New continuous high shear process

Abstract

The present invention provides a continuous process for producing a product (90) comprising a fibrous structure from a base material (1), the base material (1) being a protein-containing material (5), the process comprising a conveying stage, a high shear stage and a forming stage, the conveying stage comprising (i) providing the base material (1) at a feed pressure (Pf) into a vessel (121), (ii) conveying the base material (10) in a conveying direction (125) through the vessel (121), and (iii) discharging the treated base material (1) from the vessel (121), the conveying of the base material (1) and the discharging of the treated base material (1) being based on a pressure difference between the feed pressure (Pf) and a discharge pressure (Pd), the flow rate of the base material (1) in the vessel (121) being controlled by controlling the pressure difference between the feed pressure (Pf) and the discharge pressure (Pd), the high shear stage comprising: The method includes (i) controlling a shear stage temperature (Ts) of the base material (1) in the vessel (121) while conveying the base material (1) through the vessel (121), and (ii) providing a specific mechanical energy (SME) to the base material (1) to treat the base material (1) in the vessel (121), where the specific mechanical energy provided to the base material (1) is selected from a range of Whr to 800 Whr per kg of base material (1), where the specific mechanical energy is controlled by controlling the shear force provided to the base material (1) as a function of the flow rate of the base material (1), and the forming stage includes directing the base material (1) from the vessel (121) through a forming system (130) while controlling a forming temperature (Tf) of the treated base material (1) in the forming system (130) to provide a product (90) at an outlet (139) of the forming system (130).

Description

[Technical field]

[0001] The present invention relates to methods and systems for continuously processing polymer-containing materials. The present invention further relates to products manufactured using high shear processes. [Background technology]

[0002] Systems and methods for high shear processing of polymers or biopolymers are known in the art. Very often, extrusion systems are used to mix and shear polymers and biopolymers such as proteins and starches to form products therefrom. For example, WO 2016 / 150834 A1 relates to a process for preparing meat analogues, and describes the process, comprising the steps of: a) feeding an extrusion barrel with 40-70% by weight of water and 15-35% by weight of vegetable protein; b) injecting, at a location downstream of the feeding location of step a), 2-15% by weight, preferably 2-10% by weight of liquid oil, fat or a combination thereof into the extrusion barrel; and c) extruding the mixture through a cooling die. This document further describes the meat analogues obtainable by this process. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] International Publication No. 2016 / 150834 Brochure Summary of the Invention [Problem to be solved by the invention]

[0004] Due to recent changes in consumer attitudes regarding the health, ethical and sustainability aspects of meat consumption, the demand for plant-based meat analogues has increased exponentially. The demand is met by an expanding range of meat analogues of ever improving quality. Unlike vegetarians, the flexitarian group does not want to compromise on the typical meat taste and texture. To this end, meat analogue producers have managed to create anisotropic structures that mimic the characteristic structure and texture of meat, as well as blood and fat analogues, to complete this race.

[0005] While protein-rich products such as tofu and tempeh have been consumed for centuries in East Asia, the introduction of meat analogs that felt like meat in Western countries began in the early 1960s with the production of dry texturized vegetable protein (TVP) by extrusion cooking. TVP is usually made with defatted soybean meal, soy protein concentrate, or wheat gluten and has a chewy, spongy texture. Other approaches to mimic the fibrous, chewy structure of meat began around the same time with mycoprotein and dairy proteins. To distinguish these products, they were called "second generation" meat substitutes. In the early 1990s, research on High Moisture Extrusion Cooking introduced a new means of organizing food proteins into a fibrous structure and texture that mimics muscle meat, giving it its characteristic chewiness and mouthfeel, and is called third generation.

[0006] Over the last decade, knowledge of HME(C) and post-extrusion processes, suitable raw materials and the influence and interaction of other functional ingredients and flavors and preservatives have paved the way for new product development and a wide range of third generation products. However, extrusion remains a highly complex technology that relies more on empirical trial and error type experimentation for both process and product development. This also makes it very difficult to scale up the HME(C) process.

[0007] However, extrusion, usually twin-screw extrusion, has become the technology of choice to produce fibrous meat-like products with the desired anisotropic structure. In extrusion, the material is mixed with water and conveyed by two screws, usually contained in a tightly fitting barrel, which generates heat by viscous dissipation and shear. The screw configuration, due to the geometry of the screw elements, determines the various zones along the screw, which perform distinct functions, such as mixing, hydration, thermomechanical processing and pressure interruption for pressure build-up. At the end of the barrel, the pressure is built up to a maximum and the material is forced out of the barrel through a conical transition zone, through a die, a narrow opening at the end of the barrel, or through a breaker plate, a perforated steel plate, which is positioned to ensure a uniform pressure distribution and is thought to align the flow before it enters the die. Depending on the moisture content, a distinction can be made between low moisture extrusion (LME, Low Moisture Extrusion, moisture content < 40%) or high moisture extrusion (HME, High Moisture Extrusion (C), moisture content > 40%, usually 50-70%). In the HME(C) a longer cooling die is used which cools the dough to near boiling temperature.

[0008] Extrusion has proven to be a powerful technology, but also cumbersome and difficult. Some of the drawbacks of extrusion that are often cited are, for example, that it is a highly complex process that depends heavily on the type of extruder and on trial and error conditions, that it has proven difficult to (up)scale, i.e. the endogenous heat generation through shear and viscous dissipation and the external heating or cooling of zones within the extruder depend on many parameters that all scale differently, for example depending on the relationship between surface area and volume, that extrusion exerts large forces and introduces high specific mechanical energy (SME, i.e. energy per kg of processed material) but it is not clear whether this is used efficiently (e.g. chemical structures and chemical bonds are broken and created multiple times, there is excessive shear and viscous dissipation, shear is increased to maintain pressure in the system), and that the process parameters involved (heat, shear, viscosity, residence time, throughput, pressure, moisture content, etc.) are highly interdependent, making it difficult or impossible to change one without simultaneously changing the others. Due to the large forces deployed in high-tech shearing processes, extruders represent considerable investments, CAPEX and OPEX, and require skilled personnel and technical services.

[0009] It is postulated that the most important limitation to the large-scale advancement of meat analogs in the transition towards plant-based proteins is the availability of new technologies to achieve the characteristic chewiness and mouthfeel at a lower cost without the significant drawbacks of extrusion.

[0010] Additionally, the controllability of many of today's processes carried out in extruders is improved by the methods and systems described herein, thereby eliminating the drawbacks of extrusion for all types of processes and products.

[0011] It is therefore an aspect of the present invention to provide an alternative method / process and / or system, which preferably further at least partially overcomes one or more of the above mentioned disadvantages. It is a further aspect of the present invention to provide a (food) product, in particular comprising a fibrous structure, which preferably further at least partially overcomes one or more of the above mentioned disadvantages. The present invention may have the aim of overcoming or ameliorating at least one of the disadvantages of the prior art, or of providing a useful alternative. [Means for solving the problem]

