amount may be included. In one particular approach, the agent is effective in binding the off-flavor, thereby reducing or preventing the perception of the flavor. Suitable flavor binders include, for example, thaumatin and neohesperidin dihydrochalcone (NHDC), which may also be classified as sweeteners and are generally included in amounts ranging from greater than 0% to about 0.005% by weight, based on the total weight of the plant-based cheese product.

[0042] The plant-based cheese products described herein can be made in a variety of ways. In one approach, the plant-based cheese products can be made by a process that includes mixing a fat component with water, a vegetable protein, and at least two starches, where the first starch is a hydrophobic starch and the second starch is a modified starch. The fat component has a solid fat content ranging from about 30% to about 60% at 50°F and 0% to about 10% at 92°F. Other optional ingredients may be added at this point or later in the process. The ingredients are blended at a shear rate sufficient to provide a homogenous mixture. The ingredients are also heated to a temperature of about 160°F to about 215°F, in another embodiment about 165°F to about 200°F, and in another embodiment about 175°F to about 190°F. If desired, the ingredients may be blended while heated. Additionally, the ingredients may be held at an elevated temperature, such as by continuing the blending, for a time effective to pasteurize the mixture. The mixture may be heated by steam injection or other means.

[0043] In another approach, as described above, the fat component may be melted, such as in a cooker, before adding the other ingredients.

[0044] In another approach, the plant-based cheese product may be produced by a process that includes melting a fat component, adding at least two starches to the melted fat, where a first starch is a hydrophobic starch and a second starch is a modified starch, and mixing the at least two starches with the melted fat component to thoroughly disperse the at least two starches in the melted fat to provide a homogenous first mixture. The fat component has a solid fat content ranging from about 30% to about 60% at 50°F and 0% to about 10% at 92°F. Additional ingredients may then be added, including water, acidulants, vegetable proteins, and softening agents. Other optional ingredients may be added at this point or later in the process. The ingredients are mixed at a shear rate sufficient to provide a homogenous mixture. The ingredients may also be heated to a temperature of from about 160° F. to about 215° F., and in another embodiment from about 165° F. to about 200° F., and in another embodiment from about 175° F. to about 190° F. If desired, the ingredients may be mixed while being heated. Additionally, the ingredients may be held at an elevated temperature, such as by continuing mixing, for a time effective to pasteurize the mixture.

[0045] In another approach, the plant-based cheese product can be made by a process that includes melting a fat component and adding a vegetable protein, a softening agent, and water to the melted fat component to provide a first mixture. The fat component has a solid fat content ranging from about 30% to about 60% at 50°F and 0% to about 10% at 92°F. Other optional ingredients may be added at this point or later in the process. The ingredients are blended at a shear rate sufficient to provide a homogenous mixture. The ingredients are also heated to a temperature of about 160°F to about 215°F, in another embodiment about 165°F to about 200°F, and in another embodiment about 175°F to about 190°F. At least a first starch and a second starch are combined with water and then added to the heated mixture, where the first starch is a hydrophobic starch and the second starch is a modified starch, to provide a second mixture. The second mixture is then held at the elevated temperature, eg, with continued mixing as desired, for a time effective to pasteurize the mixture.

[0046] In one particular approach, the method includes melting a fat component having a solid fat content ranging from about 30% to about 60% at 50°F and 0% to about 10% at 92°F, adding water to the melted fat source to form a first mixture, adding a vegetable protein, a hydrophobic starch, and a modified starch to the first mixture and mixing to form a second mixture, heating the second mixture to a temperature in the range of about 170°F to about 200°F, holding the mixture at the heated temperature for a heating time in the range of about 30 seconds to about 90 seconds to form a heated mixture, and cooling the heated mixture to form a plant-based cheese product.

[0047] In another approach, a plant-based cheese product can be made by a process that includes melting a fat source having a solid fat content in the range of about 30% to about 60% at 50°F and 0% to about 10% at 92°F, adding modified starch and hydrophobic starch to the melted fat source to form a first mixture, adding water, a plasticizer, and a vegetable protein to the first mixture and mixing to form a second mixture, heating the second mixture to a temperature in the range of about 170°F to about 200°F, holding the mixture at the heated temperature for a heating time in the range of about 30 seconds to about 90 seconds to form a heated mixture, and cooling the heated mixture to form the plant-based cheese product.

