Food manufacturing method

Abstract

A method is disclosed for producing food for human consumption from a plant-based food material and a eviscerated and plucked poultry material, including bone, hard tissue, tendons, skin and / or cartilage, using extrusion.

Description

[Technical field]

[0001] The present invention relates to a method for producing food products, more particularly to a method for producing food products by extrusion from poultry, including undervalued parts of poultry. [Background technology]

[0002] Extrusion is widely used in the production of various food products. Generally, it is a continuous process that uses an extruder with one or two screws. The extruder provides the functions of transporting, compressing, mixing, cooking, shearing, heating, cooling and shaping the raw materials into the final product.

[0003] US5853790 discloses a method for commercially producing poultry meat for human consumption using extrusion, which effectively maximises the utilisation of poultry meat from the whole poultry carcass and increases the overall meat value obtained from the bird carcass. In this method, bones are removed from the meat portions of the whole bird.

[0004] US2012 / 0237642A1 discloses a method for producing a meat-based, grain-free, semi-moist animal food product by extrusion. The meat may be poultry meat.

[0005] US2008 / 0268115A1 discloses a method of processing poultry in which hot bone-in poultry meat is prepared, ground or macerated, and mixed with salt. The term "hot-bone poultry meat" refers to poultry meat that has been removed from the bone.

[0006] US2014 / 0087044A1 discloses a method for preparing food or feed ingredients for incorporation into human food or animal feed by extrusion, for example using deboned poultry meat.

[0007] RU 2223673 discloses a method for producing a composite extrusion product from meat and vegetable ingredients. The poultry meat used in the method is mechanically deboned. Veins, tendons and skin may also be used in the production. Summary of the Invention

[0008] It has been found that by effectively utilizing the whole bird, excluding the intestines and feathers, edible food products having satisfactory organoleptic properties such as attractive taste and good mouthfeel can be produced from poultry meat materials and plant-based food materials. Undervalued parts of birds including bones, hard tissues, tendons, skin, and / or cartilage, as well as poultry meat harvested from whole poultry carcasses may be utilized. Thus, poultry meat harvested from whole poultry carcasses is effectively converted into valuable food products with organoleptic properties acceptable to consumers.

[0009] The present invention provides a sustainable method for effectively using whole, eviscerated and plucked birds in the production of ready-to-eat foods for human consumption that provide environmental benefits.

[0010] The invention also provides a method that allows the use of undervalued or less hygienic parts of birds, with the economic benefit of providing a lower cost product.

[0011] The present invention further provides a method for producing a fortified food product.

[0012] Additionally, the present invention provides a method for producing food that allows for a reduction in global meat production, which provides environmental benefits.

[0013] The present invention also provides a method for producing a food product having high microbiological quality and being substantially free of Salmonella.

[0014] The food product can be used as an ingredient or bulking agent and can be combined with other food ingredients to produce a wide variety of food compositions.

[0015] The food produced by the method of the present invention is also suitable as an animal feed.

[0016] In one aspect, the present invention provides a method for producing a food product from a plant-based food material and a poultry material that includes an undervalued part of poultry.

[0017] In another aspect, the present invention provides a food product comprising a eviscerated and plucked poultry meat material, including bone, wherein the calcium content of the food product ranges from about 0.2 wt % to about 2.0 wt %.

[0018] In a further aspect, the present invention provides a food composition comprising a food product of the present invention or a food product produced by a method of the present invention.

[0019] In one aspect, the present invention provides for the use of a food product of the present invention or a food product produced by a method of the present invention in a food composition.

[0020] In a further aspect, the present invention provides an apparatus comprising means for carrying out the method of the present invention. [Brief description of the drawings]

[0021] [Figure 1] 1 shows a schematic process flow diagram of an embodiment of the method of the present invention. [Diagram 2] FIG. 2 shows a schematic process flow diagram of another embodiment of the method of the present invention. [Diagram 3] 1 shows an embodiment of an apparatus of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] In one aspect, the present invention provides a method for producing a food product, comprising the steps of: providing a eviscerated and plucked poultry meat material, including bone, hard tissue, tendons, skin, and / or cartilage; -Providing food ingredients of plant origin; - grinding the eviscerated and plucked poultry meat material in a grinder with a particle size of maximum 5 mm to produce minced poultry meat chunks; adding a plant-based food material to the minced poultry chunks to provide a mixture of the minced poultry chunks and the plant-based food material; - subjecting the mixture to extrusion to provide an extruded mass as a food product.