[0012] In a first aspect, the present invention provides a process, in particular a continuous process, for producing a product from a base material, in particular the base material is a (bio)polymer-containing material. The process in particular comprises a conveying step and a high shear step. In a further particular embodiment, the method (further) comprises a forming step. In a particular embodiment, the conveying step comprises conveying the base material in a conveying direction through the vessel and discharging the treated base material from the vessel (at the discharge port). The conveying step in particular comprises imposing a pressure difference across the base material in the vessel. The pressure difference in particular comprises a feed pressure (P f ) and discharge pressure (P d In a further embodiment, the conveying step can be defined as between a supply pressure (P f In a further particular embodiment, the conveying of the base material and the discharging of the treated base material include providing the base material at a supply pressure (P f ) and discharge pressure (P d In a further embodiment, the flow rate of the base material in the vessel is based on (and is a result of) the pressure difference between the supply pressure (P f ) and discharge pressure (P d) between the supply pressure (P ). In a further embodiment, the flow rate (velocity) of the base material is controlled by controlling the pressure differential. The (imposed) pressure differential can in particular control the transport of the base material through the vessel, in particular (also) through the forming system. In a particular embodiment, the supply pressure (P f ) may in particular be a high pressure having a value higher than 1 bara, for example at least 5 bara, in particular at least 10 bara, more in particular at least 25 bara. The conveying step in particular comprises providing the base material with a pressure which (gradually) decreases (in a downstream direction) from the inlet port to the discharge port of the vessel, in particular not increasing in a downstream direction within the vessel. Furthermore, in particular the high shear step comprises (while conveying the base material through the vessel) (i) increasing the shear stage temperature (T s), and (ii) providing a specific mechanical energy ("SME") to the base material (within the vessel) to treat the base material in the vessel (providing a treated base material at the discharge port). The specific mechanical energy can in particular be selected to deform the base material and change the properties of the treated base material relative to the untreated base material. The specific mechanical energy, in particular the magnitude of the specific mechanical energy (which may be combined with the shear stage temperature) can be selected to align molecules in the base material. In further embodiments, the specific mechanical energy can be selected to change the microstructure in the base material. The specific mechanical energy (and / or the shear stage temperature) can in further embodiments be selected to at least partially melt the base material. The specific mechanical energy can, for example in embodiments, be selected to provide (in total mechanical energy) between 25 Whr and 800 Whr (90 kJ and 2880 kJ) per kg of base material. In further embodiments, the specific mechanical energy can in particular be controlled by controlling the shear force provided to the base material as a function of the flow rate (velocity) of the base material. In certain embodiments, the method includes controlling the SME by controlling one or more of a shear force provided to the base material and a flow rate (velocity) of the base material. Further, in embodiments, the forming step includes controlling a forming temperature (T f ) through a forming system to provide a product at the outlet (or second end) of the forming system. f The term "temperature" refers to a single temperature and / or multiple temperatures (T f) or for example (forming) temperature profile (or "FTP"). In further embodiments, the forming stage can include directing the (processed) base material from (an outlet port of) a vessel through a forming system while controlling a forming temperature profile (FTP) of the processed base material across the forming system to provide a product, particularly at an outlet of the forming system. In further embodiments, the base material is a biopolymer-containing material. Further, in particular embodiments, the base material is a protein-containing material. In certain embodiments, the product comprises a fibrous structure. In further particular embodiments, the process can include controlling the feed pressure (F p ), shear stage temperature (T s ), the specific mechanical energy (SME) (magnitude or value), and the formation temperature (T f ) (one or more of) substantially independently of each other.

[0013] In a further aspect, the present invention provides a system for producing a product from a base material, in particular a base material which is a (bio)polymer-containing base material. In an embodiment, the system comprises a conveying system and a high shear device comprising a vessel and a temperature control system. In a further embodiment, the system may (further) comprise a forming system. In a further particular embodiment, the vessel comprises a high shear tool. More particularly, the vessel comprises an inlet port and an outlet port. In an embodiment, the forming system comprises a forming temperature control system. More particularly, the forming system may comprise a forming element in a further embodiment. In a further particular embodiment, a first end of the forming device is fluidly connected to the outlet port of the vessel, in particular a second end of the forming device is open. Furthermore, in particular the conveying system is adapted to supply pressure (P f ) and convey the base material through the container, particularly at discharge pressure (P d ) is specifically configured to discharge the treated base material from the vessel through the discharge port. In a further particular embodiment, the conveying system is configured to discharge the treated base material from the vessel through the discharge port at a supply pressure (Pf ) and discharge pressure (P d The high shear tool is particularly configured to provide a SME to the base material in the vessel. The high shear tool may be configured in an embodiment to be rotatable about an axis of rotation. The high shear tool is further particularly configured to block less than 75%, particularly less than 60%, for example less than 50% of the cross section of the vessel. In a particular embodiment, the high shear tool is configured to apply a shear force (F) to the base material in the vessel. s ) (providing the SME to the base material). The temperature control system is further configured to control a shear stage temperature (T s In an embodiment, the system is configured to process the base material in the vessel (particularly by providing a specific mechanical energy and configuring a shear stage temperature). Further, in an embodiment, the forming temperature control system controls the forming temperature (T f). The forming temperature control system can further be configured to control the forming temperature profile ("FTP") of the processed base material across the forming system. Moreover, in certain embodiments, the system is configured to produce products comprising fibrous structures, particularly from biopolymer-containing base materials, and more particularly from protein-containing base materials. Moreover, in particular, the system is configured to control the conveying system, the high shear device, and the forming system, particularly (substantially) independently of one another. In further particular embodiments, the system further comprises a control system particularly configured to control the conveying system, the high shear device, and the forming system (independently of one another). In further particular embodiments, the system is configured to handle (and process) the base material at high pressures, higher than 1 bara, for example at least 5 bara, particularly at least 10 bara. In embodiments, the system is configured to handle the base material at, for example, 30 bara. It is noted that in particular, the upstream side of the system can be configured to withstand high pressures. Since pressures may essentially decrease towards the downstream side of the system, in embodiments, the upstream side of the system can be configured for higher pressures than the downstream side of the system.

[0014] The process and system of the present invention can provide an alternative to extrusion processes and extrusion systems (or extruder systems). Also, the process and system can be controlled to a greater extent than comparable extrusion processes / systems. Using the process, products, especially food products, with different properties than prior art products can be made. In the process, different physical (and optionally chemical) phenomena, such as conveying, shearing, heating, (reaction), forming and structuring of the material being processed, can be controlled substantially independently of each other. The process can be easily scaled up. In addition, the system / process can allow easy change to different base materials and resetting (or determination) of the operating conditions that may be required. Also, by separating the different phenomena, the energy consumption to produce the product can be reduced compared to extrusion. With a single configuration of the system, various products and product properties, such as fiber properties (length, thickness, strength), texture and mechanical properties, can be provided by simply adapting the recipe and / or setting / controlling the desired operating parameters. The product properties, especially the fiber properties, can correspond to those of, for example, meat, poultry or fish, by controlling the operation.

[0015] Thus, in a particular embodiment, it is an aspect of the present invention to provide a continuous process for producing a product, particularly comprising a fibrous structure, from a base material, the base material being a polymer-containing material, particularly a protein-containing material, the process comprising a conveying stage, a high shear stage and particularly (also) a forming stage, the conveying stage comprising: (i) a supply pressure (P f (ii) conveying the base material in a conveying direction through the vessel; and (iii) discharging the treated base material from the vessel, wherein conveying the base material and discharging the treated base material are performed under a supply pressure (P f ) and discharge pressure (P d ), and the flow rate (velocity) of the base material in the vessel is based on the pressure difference between the supply pressure (P f ) and discharge pressure (Pd ), the high shear stage is controlled by controlling the pressure difference between the vessel and the base material while conveying the base material through the vessel, (i) increasing the shear stage temperature (T s ) and (ii) providing a specific mechanical energy to the base material to treat the base material in the vessel, the specific mechanical energy provided to the base material being selected from the range of 25 Whr to 800 Whr per kg of base material, in particular the specific mechanical energy being controlled by controlling the shear force provided to the base material as a function of the flow rate (velocity) of the base material. In a further embodiment the forming step comprises controlling the forming temperature (T f ), particularly involving directing a base material from a container through a forming system while controlling a forming temperature profile to provide a product at an outlet of the forming system.

[0016] It is further an aspect of the invention to provide, in certain embodiments, a system for forming a product, particularly comprising a fibrous structure, from a polymer-containing base material, particularly a protein-containing base material, the system comprising a conveying system and a high shear device comprising a vessel and a temperature control system, the vessel comprising a high shear tool (or "shear tool"), and a forming system comprising, particularly, a forming temperature control system, a first end of the forming device being fluidly connected to an outlet port of the vessel and a second end of the forming device being open, the conveying system being configured to (i) supply pressure (P) into the vessel via an inlet port (of the vessel); f ) and conveying the base material through the vessel to a discharge port from the vessel at a discharge pressure (P d ) to discharge the treated base material, and (ii) at a supply pressure (P f ) and discharge pressure (P d ), the high shear tool is configured to provide a specific mechanical energy to the base material in the vessel, and the temperature control system is configured to control a shear stage temperature (T sIn a further embodiment, the forming temperature control system (if present) is configured to control the forming temperature (T) of the processed base material in the forming system, particularly where the high shear tool is configured to be rotatable about an axis of rotation, and where the high shear tool blocks less than 50% of the cross section of the vessel. f ), specifically configured to control the forming temperature profile.