[0048] In one embodiment, when mixing the vegetable protein, hydrophobic starch, and modified starch with the melted fat, it may be desirable to mix the ingredients at a speed of at least about 500 rpm, and in another embodiment from about 500 rpm to about 2500 rpm, for a mixing time in the range of about 2 minutes to about 15 minutes to provide a homogenous pasteurized mixture.

[0049] In another embodiment, any of the methods described herein may further comprise charging the heated mixture into one or more containers prior to the cooling step. In another embodiment, the cooling step may be accomplished on a cooling belt.

[0050] In another embodiment, any of the methods described herein may further include adding an acidulant to the first or second mixture. In one approach, the acidulant is added in an amount effective to provide a pH of the final plant-based cheese product in the range of about 4.4 to about 5.7, in another embodiment in the range of about 4.7 to about 5.5, in another embodiment in the range of about 4.8 to about 5.3, and in another embodiment in the range of about 4.8 to about 5.0. The acidulant may be any food-grade acidulant, such as citric acid, lactic acid, or combinations thereof. In one embodiment, the acidulant is lactic acid, which can provide a characteristic dairy flavor to the plant-based cheese product. The inclusion of an acidulant to provide a pH in the described range not only provides a desirable flavor, but also contributes to the microbial stability of the product.

[0051] In another aspect, any of the methods described herein may further include combining the plant protein with a flavor masking agent and water prior to combining the plant protein with other ingredients of the plant-based cheese product.

[0052] In another aspect, any of the methods described herein may further include adding one or more of salt, preservatives, colorants, and flavorings. Particulates or inclusions (e.g., herbs, spices, peppercorns) may also be added using any of the methods described herein.

[0053] The methods described herein may further include cutting the plant-based cheese product into various shapes and sizes, such as blocks, slices, cubes, shreds, and the like.

[0054] The cheese may be cooked and processed using conventional equipment, including the use of a laydown cooker, kettle, or other device. Shredding and packaging may also be accomplished using conventional equipment.

[0055] To further illustrate the present disclosure, examples are presented herein. It should be understood that these examples are provided for illustrative purposes and should not be construed as limiting the scope of the present disclosure. EXAMPLES

[0056] [Example 1] Seven examples of the plant-based cheese products disclosed herein were made, each of which contained chickpea protein as the plant protein and coconut oil as the oil.

[0057] Each example of the plant-based cheese product was prepared by first melting coconut oil in a cooker. Water was added to the melted coconut oil, and then lactic acid was added in an amount effective to bring the pH of the final product within the range of about 4.8 to about 5.0. Chickpea protein, maltodextrin, salt, sorbic acid, color, flavor, REZISTA® starch (Tate & Lyle), and ACCUBIND® starch (Cargill) were added, and the ingredients were then mixed and heated (by steam injection) in a steam injection cooker (Stephan Machinery GmbH) at a shear rate and for a time sufficient to produce a homogenous mixture. Once the mixture was thoroughly mixed, it was further heated (by steam injection) to 185°F and held at 185°F for 1 minute. The heated mixture was then filled into boxes and allowed to cool to form blocks of plant-based cheese product.

[0058] The general formula for each plant-based cheese product, along with the weight percent of each ingredient used (based on the total weight of the plant-based cheese product), is provided in Table 1. In Table 1, the plant-based cheese products are designated "PBCA1," "PBCA2," "PBCA3," "PBCA4," "PBCA5," "PBCA6," and "PBCA7." [Table 1]

[0059] Each of the plant-based cheese product examples had an appearance, taste, cold texture, and hot / melt texture consistent with consumer expectations for a dairy-based cheese product.

[0060] Additionally, for each of PBCA1 and PBCA6, a slice of the plant-based cheese product was placed between two slices of bread and grilled to create a grilled cheese type product. Each slice of PBCA1 and PBCA6 melted. The grilled cheese type product with melted PBCA1 is shown in Figure 1. The grilled cheese type product with melted PBCA6 is shown in Figure 2.

[0061] [Example 2] Six additional examples of the plant-based cheese products disclosed herein were made, each of which had the same general formula as PBCA1 (shown in Table 1), except that the additional examples did not include colorants or flavorants, and included additional maltodextrin to compensate for the lack of colorants and flavorants.

[0062] Each additional example of the plant-based cheese product was prepared by first melting coconut oil. Water was then added to the melted coconut oil. Lactic acid was then added to adjust the pH of the final product to within the range of about 4.8 to about 5.0. Chickpea protein, maltodextrin, salt, sorbic acid, REZISTA® starch (Tate & Lyle), and ACCUBIND® starch (Cargill) were then added. The ingredients were then mixed and heated (by steam injection) in a steam injection cooker (Stephan Machinery GmbH) at a mixing speed (shown in Table 2) and for a mixing time (shown in Table 2). Once the mixture was mixed, it was heated (by steam injection) to 185°F and held at 185°F for 1 minute. The heated mixture was then filled into boxes and allowed to cool to form blocks of the exemplary plant-based cheese product.