[0023] Figure 1 illustrates one embodiment of the method of the present invention. Figure 2 illustrates another embodiment of the method of the present invention. The dotted lines in Figures 1 and 2 indicate optional method steps. The method may include further optional method steps that are not shown.

[0024] Poultry meat materials suitable for use in the methods of the present invention include, but are not limited to, chicken, turkey, duck, and goose. In one embodiment of the present invention, the poultry meat material is chicken.

[0025] In one embodiment, the eviscerated and plucked poultry meat material comprises bone, hard tissue, tendon, skin and / or cartilage. In one embodiment, the eviscerated and plucked poultry meat material comprises at least bone. In one embodiment, the eviscerated and plucked poultry meat material comprises bone, hard tissue, tendon, skin and / or cartilage and is derived from the legs, neck, skin and / or head of poultry.

[0026] The bone content of eviscerated chicken may vary from about 10% to about 60% by weight. Increasing the amount of bone in eviscerated and plucked poultry materials increases the calcium content of the final food.

[0027] The eviscerated and plucked poultry material is milled to remove bones and other hard tissue to provide a mass of ground poultry suitable for feeding into an extruder. Grinding is performed in a grinder with holes of up to 5 mm. In one embodiment, the grinder is a meat mincer with holes ranging from about 2 mm to about 5 mm.

[0028] In one embodiment, the ground poultry chunks are subjected to a colloid mill to further grind the bone particles. In general, a "colloid mill" is a machine with a high speed rotor and stator that simultaneously emulsifies, homogenizes, disperses, and grinds the material into ultra-fine particles. The rotor forces the material through a small gap between the rotor and stator, causing intense mechanical shear. In the present invention, colloidal grinding provides homogenous ultra-fine bone particles in the bone-containing poultry chunks, which beneficially promotes softening of the bone particles during subsequent extrusion. In one embodiment, colloidal grinding of the ground poultry chunks provides bone particles having an average particle size of up to 500 μm.

[0029] After comminution in a grinder and optionally further comminution in a colloid mill, the resulting minced poultry chunks are mixed with a plant-based food material. Any food-grade plant-based food material is suitable for addition to the minced poultry chunks. The plant-based food material includes, but is not limited to, food materials rich in protein, carbohydrates and / or dietary fiber. In one embodiment, the plant-based food material comprises soy protein, pea protein, cereal protein, broad bean protein, corn protein, potato starch, corn starch, or mixtures thereof. In one embodiment, the plant-based food material is provided as a finely ground powder. In one embodiment, the plant-based food material is thoroughly mixed with the minced poultry chunks to provide a homogenous mixture of the minced poultry chunks and the plant-based food material.

[0030] In one embodiment, the mixture of ground poultry chunks and plant-based food material is ground again in a meat grinder, for example with a hole size of about 5 mm, to provide a ground mixture exhibiting a thread-like structure.

[0031] The plant-derived food material is added to the ground poultry mass in an amount to provide a food product comprising about 5 wt% to about 90 wt% plant-derived food material. In one embodiment, the amount of plant-derived food material ranges from about 5 wt% to about 50 wt%. In another embodiment, the amount of plant-derived food material ranges from about 40 wt% to about 75 wt%. In a further embodiment, the amount of plant-derived food material ranges from about 40 wt% to about 50 wt%. In a further embodiment, the food product comprises about 10 wt% to about 30 wt% plant-derived food material.

[0032] In one embodiment, the food product comprises from about 10% to about 95% by weight of eviscerated and plucked poultry material or comminuted poultry material. In another embodiment, the food product comprises from about 50% to about 95% by weight of eviscerated and plucked poultry material or comminuted poultry material. In a further embodiment, the amount ranges from about 25% to about 60% by weight of the food product. In a further embodiment, the amount ranges from about 50% to about 60% by weight. In a further embodiment, the food product comprises from about 70% to about 90% by weight of eviscerated and plucked poultry material or comminuted poultry material.