[0017] Basically, the base material can be any (base) material that is commonly processed using a (cooking) extruder. The base material can comprise a polymer (or a mixture comprising multiple polymers). The base material can comprise a biopolymer. The base material can also be a polymer-containing material. The polymer can be a synthetic polymer. The polymer can in particular be a biopolymer. The term "polymer" can refer in embodiments to multiple different polymers. The base material can in embodiments comprise a mixture, such as a mixture of ingredients. In certain embodiments, the base material comprises a mixture that includes a liquid (and further ingredients). The base material can have a dough-like appearance. This can also be referred to herein as "dough". The base material can comprise a dough.

[0018] In this specification, the term "biopolymer" refers in particular to a natural polymer, such as produced by cells of a living organism. The term may in embodiments refer to, for example, a polypeptide or a protein. Additionally or alternatively, the term may refer to a polysaccharide, such as starch or cellulose. The polysaccharide may essentially be derived from any natural source, for example from cereals, legumes, tubers, vegetables, etc. Furthermore, the terms "polymer" and "biopolymer" may refer to a plurality of (different) polymers and biopolymers, such as a mixture of polymers or a mixture of biopolymers, respectively. The base material may in embodiments also comprise, for example, starch and protein (and some further components or additives). In embodiments, at least 40% by weight, such as at least 50% by weight, in particular at least 60% by weight, of the base material on a dry matter basis comprises (consists of) protein.

[0019] Furthermore, the term protein can refer to any protein. The protein can be, for example, a plant-based (vegetable) protein. The protein can be an animal protein or an insect protein. The protein can be a fungal-based protein or a mycoprotein. Additionally or alternatively, the protein can be an algae protein. The protein can be a textured protein (e.g. textured vegetable protein, TVP, e.g. textured soy protein). The base material can in embodiments comprise (pre-)textured protein (especially next to a further base material). In embodiments, the protein is selected from the group consisting of plant-based (vegetable) protein, animal protein, textured vegetable protein (TVP), mycoprotein, insect protein, and algae protein. Furthermore, the protein can in embodiments be provided as a protein isolate and / or a protein concentrate. In a further embodiment, the base material can comprise a protein isolate. Additionally or alternatively, the base material comprises a protein concentrate. The term protein can also refer to more than one different (types of) protein, in particular as described herein.

[0020] The base material is in particular processed in a vessel. The vessel can therefore also be called a (processing) vessel or, for example, a process tank. In an embodiment, the vessel is an elongated vessel. In an embodiment, the vessel comprises a polygonal cross-section (perpendicular to the (longitudinal) vessel axis). The vessel can comprise, for example, a square cross-section, a hexagonal cross-section, an octagonal cross-section, etc. The (cross-section of) the vessel may be non-circular. In a further embodiment, the vessel can comprise an at least partially cylindrical vessel (having a circular cross-section). In a further embodiment, the vessel wall ("vessel wall") encloses the vessel space (or vessel volume), in particular the "processing space" or "working space". In a further particular embodiment, the vessel wall defines at least a part of the cylindrical (processing) space. The vessel can therefore further comprise a longitudinal axis. Furthermore, in an embodiment, the vessel comprises a high shear tool, in particular for applying shear forces to the base material, in particular for providing specific mechanical energy to the base material. The high shear tool may in an embodiment be configured (i) to be rotatable about a (virtual) axis of rotation (or a "(virtual) rotatable shaft"). The axis of rotation is in particular configured parallel to the longitudinal axis of the vessel. The axis of rotation may be the axis of the (rotatable) shaft (of the shear element). However, the axis of rotation may also be a virtual axis. The axis of rotation may in an embodiment coincide with the vessel axis. In a further embodiment, the axis of rotation and the vessel axis do not coincide. The high shear tool is in particular arranged in the treatment space.

[0021] The terms "working space", "vessel space", "vessel volume" and equivalent terms refer in particular to the interior volume of the vessel (defined in particular by the vessel wall).

[0022] The shear tool may further comprise a shear element extending along the axis of rotation. The term "shear element" may refer to a plurality of (different) shear elements. The shear tool may in embodiments comprise a plurality of shear elements (extending along the axis of rotation). The shear tool may in embodiments have a (central) opening, such as a central channel, defined in the shear element. This opening may further be defined between the shear elements, and in particular at the axis of rotation. Such an opening may in embodiments have an annular shape shaped around the physical axis of rotation of the shear element. This opening may in further embodiments have a cylindrical shape. The shape, such as an annular or cylindrical shape, may vary locally. For example, in embodiments the shear element may be connected to the axis of rotation at a certain longitudinal position, while at other longitudinal positions this element is not directly connected to the axis of rotation (at that longitudinal position). This opening or channel may promote an (overall) axial flow of the base material, see further below. In further embodiments comprising a plurality of shear tools (see further below), an opening may also be formed between the shear tools. The term "opening" may refer to a plurality of openings.

[0023] Moreover, the shearing elements in particular extend from the axis of rotation. The shearing elements are essentially configured to shear and / or mix, in particular while maintaining the base material in substantially the same longitudinal position (unless an external conveying force is applied to the base material). The shearing elements can be configured to minimize the conveying force imposed on the base material (in the conveying direction). By minimizing the conveying force or by providing a conveying force at least in one direction only, an all-unidirectional processing of the base material can be provided. A unidirectional processing of the base material, in particular a processing that is rather constant throughout the base material, can facilitate controlling the final structure of the product. The shearing elements can for example be configured (almost) parallel to the longitudinal axis of the container. In a further embodiment, the shearing elements can be configured at a small angle to the axis of the container, for example in the range of -45° to (+)45°, for example in the range of -30° to 30°, for example in the range of -20° to 20°, in particular in the range of -10° to 10°. Herein, a shearing element arranged parallel to the axis of rotation can also be called a helix. For such parallel arranged elements, this angle is substantially 0.degree.. In a particular embodiment, the shear elements are arranged parallel to the axis of rotation of the shear tool.

[0024] The axis of the vessel is in particular parallel to (the direction of) the lead (L) of the helical shear element. In a further embodiment, the (helical) shear element may be arranged at an angle to the vessel axis, in particular the lead may be arranged at less than that angle to the vessel axis. The term "lead" (L) is known to the skilled person and indicates the total axial distance defined by one revolution of the helix (helical shear element). Said angle may also be known for the helix angle. For a helical element, the helix angle is equal to the arctan (arctangent or arctangent) of the circumference of a cylinder defined by the helical element (e.g. shear element) over the lead of the helical element, i.e. arctan(2πr / L), where r is the radius of the cylinder. The helix angle is complementary to (adding to 90°) the lead angle of the helix, i.e. the angle between the helix and the plane of rotation of the helix.

[0025] In an embodiment, for example, the (helical) angle is equal to 10°, which indicates that the L / r ratio is about 36 (35.633), indicating that if the diameter defined by the helix is ​​10 cm, then the total axial length for one revolution of the helix is ​​about 3.6 meters. At an angle of 20°, L divided by r is about 17, and at an angle of 0°, the shear elements are arranged parallel to the longitudinal axis (which can be considered as the limit of the helix). In an embodiment, the ratio of the lead of the shear elements to the radius (defined by) of the shear elements is at least 15, for example at least 20, in particular at least 30. This ratio can be in an embodiment 100, or even higher, in particular infinite. In an embodiment, the shear elements are arranged (substantially) parallel to the axis of rotation (corresponding to the above ratio being substantially infinite).