[0063] The mixing speeds and mixing times for each additional example plant-based cheese product are shown in Table 2. In Table 2, the additional examples of plant-based cheese products are referred to as "PBCA8," "PBCA9," "PBCA10," "PBCA11," "PBCA12," and "PBCA13." [Table 2]

[0064] Each additional example of the plant-based cheese product had an appearance, taste, cold texture, and hot / melt texture consistent with consumer expectations for a dairy-based cheese product.

[0065] [Example 3] Additional examples of plant-based cheese products disclosed herein were made that had the same general formula as PBCA1 (shown in Table 1), except that the additional examples did not include colorants and included additional maltodextrin to make up for the lack of colorants.

[0066] Additional examples of plant-based cheese products were prepared by first melting coconut oil. Then, REZISTA® starch and ACCUBIND® starch were added, and the combined melted coconut oil, REZISTA® starch, and ACCUBIND® starch were thoroughly mixed to provide a homogenous mixture of starch in the melted coconut oil. Water and lactic acid were added. Lactic acid was added in an amount effective to bring the pH of the final product to a range of about 4.8 to about 5.0. Chickpea protein, maltodextrin, salt, and sorbic acid were then added. The ingredients were mixed and cooked (by steam injection) in a steam injection cooker (Stephan Machinery GmbH) at 2500 rpm for 10 minutes. Flavoring was added, and the mixture was heated (by steam injection) to 185°F and held at 185°F for 1 minute. The heated mixture was filled into boxes and allowed to cool to form about 20 pound to about 24 pound blocks of the exemplary plant-based cheese product.

[0067] Additional examples of plant-based cheese products had appearance, taste, cold texture, and hot / melty texture consistent with consumer expectations for a dairy-based cheese product.

[0068] [Example 4] Additional examples of the plant-based cheese products disclosed herein can be made. The additional examples of the plant-based cheese products have the same general formula as PBCAl (shown in Table 1), except that the additional examples did not include colorants or flavorants, and included additional maltodextrin to make up for the lack of colorants or flavorants.

[0069] Additional examples of plant-based cheese products are prepared by first melting coconut oil. Water and lactic acid are added. Lactic acid is added in an amount effective to bring the pH of the final product to within the range of about 4.8 to about 5.0. Chickpea protein, maltodextrin, salt, and sorbic acid are then added. The ingredients are mixed and heated (by steam injection) in a steam injection cooker (Stephan Machinery GmbH) at a shear rate and time sufficient to produce a homogenous mixture. The mixture is then heated (by steam injection) to 185°F. REZISTA® starch and ACCUBIND® starch are then added to the water and mixed thoroughly to prepare a homogenous mixture. The starch and water mixture is added to the mixture in the steam injection cooker, and the mixture is then held at 185°F for 1 minute. The heated mixture is filled into boxes and allowed to cool to form blocks of exemplary plant-based cheese product that have the appearance, taste, cold texture, and hot / melty texture consistent with consumer expectations for dairy-based cheese.

[0070] It should be understood that the ranges provided herein include the stated ranges and any values ​​or subranges within the stated ranges. For example, the range of about 5% to about 15% by weight should be interpreted to include not only the explicitly stated limits of the range of about 5% to about 15% by weight, but also individual values ​​such as 6.35%, 7.5%, 10%, 12.75%, 14% by weight, and subranges such as about 7% to about 10.5%, about 8.5% to about 12.7%, about 9.75% to about 14% by weight, etc. Furthermore, when "about" is used to describe a value, this is meant to encompass slight variations (up to + / - 10%) from the stated value.

[0071] All percentages and ratios are calculated by weight unless otherwise specified. All percentages and ratios are calculated based on the total weight of the compound or composition unless otherwise specified.

[0072] References throughout this specification to "one example," "another example," "some examples," "other examples," etc. mean that particular elements (e.g., features, structures, and / or characteristics) described in connection with an example are included in at least one example described herein and may or may not be present in other examples. Further, unless the context clearly dictates otherwise, it should be understood that the elements described with respect to any example can be combined in any suitable manner in the various examples.