[0033] In one embodiment, chunks of ground poultry are cut into pieces having a diameter of about 0.5 to about 15 mm, for example about 2 mm, and the pieces are then fed into the extruder.

[0034] In one embodiment, compressed air is used to facilitate feeding the minced poultry chunks into the extruder and to avoid clogging of the extrusion nozzle. In one embodiment, the minced poultry chunks are cooled to a temperature of about -25°C to about 6°C. Cooling the chunks facilitates feeding the chunks into the extruder. Additionally, cooling provides structural strength to the chunks and avoids the formation of a gel-like structure. Cooling the mixture of minced poultry chunks and plant-based food material further improves the microbiological quality of the chunk mixture prior to feeding into the extrusion process.

[0035] The mixture of ground poultry chunks and plant-based food material is subjected to extrusion to provide an extruded mass. In one embodiment, the extrusion is performed at a moisture content of at least 20%. In one embodiment, the extrusion is wet extrusion to provide an extruded mass. In the context of the present invention, the term "wet extrusion" means that the mixture of ground poultry chunks and plant-based food material to be extruded has a moisture content of at least 30%. In one embodiment, the moisture content of the mixture of ground poultry chunks and plant-based food material ranges from 30% to about 70%. A moisture content below 30% may make it difficult to carry out the extrusion process due to the dryness of the mixture in the extruder. On the other hand, a moisture content higher than 70% may result in undesirable separation of liquid from the dry matter of the mixture.

[0036] Extrusion may be carried out in a single or twin screw extruder. The combination of shear and tearing, along with moisture during the extrusion step, tenderizes the tough tissues of the chicken meat and gives the final food product a unique structure.

[0037] In one embodiment, extrusion, such as wet extrusion, is carried out at a temperature of about 100° C. to about 400° C. Depending on the extruder used in the process, the extruder must include at least one heating section with a temperature of at least 100° C. In addition, there may be additional heating sections that perform extrusion at temperatures below 100° C., for example 70° C. In one embodiment of the present invention, an extruder is used that includes multiple heating sections, each operating at a different temperature. In one embodiment, the temperature of the heating section increases as the mass advances through the extruder.

[0038] The duration of the extrusion process depends on the equipment configuration and settings.

[0039] In one embodiment, the extrusion is carried out using a speed of about 100 rpm to about 1000 rpm. In another embodiment, the extrusion is carried out using a speed of about 200 rpm to about 600 rpm. In one embodiment, about 500 rpm is employed for extrusion.

[0040] In one embodiment, the wet extrusion is carried out using a speed of about 100 rpm to about 1000 rpm. In another embodiment, the wet extrusion is carried out using a speed of about 170 rpm to about 600 rpm. In one embodiment, about 170 rpm is employed for wet extrusion.

[0041] In one embodiment, the extrusion of the minced poultry meat chunks results in an extruded chunk having a temperature of at least 100°C.

[0042] In one embodiment, the extruded mass is cooled to a temperature of about +60°C to about -30°C. In one embodiment, cooling of the extruded mass occurs within the extruder before the extruded mass exits the extruder. Cooling in the extruder is conveniently accomplished with a cooling die. When the extruded mass is cooled within the extruder, the temperature of the mass exiting the extruder may range from about 1°C to about 80°C, or from about 1°C to about 60°C. In one embodiment, the temperature of the extruded mass ranges from about 30°C to about 60°C.

[0043] In another embodiment of the invention, the minced poultry meat chunks in the extruder are forced into holes smaller or equal to the cylinder area at the end of the extrusion cylinder. The extruded chunks lose some of the water vapor when they leave the process if the temperature exceeds 100°C. The chunks have a different taste, aroma, structure (viscosity, sharpness, etc.) and react differently in post processing compared to processes that include a cooling die step.

[0044] This extrusion process provides the extruded mass as a food-grade product that can be consumed as is.