[0026] Furthermore, the shear tool is particularly configured to shear the base material between the vessel wall and the (rotating) shear tool, in particular between the vessel wall and the shear element of the rotating shear tool. The vessel wall surrounding the shear tool can in particular be configured according to the vessel cross section described above. The vessel wall can in an embodiment be at least partially polygonal. In a further embodiment, the vessel wall can be at least partially cylindrical. Thus, in an embodiment, the shear tool, in particular the shear element, can be configured to shear the base material continuously during a (single) rotation of the shear tool. The (minimum) distance between the wall and (a particular location of) the shear tool can remain constant during the rotation (e.g. if the vessel cross section is circular and the axis of rotation coincides with the vessel axis). In a further embodiment, the minimum distance between the wall and the shear tool can change during the rotation of the shear tool (e.g. in vessels of non-circular cross section and / or when the axis of rotation does not coincide with the vessel axis). In the latter embodiment, the base material can undergo relaxation at locations where the (minimum) distance between the vessel and the shear tool increases (during rotation).

[0027] In a further embodiment, the high shear tool comprises a shear element extending along a rotation axis, the shear element being configured at an angle of -45° to 45°, for example -20° to 20°, in particular -10° to +10°, relative to the longitudinal axis of the vessel (or to the axis of rotation of the (helical) shear element).

[0028] Thus, in a further embodiment, in the high shear stage, the high shear is provided by rotating a high shear tool in the vessel about a (virtual) axis of rotation, in particular the axis of rotation is configured parallel to the conveying direction, in particular the base material is sheared between the vessel wall and the (rotating) high shear tool. Furthermore, in particular in the high shear stage, the shear force (F s ) is selected substantially perpendicular to the transport direction of the base material.

[0029] In an embodiment, the discharge ports can be arranged to discharge the treated base material in a radial direction, in particular in a direction substantially perpendicular to the conveying direction. Such a configuration can be advantageously combined with an embodiment in which the direction of the shear forces is substantially perpendicular to the conveying direction. In this way, distortion of the flow rate (profile) of the base material at the discharge ports can be minimized. In other embodiments, the configuration of the discharge ports can be different. For example, the direction of the discharge ports can be (also) aligned with the vessel axis.

[0030] In an embodiment, the minimum distance between the vessel wall and the high shear tool (or shear element) may be at least 0.05 mm, such as at least 0.1 mm, in particular at least 0.5 mm, such as at least 1 mm. The minimum distance may be more particularly not more than 30 mm, in particular not more than 25 mm, such as not more than 20 mm, more particularly at most 15 mm. In an embodiment, the minimum distance between the vessel and the high shear tool (or shear element) is in the range of 0.1 to 20 mm, in particular in the range of 0.5 to 10 mm. It is noted that the distance between the vessel wall and the high shear tool may be equal to the minimum distance at a particular location of the vessel wall in an embodiment. For example, in an embodiment, the axis of rotation of the high shear tool and the axis of the vessel do not coincide. In such an embodiment, the distance between the wall and the shear tool may vary (significantly) in the radial direction. Also, in a polygonal vessel, the distance between the wall and the shear tool may vary.

[0031] Furthermore, especially in the high shear stage, the base material can be subjected to a shear force for a given shear duration. The shear force and / or especially the SME can be controlled by the configuration of the shear tool. The shear force and / or the specific mechanical energy can further be controlled by the rotation speed of the shear tool. The shear duration can be controlled by controlling the flow rate (velocity) of the base material through the vessel. The shear duration can be controlled in embodiments by controlling the conveying speed of the base material (especially in the conveying stage). Furthermore, especially the specific mechanical energy provided to the base material is a combination of flow rate and shear force, which can be controlled in embodiments by controlling the shear force and / or the flow rate of the base material. The shear force can be a function of especially the configuration of the shear tool (in the vessel) and the rotation speed of the shear tool. Furthermore, especially the shear force is a function of the SME. In an embodiment, the specific mechanical energy provided to the base material may range from 25 Whr to 800 Whr / kg (base material), in particular from 50 to 800 Whr / kg, for example from 100 to 800 Whr / kg, in particular from 100 to 400 Whr per kg of base material. In a further embodiment, the SME provided to the base material may be at least 25 Whr / kg (base material), for example at least 40 Whr / kg, in particular at least 50 Whr / kg, or at least 100 Whr / kg. The SME may in a further embodiment be up to 800 Whr / kg, for example up to 400 Whr / kg, in an embodiment up to 200 Whr / kg. The SME may in particular be in the range of 50 Whr / kg base material, for example 50±50% Whr / kg. Thus, in a further embodiment, the SME provided to the base material may range from 25 to 400 Whr / kg base material.

[0032] The term "flow rate" as in the phrase "controlling the flow rate" refers specifically to flow rate, for example in mass per time unit or volume per time unit (mass flow rate (velocity) and volume flow rate (velocity) respectively).

[0033] The high shear tool may in embodiments include or define a screw-like or helical configuration. The high shear tool may further include a plurality of shear elements, for example two shear elements, or three shear elements, or even four, five, six, eight, or even more shear elements. It is noted that in a shear tool with a single shear element, the lead of the shear element may also be referred to as the pitch of the element. In a tool with two or four, etc. (identical) shear elements, the pitch may be half or a quarter, etc., of the lead, respectively. The shear element may in embodiments be configured as a flight extending from the axis of rotation. Such flights may be particularly open over a (substantial) length of the axis of rotation close to the axis of rotation and closed away from the axis of rotation. In certain embodiments, the shear tool may, for example, be a plurality of shear elements that together define a helical configuration. In further embodiments, the shear tool may have a linear configuration, for example with one or more shear elements configured parallel to the axis of rotation of the high shear tool. The helical configuration is defined by the shearing tools in an embodiment, in particular the shearing elements are configured at an angle to the axis of rotation of the shearing tools (or the axis of the container, in case of a single shearing tool and the axis of rotation is arranged parallel to the container axis). The high shearing tools may in an embodiment include an open configuration. The term "open configuration" particularly relates to a configuration of the shearing tools that defines a relatively high flow area in the conveying direction. For example, in an embodiment the base material flows (in the conveying direction) through at least 50%, for example at least 75%, or even at least 90% of the cross section (perpendicular to the conveying direction) of the working space (container space), the remainder of the cross section being occupied by the shearing tools. In an embodiment the high shearing tools may block less than 50%, for example less than 40%, in particular less than 35%, more particularly less than 25% of the cross section of the container. Also, in an embodiment, the ratio of the total volume of the shear tools (sum of the shear tools) to the total volume of the operating space (within the vessel) (at the location including the shear tools) may be in the range of 1:20 to 1:2, for example 1:10 to 1:2, in particular 1:10 to 1:5.

[0034] In an embodiment, the ratio of the (sum of) total volume of the shear tools to the total volume of the vessel may be in the range of 1:20 to 1:2, for example 1:10 to 1:2, in particular 1:10 to 1:5. In a further embodiment, less than 50%, in particular less than 40%, for example less than 35% of the total volume of the vessel is occupied (filled) by the shear tools. In a further embodiment, the ratio of the total volume of the shear tools to the total volume of the vessel is in the range of 0.05 to 0.5, in particular 0.05 to 0.3. In a further embodiment, the ratio of the total volume of the shear tools to the total volume of the vessel is in the range of 0.2 to 0.5, in particular 0.2 to 0.4. The high shear tool may in an embodiment cut off less than 50%, in particular less than 25%, for example less than 10% of the cross section of the vessel. This cut off rate may vary along the axis of rotation. These given percentages may in particular relate to the average cut off rate, i.e. the cut off rate of the cross section of the vessel averaged over the length of the shear tool.

[0035] The term "flow" in expressions such as "flow opening" particularly refers to a structure or device, such as a channel, through which a fluid or flowable mixture can enter the structure or device at an initial location (or end) and exit the structure or device at a further location (or end) different from the initial location.

[0036] The term "high shear tool" can refer to multiple (different or the same) high shear tools, such as two high shear tools, at least three high shear tools, for example, four, five, six, or even more high shear tools.