[0073] In the description of the examples disclosed herein and in the claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0074] Although several examples have been described in detail, it is understood that the disclosed examples may be modified, and therefore the foregoing description should not be considered as limiting.

Claims

1. 1. A plant-based cheese product comprising: Plant protein and at least a first starch and a second starch, the first starch comprising a hydrophobic starch and the second starch comprising a modified starch; a fat component having a solid fat content ranging from 30% to about 60% at 50° F. and 0% to about 10% at 92° F.; an acidulant in an amount effective to provide a pH of the plant-based cheese product of from about 4.5 to about 5.7; A plant-based cheese product comprising:

2. 10. The plant-based cheese product of claim 1, wherein the plant protein is present in an amount in the range of about 1% to about 25% crude protein by weight, based on the total weight of the plant-based cheese product.

3. 10. The plant-based cheese product of claim 1, wherein the plant protein is present in an amount in the range of about 4% to about 15% crude protein by weight, based on the total weight of the plant-based cheese product.

4. 10. The plant-based cheese product of claim 1, wherein the plant protein is present in an amount in the range of about 4% to about 10% crude protein by weight, based on the total weight of the plant-based cheese product.

5. 10. The plant-based cheese product of claim 1, wherein the first starch is present in an amount in the range of about 0.5% to about 15% by weight, based on the total weight of the plant-based cheese product.

6. 10. The plant-based cheese product of claim 1, wherein the second starch is present in an amount in the range of about 0.5% to about 10% by weight, based on the total weight of the plant-based cheese product.

7. 10. The plant-based cheese product of claim 1, wherein the fat component is present in an amount in the range of about 15% to about 30% by weight, based on the total weight of the plant-based cheese product.

8. 10. The plant-based cheese product of claim 1, wherein the plant-based cheese product has a total solids content in the range of about 45% to about 65% by weight.

9. 10. The plant-based cheese product of claim 1, wherein the plant protein comprises one or more of chickpea protein, fava bean protein, soy protein, mung bean protein, pea protein, canola protein, and lentil protein.

10. 10. The plant-based cheese product of claim 1, wherein the fat component comprises one or more of coconut oil, palm oil, palm oil fractions, shea butter, and shea olein.

11. 10. The plant-based cheese product of claim 1, wherein the fat component further comprises one or more of soybean oil, sunflower oil, olive oil, canola oil, peanut oil, sesame oil, and corn oil.

12. 10. The plant-based cheese product of claim 1, wherein the plant-based cheese product is free of dairy proteins.

13. 1. A method for producing a plant-based cheese product, comprising: melting a fat component having a solid fat content ranging from 30% to about 60% at 50°F and 0% to about 10% at 92°F; adding water to the melted fat component to form a first mixture; adding vegetable protein, hydrophobic starch, and modified starch to the first mixture and mixing to form a second mixture; heating the second mixture to a temperature within the range of about 160° F. to about 215° F.; holding the mixture at the heating temperature for a heating time ranging from about 30 seconds to about 90 seconds to form a heated mixture; cooling the heated mixture to form the plant-based cheese product; A method for producing a plant-based cheese product comprising:

14. 1. A method for producing a plant-based cheese product, comprising: melting a fat component having a solid fat content ranging from 30% to about 60% at 50°F and 0% to about 10% at 92°F; adding modified starch and hydrophobic starch to the melted fat component to form a first mixture; adding water and vegetable protein to the first mixture and mixing to form a second mixture; heating the second mixture to a temperature within the range of about 160° F. to about 215° F.; holding the mixture at the heating temperature for a heating time ranging from about 30 seconds to about 90 seconds to form a heated mixture; cooling the heated mixture to form the plant-based cheese product; A method for producing a plant-based cheese product comprising:

15. 15. The method of claim 13 or 14, wherein the vegetable protein comprises chickpea protein.

16. 15. The method of claim 13 or 14, wherein the fatty component comprises coconut oil.

17. 1. A method for producing a plant-based cheese product, comprising: combining a fat component with water, vegetable protein, and at least two starches to form a combination, wherein the first starch is a hydrophobic starch, the second starch is a modified starch, and the fat component has a solid fat content ranging from 30% to about 60% at 50° F. and 0% to about 10% at 92° F.; mixing said combination at a shear rate sufficient to form a homogenous mixture; heating the combination at a temperature within the range of about 160° F. to about 215° F.; A method for producing a plant-based cheese product comprising:

18. 20. The method of claim 17, wherein the vegetable protein comprises chickpea protein.

19. 20. The method of claim 17, wherein the fatty component comprises coconut oil.

Images