[0045] In one embodiment, the extruded mass is further minced in a colloid mill to improve the organoleptic properties of the resulting food product. The colloid mill at this stage may be the same or different from the colloid mill used to grind the minced poultry mass. In one embodiment, water and / or oil is added to the extruded mass prior to colloidal grinding to enhance the performance of the colloidal grinding. Grinding the extruded mass in a colloid mill results in a bone-containing food product with an average particle size of about 1 μm to about 500 μm. The colloidal-ground food product exhibits a smooth mouthfeel without observable bone particles.

[0046] Colloidal milling of the extruded mass provides a ready-to-eat food grade product with attractive organoleptic properties.

[0047] The extrusion process reduces the microbial load of poultry carcasses, as it allows the use of less hygienic poultry. The microbial load decreases by approximately 1000–1000% during the process. 12 It is reduced to one-fifth.

[0048] Food products extruded by the method of the present invention can mimic the texture, flavor and mouthfeel of meat.

[0049] The method of the present invention provides a food product that exhibits improved nutritional value. By using calcium-containing parts of poultry, i.e. bone, hard tissue, tendon, and / or cartilage, the calcium content of the food product produced by the method is higher than that of typical poultry products. In one embodiment, the food product has a calcium content of about 0.2 wt% to about 2.0 wt%. In another embodiment, the calcium content of the food product is about 0.2 wt% to about 1.2 wt%. In a further embodiment, the calcium content of the food product is about 0.2 wt% to about 0.7 wt%. In a further embodiment, the calcium content of the food product is about 0.2 wt% to about 0.5 wt%. In one embodiment, the calcium content of the food product is about 0.5 wt% to about 0.7 wt%. In one embodiment, the calcium content of the food product is about 0.52 wt%.

[0050] In one embodiment, the extruded and optionally colloidally milled food product is heat treated at a temperature ranging from about 110° C. to about 400° C. to further improve the organoleptic properties and mouthfeel of the product. Heat treatment may be performed, for example, by cooking in oil at 150-300° C., grilling at 200-400° C., pan-frying, baking, freeze-drying at -70° C. or below, microwave treatment, infrared radiation, and the like.

[0051] Extrusion of poultry meat material with undervalued parts such as bone and other hard tissues, together with heat treatment, provides a ready-to-eat food product with unique and appealing taste, structure and mouthfeel.

[0052] The sensory properties of the food product can be further improved by adding ingredients commonly used in food manufacturing, such as flavors, aromatics, salts, stabilizers, emulsifiers, carbohydrates, fiber, fats and oils, to the food product produced by the method of the present invention.

[0053] In one aspect, the present invention provides a eviscerated and plucked poultry material comprising bones, the calcium content of the food product ranges from about 0.2 wt% to about 2.0 wt%. In one embodiment, the calcium content of the food product is from about 0.2 wt% to about 1.2 wt%. In a further embodiment, the calcium content is from about 0.2 wt% to about 0.7 wt%. In a further embodiment, the calcium content of the food product is from about 0.2 wt% to about 0.5 wt%. In an embodiment, the calcium content of the food product is from about 0.5 wt% to about 0.7 wt%. In one embodiment, the calcium content is about 0.52 wt%.

[0054] The extruded food product may be combined with other food ingredients to provide a wide variety of food compositions with different appearances, tastes and structures. Thus, in one embodiment, the present invention provides the use of the food product produced by the method of the present invention or the food product of the present invention as an ingredient or extender in the manufacture of a food composition. The food product may be combined, for example, with a vegetable food ingredient or a poultry meat material that does not contain bone, hard tissue, tendon, skin and / or cartilage. The food product produced by the method of the present invention or the food product of the present invention may be included in a food product in an amount of up to about 50 wt% without adversely affecting the organoleptic properties of the food composition.

[0055] In another aspect, the present invention provides a food composition comprising a food product produced by the method of the invention or a food product of the invention.

[0056] In a further aspect, the present invention provides an apparatus for carrying out the method of the present invention, comprising means for carrying out the method of the present invention. One embodiment of the apparatus of the present invention is shown in Figure 3. The dotted lines indicate optional units. The apparatus may further comprise optional units not shown.