[0037] In further embodiments, two (or more) (helical) high shear tools can be arranged parallel to each other. The multiple, especially helical, shear tools can be configured in embodiments to be intermeshed, partially intermeshed, or non-intermeshed (with respect to one or more of the other shear tools). Furthermore, multiple rotatable shear tools can be configured to co-rotate or counter-rotate. In embodiments, the polygonal vessel wall can be configured to accommodate multiple high shear tools, e.g. with two different portions for two shear tools. In further embodiments, the vessel wall can define more than one at least partially cylindrical space. For example, in a first (at least partially cylindrical) space, a first shear tool can be rotatably configured, and in a second (at least partially cylindrical) space, a second shear tool can be rotatably configured. Thus, in embodiments, the vessel includes multiple high shear tools arranged parallel to each other. In alternative embodiments, one or more of the high shear tools can be configured at an angle to the vessel axis. In embodiments, the shape of the high shear tools can be tapered (longitudinally). In embodiments including tapered high shear tools, the high shear tools may be configured at an angle to one another.

[0038] The system further measures the shear stage temperature (T s). The temperature control system may include one or more temperature control elements in embodiments. In an embodiment, for example, the vessel wall may include a temperature control element (or a plurality of temperature control elements) configured to control the temperature within the vessel (wall). The vessel, in particular the vessel wall, may include, for example, a heating element and / or a cooling element. Additionally or alternatively, the vessel wall may include one or more fluid channels through which a temperature control medium (coolant or heating medium) flows. The vessel may include, in further embodiments, a jacketed wall (for cooling and / or heating the vessel). In further embodiments, the shear tool, in particular the shear element, may (also) include a temperature control element. The shear tool, in particular the shear element, may be hollow. The shear tool may include, for example, a fluid channel configured to accommodate (flow) a temperature control fluid (to provide or absorb heat to / from the base material). The fluid channel may be configured in the shaft of the shear tool in an embodiment. Additionally or alternatively, the fluid channel may be configured in the shear element. The shear element may include, in particular, a fluid channel at a location that extends furthest from the axis of rotation (i.e., closest to the vessel wall during rotation). Thus, in particular the temperature of the base material (shear stage temperature) can be controlled by one or more temperature control elements.

[0039] Depending on the base material and / or other circumstances, the temperature control fluid can have a low temperature to cool the base material being processed, or the fluid can have a high temperature to heat the base material being processed. By varying the temperature with the temperature control system, in particular the temperature control element, the shear temperature can be controlled to a temperature in the range of, for example, 65-150°C, in particular 70-150°C, or 80-150°C, for example 90-140°C, 100-140°C, or for example 80-90°C. In a particular embodiment, the shear temperature can be set to about 100-120°C. The desired temperature depends in particular on the base material being processed. For proteins, it may be advantageous to at least partially denature the protein during processing. At least partially denaturing the protein may facilitate providing the desired properties to the product being formed in the forming stage.

[0040] Thus, in an embodiment, the method includes controlling the shear stage temperature (T s In a further particular embodiment, the step of controlling the shear stage temperature (T s ) is selected to (at least partially) denature at least a portion of the protein. Additionally, the term "shear stage temperature" can refer in embodiments to the (shear stage) temperature profile ("STP") across the vessel.

[0041] Thus, it is an aspect of the invention to process a base material in a vessel while conveying the base material through the vessel (including temporarily holding / maintaining the base material at a predefined axial location within the vessel). Conveyance can be provided (substantially entirely) by a conveying system configured in fluid connection with the vessel. The conveying system may not be included in the vessel in embodiments. The shearing tool in the vessel may not function like a screw as in an extruder, used for conveying in combination with shearing (and mixing). Conveying the base material through the vessel or the flow of the base material through the vessel may be the result of a pressure difference between a feed pressure and a discharge pressure, in particular provided at the inlet port and the discharge port of the vessel, respectively. In embodiments, at least 75% of the flow rate of the base material through the vessel is the result of said pressure difference. In further embodiments, at least 80%, such as at least 90%, of the flow rate of the base material through the vessel is the result of said pressure difference. For example, in embodiments, less than 25%, in particular less than 20%, such as less than 10% of the (further) flow rate may be the result of conveying induced by the high shear tool.

[0042] The feed pressure may in embodiments be provided by a feed device such as a feed pump that feeds the base material into the vessel. The feed pressure may in particular be higher than 1 bara (bar absolute), for example at least 5 bara. The feed pressure may in embodiments be less than or equal to 100 bara, for example 50 bara, in particular 30 bara, even more in particular 25 bara, for example at most 10 bara. In embodiments, the feed pressure may be in the range of 1.1 to 100 bara, in particular 1.1 to 90 bara, for example 5 to 90 bara, in particular 10 to 90 bara. In further embodiments, the feed pressure may be in the range of 2 to 50 bara, in particular 2 to 25 bara, for example 2 to 10 bara. Furthermore, the discharge pressure may in embodiments be at least 1 bara, in particular at least 1.5 bara, for example at least 2 bara. In embodiments, the discharge pressure may be at least 5 bara. Based on the difference between the feed pressure and the discharge pressure, the base material may flow through the vessel. Additionally or alternatively, the transport system may (also or alternatively) include a transport device configured to be fluidly connected to the exhaust port. The (further) transport device may in an embodiment be configured with a suction side connected to the exhaust port. Thus, in an embodiment, the exhaust pressure may (also) be less than 1 bara, for example between 0.5 and 1 bara. The (further) transport device may in an embodiment be configured to provide a vacuum at the exhaust port. Depending on the configuration of the system, the pressure in the vessel may (only) decrease in an embodiment, in particular (substantially) in the downstream direction.

[0043] In certain embodiments, the conveying system is configured to provide the treated base material at high pressure at the discharge port. Thus, in embodiments, the conveying step comprises conveying the base material into the vessel using a conveying device arranged upstream of the vessel. The base material can in particular be conveyed into the vessel at a supply pressure of more than 1 bara, in particular more than 2 bara, for example selected from the range of 10-90 bar. By applying high pressure, a flow rate of the base material through the system can be induced. Furthermore, such high pressure can affect the processing in the vessel. High pressure can in embodiments, for example, prevent liquid in the mixture from evaporating during processing. High pressure can further facilitate processing. A pressure of more than 1 bara at the discharge port may further be required to induce the treated base material further through the forming system. However, in certain embodiments, a (further) conveying device fluidly connected to (the outlet / first end of) the forming system can be configured to convey (pump) the treated material through the forming system. In embodiments, the (further) conveying device is configured between the discharge port of the vessel and (the first end of) the forming system.

[0044] In a further embodiment, the supply pressure (P f ) and discharge pressure (P d ) is selected to provide at least 70%, particularly at least 85%, particularly at least 95%, e.g. substantially all, of the total energy required to convey the base material through the vessel. Additionally, in embodiments, particularly when the vessel includes a high shear tool that provides specific mechanical energy (SME) to the base material (to process the base material in the vessel), up to 30%, e.g. up to 15%, particularly up to 5% of the total energy required to convey the base material through the vessel is provided by the high shear tool.

[0045] In a further specific embodiment, the system, in particular the conveying system, can further include an additional conveying device. The additional conveying device can be located particularly downstream of the discharge port and particularly upstream of the forming system. Such additional conveying device can facilitate conveying the processed base material through the forming system. In a further specific embodiment, the process includes providing 30% or less of the total energy required to convey the base material through the container and through the forming system with the additional conveying device, in particular configured at a location upstream of the forming system, in particular between the discharge port and the forming system.

[0046] The term "conveying device" can refer to a number of different conveying devices. Moreover, the use of the term "further" in "(further) conveying device" does not necessarily mean that the system includes at least one conveying device and a further conveying device. The term is also used herein to describe an embodiment in which the "conveying device" can be configured upstream of the vessel and the "(further) conveying device" can be located downstream of the vessel. In an embodiment, the first conveying device is configured upstream of the vessel and the further conveying device is configured downstream of the vessel.

[0047] The terms "upstream" and "downstream" refer to the location of an article or feature relative to the propagation of an element such as a particle, fluid, or base material within a channel, flow path, or fluid circuit, such that with respect to a first location within the channel, flow path, or circuit, a second location within the channel, flow path, or fluid circuit up to an inlet (for the fluid, particle, or base material) of the channel, flow path, or fluid circuit is "upstream" and a third location within the channel, flow path, or circuit further away from the inlet is "downstream."

[0048] Thus, in embodiments, different pressures can be provided by the conveying system, in particular from less than 1 bara to well above 1 bara. However, in particular the system, in particular the conveying system, is configured to provide (create) a pressure differential between the supply pressure and the discharge pressure. The conveying system is in embodiments configured to provide a pressure differential across the vessel, in particular based on a pressure imposed on the vessel from outside the vessel.

[0049] Furthermore, in particular pressures are imposed, so that the system, in particular the vessel, in embodiments is configured to operate at these pressures. In embodiments, for example, the system, in particular the vessel, is configured for a (working) pressure in the range of 0.4-100 bara, such as 0.5-100 bara, more particularly at least 1.5 bara, such as at least 5 bara. The system, in particular the vessel, in embodiments, can be configured for a (working) pressure in the range of 0.4-10 bara, such as 0.4-5 bara. In further particular embodiments, the system, in particular the vessel, is configured for a (working) pressure in the range of 1.1-100 bara, such as 1.1-90 bara, such as at least 2 bara, in particular at least 5 bara, more particularly at least 10 bara, and more particularly up to 90 bara, such as up to 75 bara, in particular up to 50 bara.

[0050] The vessel can be made of a vessel material. The vessel material can include, for example, a metal, in particular a steel, such as stainless steel. The vessel material can further be selected as a food grade material. Furthermore, the vessel wall can be configured to operate at the operating pressures described herein, in particular between the supply pressure and the discharge pressure. The wall thickness ("wall thickness") can be at least 3 mm in embodiments, for example at least 5 mm, in particular at least 7 mm. The wall thickness can essentially have any maximum value. For economic reasons, the wall thickness can in particular be at most 30 mm, for example at most 20 mm. The system can further include seals between different elements or "parts" of the system (e.g. the vessel and the shear tool) that can withstand high pressures, in particular at a location upstream of the vessel. The seals can include, for example, ceramic seals. The system can include, in embodiments, a seal between the rotation axis (or rotatable shaft) of the shear tool and the vessel. The term "seal" can refer to multiple (different) seals.

[0051] As indicated above, downstream of the vessel, the treated base material can be directed into (a first end of) the forming system. In an embodiment, the treated material is formed in the forming system to provide a product that leaves the forming system, in particular at the (open) second end of the forming system (or "outlet" of the forming system). To prevent excessive expansion of the product, for example due to (rapid / instantaneous) evaporation of liquid in the product, the method can include a step of controlling the (forming) temperature of the treated base material (in the forming system), in particular to a value below the boiling point of the liquid (at the outlet of the forming system). In an embodiment, the base material can for example comprise water, and the temperature can be controlled to less than or equal to 100°C, in particular below 100°C. Also, by controlling the forming temperature in the forming system, the flow rate of the treated material can be controlled. In an embodiment, the flow rate (and temperature) is controlled in particular to provide a product comprising a fibrous structure. The forming system can be configured in a further embodiment to provide a laminar flow (of the treated base material in the forming system). In particular, such a laminar flow of treated material can be solidified in the forming system to provide a fibrous system. In an embodiment, the flowing processed material can be cooled in the forming system. The cooling of the flow can gradually reduce the temperature of the flowing processed material from the outside of the flow to the center of the flow, resulting in a fibrous structure. In addition, or instead, the flowing processed base material can be heated. The cooling and / or heating can cause the growth or reduction of crystalline sectors in the processed material, which can further allow the structure of the product leaving the forming system to be controlled.

[0052] Thus, in an embodiment, the product leaves the forming system at (slightly above) atmospheric pressure, but at the forming temperature (T f) is controlled to provide a fibrous structure. The forming temperature is particularly controlled to provide a product, particularly a fibrous structure. In an embodiment, the forming temperature is controlled to prevent expansion, particularly puffing, of the product leaving the forming system. The forming temperature can particularly be controlled to provide a product at a temperature of approximately 100°C, for example below 100°C, particularly below 100°C. The forming temperature at the downstream end of the forming system can in an embodiment be approximately 100°C, for example (just) below 100°C. However, in further particular embodiments, the forming temperature at the downstream end of the forming system may be higher. Furthermore, the forming temperature further upstream (at the downstream end) in the forming system can be higher and / or lower than said temperatures at the downstream end, as described above (particularly to control the structure or texture of the product). The forming temperature at a further upstream location (for example at the upstream end of the forming system or at a location between the upstream and downstream ends) can be, for example, at least 120°C, for example at least 150°C, or even higher. The forming temperature further upstream of the downstream end can be, for example, in the range of 70-200° C., such as in the range of 70-160° C., such as in the range of 100-150° C., and / or in the range of 70-100° C. In a further embodiment, the process and / or system is configured to provide a substantially laminar flow rate of the treated base material in the forming system.

[0053] As used herein, the term "forming temperature" can refer to a number of different forming temperatures. The term can refer, for example, to a (forming) temperature profile (or "FTP") across a forming system, the forming temperature at a particular forming element, and the temperature profiled across different forming elements. Similarly, the term "shear stage temperature" can refer to a (base material) temperature profile across a vessel. The temperature profile can be based, for example, on the temperature at (the location of) the shear tool and / or, for example, on the temperature at the wall of the vessel.

[0054] The forming system essentially comprises a hollow (tubular) forming element (enclosing the flowing processed material). Essentially the forming element can comprise any shape or cross-section. The cross-section of the forming element can for example resemble the shape of (the cross-section of) a meat product, in particular to provide a product similar to said meat product. In a further embodiment, the shape can resemble a fish product. The cross-section can be rectangular (including square). The cross-section of the forming element can be circular. Also, in an embodiment, the cross-section can vary along the length of the forming element. In an embodiment, the flow area of ​​the forming system is smaller than the flow area of ​​the container.

[0055] In this specification, the term "forming element" may refer to multiple forming elements in an embodiment. The forming system may, for example, include multiple (different) forming elements arranged parallel to each other. The multiple forming elements may be fluidly connected at both ends of the forming elements (at first and second ends). In this way, the processed base material from the container may be divided across the multiple forming elements (at the first ends of these elements) and recombined (to provide the product) in a continuous manner (at the other ends of the forming elements). Furthermore, the dimensions, such as the length or cross-sectional area, of the different forming elements may differ from each other. Thus, in an embodiment, one end of a first forming element may not be connected to one end of a further forming element, but may be fluidly connected to a further location of that further forming element. The different dimensions may provide different flow profiles within the forming elements. Such a configuration may further control the structure of the product.

[0056] Thus, in an embodiment, the forming system comprises one or more hollow (particularly tubular) forming elements. The forming system may comprise a plurality of forming elements arranged parallel to one another, the forming elements being fluidly connected to one another at both ends of the forming elements. In a further embodiment, the forming step comprises splitting the treated base material from an exit port across the plurality of (tubular) forming elements, and recombining the treated base material exiting the plurality of (tubular) forming elements to provide a product at the outlet of the forming system, in particular comprising a fibrous structure.

[0057] As discussed above, the base material may comprise a mixture of ingredients. In an embodiment, all ingredients may be provided to the container at once. These ingredients may be provided as (a mixture of) dry ingredients and optionally wet ingredients. The base material may also comprise a mixture, particularly including a liquid having a dough-like appearance. In an embodiment, further ingredients or additives may also be added to the base material at one or more further locations in the system. Such additives may include, for example, one or more additives selected from the group (of food additives) consisting of colorants, fats, oils, vitamins, binders, and flavors. The additives may essentially comprise any appearance, such as a single component, a mixture, a liquid, a solid, a gas, and an emulsion, or a combination thereof.