[0057] In one embodiment, the means comprises: a meat grinder for grinding the eviscerated and plucked poultry meat material to provide minced poultry meat chunks; an extruder connected to the meat grinder and configured to receive the ground poultry meat chunks and provide an extruded chunk; - optionally a colloid mill connected to the extruder and configured to receive the extruded mass to provide a food product; has.

[0058] The following examples are presented to further illustrate the invention without limiting it thereto.

[0059] The calcium content of the foods was determined according to SFS-EN ISO 11885,2009.

[0060] The levels of aerobic microorganisms were measured according to the standard NMKL 86:2013.

[0061] Salmonella load was determined according to ISO / DIS 20976-2.

[0062] Example 1 58 kg of chicken carcass (with bone and skin) was minced in a meat grinder with hole size of 2 mm. The minced poultry meat chunks were then mixed properly with 42 kg of a mixture consisting of 21 kg of soybean concentrate powder (protein content 66 wt%) and 21 kg of pea concentrate powder (protein content 79 wt%). The mixture was kept at about 4°C. The mixture was fed into a meat grinder with hole size of 5 mm. The resulting ground mixture was cooled to about 2°C and cut into pellets of about 5 mm length. The cooled pellets were fed into the extruder as a constant feeding process using air pressure bursts to avoid feeding stoppages.

[0063] The extrusion process was carried out using a twin screw extruder with a temperature profile of the cylinder (from the feeder to the cooling die) of 65-70-80-100-120-140-150° C. and the cooling die at 25° C. Extrusion was carried out at a speed of about 400 rpm to provide an extruded mass, which showed a temperature of about 35° C. at the exit.

[0064] The extruded mass was collected and cooled to +4° C. to obtain the ready-to-eat food product, which had a calcium content of 0.52 wt %.

[0065] The aerobic microbial levels measured at 30°C / 72 hours were less than 1000 pmy / g. The measured aerobic microbial levels indicate that a food grade product for human consumption has been obtained.

[0066] The extruded mass at +4°C was torn into particles with a diameter of about 1 to 5 mm. The particles were marinated in a mixture of rapeseed oil and spices at +4°C for about 2 hours. The marinated particles were cooled and formed into patties with the addition of eggs, spices, flour and dried vegetable particles. The patties were cooked in rapeseed oil, cooled to 2°C and then vacuum packed. The resulting food exhibited an attractive taste and mouthfeel.

[0067] A similar cooked product may also be produced from extruded mass frozen below -18°C. The frozen extruded mass is first broken into small particles and then marinated and cooked as above.

[0068] Example 2 Extruded mass was prepared from poultry carcasses and soy protein concentrate in a manner similar to Example 1. The extruded mass was collected and frozen at -20°C.

[0069] The extruded mass at -20°C was thawed to approximately +4°C. The thawed extruded mass was torn into particles with a diameter of approximately 1-5 mm. Fresh minced chicken meat was added to the particles in a ratio of 65:35 w / w. Beef tallow was added to the resulting mixture in a ratio of 1:10 w / w, which was then ground in a meat grinder equipped with a 5 mm sieve to obtain a dough.

[0070] 2.0 wt% salt and spices such as black pepper powder, hot pepper powder, cumin powder, garlic powder, onion powder, and cayenne pepper were added to the dough. The dough was kneaded for approximately 20 minutes until a smooth mass was formed. The mass was wrapped in oil-coated aluminum foil and baked in a 125°C oven until the internal temperature of the kebab-like mass reached 80°C.

[0071] The product was cooled to +4°C and vacuum packed.

[0072] The resulting kebab-like food exhibited appealing taste and texture.

[0073] Example 3 70 kg of poultry carcasses (with bones and skin) were minced in a meat grinder with a 2 mm aperture. The poultry mince chunks were then colloidally milled to produce fine chunks containing bone particles of about 100 μm in diameter. The milled chunks were mixed properly with 30 kg of soybean concentrate powder (protein content 66 wt%). The resulting mixture was kept at about 4°C. The mixture was loaded into a silo connected to a conveyor screw connected to a hopper with a volume of about 30 liters. The mixture was led from the hopper to the extruder by an auger and screw at a controlled rate of about 55 kg / h.

[0074] The mixture of ground poultry chunks and soybean concentrate powder was directed into an extruder incorporating a cooling die. The moisture content of the mixture was approximately 55 wt%. The mixture was extruded at 170 rpm. The heating zones of the extruder were adjusted to 60°C, 70°C, 80°C, 100°C, 120°C, 150°C, and 170°C. The first zone of the cooling die was set at 60°C and the last zone was set at 40°C. The extrusion process took approximately 1 minute.

[0075] The extruded mass exited the cooling die at below 100°C. A small amount of steam was released in the process. The solids and some of the separated oil were discharged at the end of the cooling die.

[0076] The aerobic microbial load of the solids resulting from the wet extrusion and the mixture of ground poultry chunks and soy concentrate powder fed to the wet extrusion (i.e., the "feedstock") was measured at 30°C / 72 hours and was found to be less than 100 pmy / g for the solids and more than 30 000 000 pmy / g for the feedstock. The measured aerobic microbial levels indicate that a food grade product for human consumption has been obtained.

[0077] The calcium content of the food, i.e., the solid matter, was 0.52 wt%.

[0078] There was a 7-log reduction in Salmonella in the solids, indicating complete elimination of Salmonella.

[0079] The solids were ground in a meat grinder with 2 mm holes. Sunflower oil and water were added to the ground mass in the ratio of 2:10 (w / w) respectively and left at 4°C for 60 minutes to be absorbed by the mass. The batches of mass were milled in a colloid mill. Colloidal milling provides a food mass that is ready for consumption.

[0080] This mass may be used as an ingredient in a food composition in an amount of up to 50 wt % based on the total weight of the food composition.

[0081] Example 4 The extruded mass was prepared as described in Example 3. The extruded mass was torn into particles with a particle size of about 1 to 5 mm. Fresh ground chicken meat was added to the particles in a ratio of 65:35 (w / w). Beef tallow was added to the resulting mixture in a ratio of 1:10 (w / w) and then ground in a meat grinder equipped with a 5 mm sieve to obtain a dough.

[0082] 2.0 wt% salt and spices including black pepper powder, hot pepper powder, cumin powder, garlic powder, onion powder, and cayenne pepper were added to the dough. The dough was kneaded for approximately 20 minutes until a smooth mass was formed. The mass was wrapped in oil-coated aluminum foil and baked in an oven at 125°C until the internal temperature of the kebab-like mass reached 80°C.

[0083] The product was cooled to +4°C and vacuum packed.

[0084] The resulting kebab-like food exhibited appealing taste and texture.

[0085] Example 5 93 kg of poultry carcasses (with bones and skin) were minced in a meat grinder with a 2 mm aperture. The poultry mince chunks were then colloidally milled to produce fine chunks containing bone particles of about 100 μm in diameter. The milled chunks were mixed properly with 7 kg of soybean concentrate powder (protein content 66 wt.%). The resulting mixture was kept at about 4°C. The mixture was loaded into a silo connected to a conveyor screw connected to a hopper with a volume of about 30 liters. The mixture was led from the hopper to the extruder with an auger and screw at a controlled rate of about 55 kg / h.

[0086] The mixture of ground poultry chunks and soybean concentrate powder was directed into an extruder incorporating a cooling die. The moisture content of the mixture was approximately 65 wt%. The mixture was extruded at 170 rpm. The heating zones of the extruder were adjusted to 60°C, 70°C, 80°C, 100°C, 120°C, 150°C, and 170°C. The first zone of the cooling die was set at 60°C and the last zone was set at 40°C. The extrusion process took approximately 1 minute.

[0087] The extruded mass exited the cooling die at below 100°C. A small amount of steam was released in the process. The solids and some of the separated oil were discharged at the end of the cooling die.