[0058] Thus, in an embodiment, the system is configured to add additives to the (processed) base material (within the system). The system may, for example, include a dosing system (to administer additives). The dosing system may be fluidly connected to one or more of the (processing) space within the container and / or the (space within) the forming system to provide additives to the base material (and / or the processed base material) within the container and / or the forming system (respectively). The dosing system may, for example, be fluidly connected to the forming system and may be particularly configured to provide a layer (or coating) of additives at a location between the processed base material and the forming system, particularly the walls of the forming elements. The layer may, in an embodiment, include a fat substitute, particularly mimicking a fat layer of meat.

[0059] Further, in embodiments, the process can include adding additives to the base material during one or more of the high shear and forming stages. In yet other particular embodiments, the process can further include a (dough) preparation stage, which includes mixing the base material starter material with a liquid to provide the base material for the conveying stage. Thus, the system can, in embodiments, further include a (dough) preparation system fluidly connected to the conveying system for providing the base material (particularly the dough) to the inlet port of the container.

[0060] The process and the system can be automated. To be automated, the system and the process can include, for example, a control system including a plurality of control units operatively connected to the system. The system can further include one or more sensors and controllable elements (such as the above-mentioned temperature control system / elements, actuators of the feeding device, and actuators of the shearing tool, etc.) for controlling the process. Examples of sensors are known to the skilled person and can include, for example, (mass) flow meters (including Coriolis mass flow meters), dielectric sensors, and infrared sensors, pressure sensors, scales, etc. The sensors and the controllable elements are in particular (also) operatively connected to the control system. The sensor can in an embodiment be operatively connected to or consist of a measurement system. The system can be controlled based on signals of the measurement system. The measurement system is in particular operatively connected to the control system. Additionally or alternatively, the control system includes at least a part of the measurement system.

[0061] Thus, in an embodiment, the system measures the (volume and / or mass) flow rate of the base material in the vessel, the shear temperature (T s ), formation temperature (T f), the velocity of the processed base material in the forming system, the total mechanical energy (or specific mechanical energy) provided to the base material (and / or provided to and by the shear tool), the density of the base material, the moisture content of the base material, the pressure (particularly one or more pressures) in the vessel, and the pressure (particularly one or more pressures) in the forming system. The measuring system is particularly adapted to measure one or more operating parameters (P f , P d , T s , T f , SME). The (measurement) system may comprise one or more temperature sensors. The (measurement) system may comprise one or more pressure sensors. Furthermore, the (measurement) system may comprise one or more flow (mass and / or volume) sensors. The system may in particular comprise a sensor or detector measuring the power of a motor driving the shear tool. The measurement system may be configured to measure and / or determine the specific mechanical energy (provided to the base material) and / or the shear force.

[0062] In yet another aspect, the present invention provides a product comprising a fibrous structure, particularly obtainable by the process described herein. The fibrous structure may at least partially define a solidified (fixed) lamellar or Hagen Poiseuille (like) flow pattern. The structure may in embodiments comprise fibers that may define (at least a portion of) a parabolic structure. Such structures are particularly found using circular forming systems. However, comparable fibrous structures may be provided using other types of (cross-sectional) shapes of forming systems. In certain embodiments, the product comprises fibers having a length of at least 10 cm. In further embodiments, the product comprises fibers having a length of at least 1 cm, such as at least 3 cm. These fibers may in embodiments have a length in the range of 3 cm to 10 cm. These fibers may in further embodiments be 25 cm or less, such as 15 cm or less. The product may comprise an anisotropic structure. The product may further comprise a coating, such as a fat (substitute) coating, disposed on the surface of the product. The product may comprise one or more (discrete) sections comprising (consisting of) the additives described herein (e.g. fat (substitute) and / or emulsion). The product may in certain embodiments comprise a food product. The food product may in particular comprise vegetable protein, in an embodiment the food product is a vegetarian food.

[0063] In this application, the feature "cross-sectional area" is used. In this regard, the cross-sectional area may also be referred to as a flow cross-sectional area or a cross section. This cross-sectional area may be, for example, rectangular, elliptical, or round (like a ring).

[0064] The term "on a dry matter basis" (or "by dry matter weight") is known by the person skilled in the art. The term "on a dry matter basis" as in "based on dry matter (weight)" and "with respect to dry matter weight" relates to the total weight (mass) of the product (including a determined weight of water) minus the weight of water in the product (a determined weight of water). The dry matter weight of a product is in particular equal to the total weight of the product after substantially all of the water has been removed from the product, for example by heating the product (especially for an extended period of time) (above 100°C). In particular, when the amount of an ingredient in a product (or in a defined combination of ingredients) is based on dry matter (weight), the dry matter weight of that ingredient is defined relative to the dry matter weight of the entire product (or in a defined combination of ingredients).

[0065] The terms "oil" and "fat" may be used interchangeably herein. Thus, in embodiments, the term "oil or fat" may be replaced by the term "fat". The terms "fat" and "oil" may refer to multiple (different) fats and / or oils. The terms may further refer to a mixture of different fats and / or oils. Furthermore, the term "oil" may refer to a product that is liquid at room temperature, whereas "fat" may refer to a product that is solid or may not flow at room temperature. [Brief description of the drawings]

[0066] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying schematic drawings in which corresponding reference symbols indicate corresponding parts, and in which: [Figure 1] FIG. 1 is a schematic diagram illustrating process and system aspects of the present invention. [Diagram 2] FIG. 1 is a schematic diagram illustrating process and system aspects of the present invention. [Diagram 3] FIG. 1 is a schematic diagram illustrating process and system aspects of the present invention. [Figure 4] FIG. 1 shows a schematic diagram of an embodiment of a shear tool. [Diagram 5] FIG. 1 is a schematic diagram illustrating one embodiment of a forming system. [Figure 6] Photograph of the fibrous structures produced by this system. [Figure 7] Photographs of the fibrous structures produced by this system. These schematics are not necessarily to scale. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0067] FIG. 1 shows a schematic representation of an embodiment of a system 100 of the present invention. This figure also shows a schematic representation of an embodiment of a method of the present invention. The system 100 is particularly configured to form a product 90 from a base material 1. The base material 1 may be a protein-containing base material 5. In a further embodiment, the product 90 comprises a fibrous structure, which is shown in the figure as being diagrammatically represented by a line within the product 90. The illustrated system 100 comprises a conveying system 110, a high shear device 120 and a forming system 130. The forming system 130 comprises a forming temperature control system 136, which is shown in this embodiment as being diagrammatically represented by a jacketed or double wall 134. The high shear device 120 comprises a vessel 121 and a temperature control system 126, which in the illustrated embodiment is constituted by a high shear tool 124 (see also FIG. 4). Further shown are an inlet port 122 and an outlet port 129 of the vessel 121.

[0068] As shown, a first end 132 of the forming device 130 is fluidly connected to the outlet port 129 of the container 121, and a second end 139 (or outlet 139) of the forming device 130 is open. The delivery system 110 delivers the base material 1 at a supply pressure P f The base material 1 is fed into the container 121 via an inlet port 122 , the base material 1 is conveyed through the container 121 in a conveying direction 125 , and the treated base material 1 is discharged from the container 121 via a discharge port 129 .

[0069] During the transport, the base material 1 is treated in a vessel 121. In the vessel 121, a high shear tool 124 applies a shear force F s1. Further, the temperature control system 126 is configured to provide a specific amount of energy (SME) to the base material 1 via the shear stage temperature T s The shear stage temperature T s can be controlled, for example, by controlling the temperature (profile) of the (wall 123) of the vessel 121 and / or the temperature of the (hollow) shear element 1241. Downstream of the vessel 121 is arranged the forming system 130. The forming temperature control system 136 controls the forming temperature T f , particularly at multiple locations. The forming temperature control system 136 may, in embodiments, control the forming temperature profile FTP.