[0088] The aerobic microbial load of the solids from the wet extrusion and the mixture of ground poultry chunks and soy concentrate powder fed to the wet extrusion (i.e., the "feedstock") was measured at 30°C / 72 hours and was found to be less than 100 pmy / g for the solids and more than 30 000 000 pmy / g for the feedstock. The measured aerobic microbial levels indicate that a food grade product for human consumption has been obtained.

[0089] The calcium content of the food, i.e., solid matter, was 1.2 wt%.

[0090] There was a 7-log reduction in Salmonella in the solids, indicating complete elimination of Salmonella.

[0091] The solids were ground in a meat grinder with 2 mm holes. Sunflower oil and water were added to the ground mass in the ratio of 2:10 (w / w) respectively and left at 4°C for 60 minutes to be absorbed by the mass. The batches of mass were milled in a colloid mill. Colloidal milling provides a food mass that is ready for consumption.

[0092] The mass may be used as an ingredient in a food composition in an amount of up to 50 wt % based on the total weight of the food composition.

[0093] It will be obvious to those skilled in the art that with the advancement of technology, the concept of the present invention can be implemented in various ways. The present invention and the embodiments are not limited to the above-mentioned examples, but can be modified in various ways within the scope of the claims.

Claims

1. A method for producing a food product, comprising: - providing a eviscerated and plucked poultry material having bone, hard tissue, tendons, skin and / or cartilage; - providing a food material of plant origin; - grinding the eviscerated and plucked poultry material in a grinder having a particle size of maximum 5 mm to provide minced poultry chunks; - adding a plant-based food material to the minced poultry chunks to provide a mixture of the minced poultry chunks and the plant-based food material; - subjecting the mixture to extrusion to provide an extruded mass as a food product; A method comprising:

2. 10. The method of claim 1, wherein the eviscerated and plucked poultry material includes bone.

3. 10. The method of claim 1, wherein the eviscerated and plucked poultry material is chicken meat.

4. 10. The method of claim 1, wherein the eviscerated and plucked poultry material comprises poultry legs, necks, skin and / or heads.

5. 10. The method of claim 1, wherein the gutted and plucked poultry material has bone in an amount of about 10 wt% to about 60 wt%, based on the weight of the gutted and plucked poultry material.

6. The method of claim 1 , wherein the grinder has a hole size in the range of about 2 mm to 5 mm.

7. 10. The method of claim 1, wherein the plant-derived food material comprises soy protein, pea protein, cereal protein, fava bean protein, corn protein, or mixtures thereof.

8. 10. The method of claim 1, wherein the plant-derived food material is added to provide a food product comprising about 5 wt% to about 90 wt%, or about 5 wt% to about 75 wt%, or about 5 wt% to about 50 wt%, or about 5 wt% to about 50 wt%, or about 10 wt% to about 50 wt%, or about 10 wt% to about 30 wt%, or about 20 wt% to about 40 wt%, or about 40 wt% to about 75 wt%, or about 40 wt% to about 50 wt% of the plant-derived food material.

9. 10. The method of claim 1, wherein the food product comprises about 10 wt% to about 95 wt%, or about 25 wt% to about 95 wt%, or about 50 wt% to about 95 wt%, or about 50 wt% to about 90 wt%, or about 60 wt% to about 80 wt%, or about 25 wt% to about 60 wt%, or about 50 wt% to about 60 wt%, or about 70 wt% to about 90 wt% of the eviscerated and plucked poultry material.

10. 10. The method of claim 1, wherein the mixture of ground poultry chunks and plant-based food material is cooled prior to extrusion.

11. 11. The method of claim 10, wherein the ground poultry chunks are cooled to a temperature of from about -25°C to about 6°C.

12. The method of claim 1 , wherein the extrusion is carried out at a temperature of from 100° C. to about 400° C.

13. The method of claim 1 , wherein the extrusion is carried out at a moisture content of at least 20%.

14. The extrusion is wet extrusion, 10. The method of claim 1, wherein the mixture of ground poultry chunks and plant-derived food material has a moisture content of about 30 wt% to about 70 wt%.

15. 10. The method of claim 1, wherein the extrusion is carried out using a speed of about 100 rpm to about 1000 rpm, specifically about 200 rpm to about 600 rpm, and more specifically about 500 rpm.

16. 15. The method of claim 14, wherein the wet extrusion is carried out using a speed of about 100 rpm to about 1000 rpm, specifically about 170 rpm to about 600 rpm, more specifically about 170 rpm.

17. 10. The method of claim 1, wherein the temperature of the extruded mass is at least 100°C.

18. 10. The method of claim 1, wherein the extruded mass is cooled to a temperature of from about +60°C to about -40°C.

19. 2. The method of claim 1, wherein the extruded mass is ground in a grinder having a hole size of maximum 2 mm.

20. 10. The method of claim 1, further comprising mincing the extruded mass in a colloid mill.

21. 21. The method of claim 20, wherein the minced extruded mass has bone particles with an average particle size of about 1 μm to about 500 μm.

22. 10. The method of claim 1, wherein the food product has a calcium content of about 0.2 wt % to about 2.0 wt %, specifically about 0.2 wt % to about 1.2 wt %, even more specifically about 0.2 wt % to about 0.7 wt %, even more specifically about 0.2 wt % to about 0.5 wt %, even more specifically about 0.5 wt % to about 0.7 wt %, and even more specifically about 0.52 wt %.

23. 10. The method of claim 1, wherein the extruded mass is subjected to a heat treatment at a temperature in the range of about 150°C to about 400°C.

24. a eviscerated and plucked poultry material having bones, 1. A food product having a calcium content of about 0.2 wt% to about 2.0 wt%, specifically about 0.2 wt% to about 1.2 wt%, even more specifically about 0.2 wt% to about 0.7 wt%, still more specifically about 0.2 wt% to about 0.5 wt%, still more specifically about 0.5 wt% to about 0.7 wt%, and even more specifically about 0.52 wt%.

25. 25. The food product of claim 24, wherein the calcium content is from about 0.2 wt% to about 0.5 wt%, specifically from about 0.5 wt% to about 0.7 wt%, and more specifically about 0.52 wt%.

26. 25. The food product of claim 24, wherein the gutted and plucked poultry material has bone in an amount of about 10 wt% to about 60 wt%, based on the weight of the gutted and plucked poultry material.

27. 25. The food product of claim 24, wherein the eviscerated and plucked poultry material is chicken meat.

28. 25. The food product of claim 24, further comprising a plant-derived food ingredient.

29. 25. The food product of claim 24, comprising about 5 wt% to about 90 wt%, or about 5 wt% to about 75 wt%, or about 5 wt% to about 50 wt%, or about 5 wt% to about 50 wt%, or about 10 wt% to about 50 wt%, or about 10 wt% to about 30 wt%, or about 20 wt% to about 40 wt%, or about 40 wt% to about 75 wt%, or about 40 wt% to about 50 wt% plant-derived food material.

30. 30. The food product of any one of claims 24 to 29, comprising from about 10 wt% to about 95 wt%, or from about 25 wt% to about 95 wt%, or from about 50 wt% to about 95 wt%, or from about 50 wt% to about 90 wt%, or from about 60 wt% to about 80 wt%, or from about 25 wt% to about 60 wt%, or from about 50 wt% to about 60 wt%, or from about 70 wt% to about 90 wt% of the eviscerated and plucked poultry material.

31. 24. Use of a food product produced by a method according to any one of claims 1 to 23 as an ingredient in a food composition.

32. 32. Use of the food product of claim 31, wherein the food product is used to constitute up to about 50 wt% of the food product composition.

33. 24. A food composition comprising a food product produced by the method of any one of claims 1 to 23.

34. 34. The food composition of claim 33, wherein the amount of food is about 50 wt% of the food composition.

35. Apparatus having means for carrying out the method according to any one of claims 1 to 23.

36. The means comprises: - a meat grinder for grinding the gutted and plucked poultry material to provide chunks of minced poultry meat; an extruder connected to the meat grinder and configured to receive the ground poultry meat chunks and provide an extruded chunk; - a colloid mill connected to the extruder and configured to receive the extruded mass to provide a food product.

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