[0070] The high shear tool 124 is configured to be rotatable about a rotation axis 127. In an embodiment, the rotation axis 127 may be a virtual axis. In other embodiments, the rotation axis 127 may be defined, for example, by an elongated axis of the shaft of the high shear tool 124. The rotation axis 127 is in particular parallel to the longitudinal axis 128 of the vessel 121. In the illustrated embodiment, the rotation axis 127 and the axis 128 of the vessel 121 are coincident. However, in further embodiments, these axes 127, 128 may exhibit an eccentric configuration. Additionally or alternatively, the rotation axis 127 may be arranged at an angle to the vessel axis 128. Also, further embodiments may include a plurality of high shear tools 124 each rotating about a different rotation axis 127. By rotating the shear tool 124, the base material 1 is sheared between the wall 123 of the vessel 121 and the high shear tool 124. The high shear tool 124 of the embodiment in Figures 1 and 4 includes a shear element 1241 extending along the axis of rotation 127. The shear tool 124 may be configured in particular to provide a shear force substantially perpendicular to the conveying direction 125. Thus, for example, the shear element 1241 may be configured parallel to the longitudinal vessel axis 128 and / or the axis of rotation 217 or at a very small angle.

[0071] In FIG. 4, a part of the high shear tool 124 is depicted, showing the location of the tool 124 where the shear element 1241 is directly connected to the axis of rotation 127. As shown, at further locations (extending longitudinally (back and forth)) there may be openings between the element 1241 and the axis of rotation 127 (see also FIG. 1). Thus, the flow area may vary all along the length of the tool 124. The interruption of the cross-sectional area of ​​the vessel 121 may vary along the length of the vessel 121. Also further connections between the element 1241 and the axis of rotation 127 may be made. In the figure, furthermore, a cylinder 1242 is shown, which is defined by the helical shear element 1241. The radius of the cylinder 1241 is indicated with the reference r. An angle is indicated as α, which may be described herein as the angle α between the axis of rotation 127 and the shear element 1241. In the figure, this angle α is shown as the angle between the shearing element 1241 (drawn at the top in the figure) and an imaginary line 127' located on the cylinder 1242 parallel to the axis of rotation 127. This line 127' is in particular also perpendicular to the plane of rotation of the shearing element 1241. The minimum distance d between the shearing tool 124 and the vessel wall 123 is c can range from a few micrometers up to one or two centimeters. It is noted that in Fig. 4, for reasons of clarity, the vessel wall 123 is only very diagrammatically shown by dotted lines as a cylindrical wall 123 arranged concentrically around the shearing tool 124. As described herein, in further embodiments this configuration may be eccentric and / or the vessel 121 may include multiple shearing tools 124, with the minimum distance d c may only be present at certain locations in the cross section of the vessel 121. Also, the vessel 121 may have a non-cylindrical configuration in embodiments. Thus, the cross section or wall 123 of the vessel 121 is not necessarily circular. Furthermore, d c may vary along the length and / or radius of the shear element 1241.

[0072] Furthermore, the embodiment of Fig. 4 shows a fluid channel 1262 in the shearing element 1241. Such a fluid channel 1262 is one embodiment of an element 1261 of the temperature control system 136. By flowing a (temperature) fluid through the channel 1262, the temperature of the base material 1 being processed can be controlled. The channel 1262 is thus a controllable element 181 (see further below). Additionally or alternatively, the temperature control element 1261 can be arranged, for example, at another location in the shearing tool 124 and / or in the vessel wall 123.

[0073] 4 further shows the high shear tool 124 in an open configuration. The shear tool 124 defines a relatively high flow area in the conveying direction 125 with respect to the total flow area of ​​the vessel 121. In the figure, a cross-section of (the working space within) the vessel 121 is indicated with reference numeral 1231. In this embodiment, the base material 1 is allowed to flow through about 50% of the cross-section 1231, while the remainder of the cross-section 1231 is occupied by the shear tool 124. FIG. 4 also shows (in the high shear phase) the shear force F s 12, the direction of the base material 1 is substantially perpendicular to the conveying direction 125 of the base material 1.

[0074] FIG. 1 also illustrates, inter alia, one embodiment of the process of the present invention for producing a product 90 comprising a fibrous structure from a protein-containing (base) material 5 .

[0075] The process may therefore include a conveying step, in which the base material 1 is conveyed under a supply pressure P f The base material 1 is provided in the container 121 at a pressure of 0.1 to 1000 MPa, conveyed through the container 121, treated in the container 121, and then discharged again from the container 121. Furthermore, the conveying of the base material 1 and the discharge of the treated base material 1 are in particular effected by a pressure difference P f -P d The shear stage temperature T of the base material 1 in the vessel 121 during the high shear stage is based on sis controlled to provide specific mechanical energy to the base material 1 in the vessel 121 to process the base material 1. The high shear stage and the conveying stage are particularly overlapped in time. Furthermore, in the forming stage, the treated base material 1 is guided from the vessel 121 through a forming system 130 to provide a product 90 at an outlet 139 of the forming system 130. Meanwhile, the forming temperature T f And / or the forming temperature profile is controlled.

[0076] In this process, in particular, the supply pressure P f , shear stage temperature T s , specific mechanical energy, and formation temperature T f (one or more of) can be controlled independently of each other. s In an embodiment, the shear stage temperature T can be controlled in the range of, for example, 65 to 150° C. In the present specification, this can also be expressed as "the temperature can be set in the range of 65 to 150° C." s can be set, for example, to at least partially denature protein 2. It is noted that the phrase "controlling (the parameters) independently of one another" specifically indicates that the parameters can be set to desired values. This does not necessarily mean that setting one parameter may not affect the other. If one parameter affects the other, the other parameter can be set again to reverse the effect. For example, the supply pressure P f Increasing the rotational speed of the high shear tool 124 can affect the specific mechanical energy, but the specific mechanical energy can again be controlled, for example by controlling the rotational speed of the high shear tool 124.

[0077] As discussed above, in embodiments, the operating parameters may be specifically controlled independently of one another. Generally, the phrase "controlling the parameters independently of one another" is illustrated in the following table for several parameters, where P is the supply pressure (P f ) and discharge pressure (P d), n indicates the rotational speed of the high shear tool, "flow" refers to the flow rate (velocity) of base material through the vessel, SME refers to the SME provided to the base material, ↑ and ↓ indicate an increase and decrease respectively, = indicates no change; JPEG2025504915000002.jpg77 indicates that it is not substantially affected, e.g. only in the range of 10-15%. [Table 1]

[0078] For example, if the pressure at the inlet is increased and other control parameters are not changed, the flow rate will increase and based on that increase the SME will be less. Therefore, to increase the flow rate with the same SME, both P and n should be increased. It is noted that not all controllable parameters are included in the table. For example, the temperature can also be controlled. An increase in temperature may result in a lower viscous mass in the vessel depending on further conditions, and a lower pressure difference may be required to obtain the same flow rate. Inducing a temperature change may result in denaturation of proteins under other conditions, resulting in a higher viscosity and a lower flow rate (unless the supply pressure is changed). It will be understood that many scenarios are possible. However, by changing again another predetermined parameter, the conditions can be set as required.

[0079] Furthermore, the base material 1 can be subjected to defined shear conditions, in particular for a (defined) shear period, to achieve a desired (fibrous) structure.

[0080] FIG. 2 further illustrates an embodiment of the system 100 and of this process. This embodiment further includes a (dough) preparation stage. The system 100 includes a (dough) preparation system 190 fluidly connected to the conveying system 110 to supply the base material 1 to the inlet port 122 of the container 121. In the preparation stage, the base material starter material 3 and the liquid 6 are mixed to provide the base material 1 for the conveying stage. The base material 1 may therefore in particular include a flowable / pumpable base material 1. Furthermore, in the embodiment illustrated in FIG. 2, the conveying system 110 includes two conveying devices 111 or pumps 111. The first device 111 is configured upstream of the container 121 and the second conveying device 111 is configured downstream of the container 121 and upstream of the forming system 130. In most embodiments, substantially all of the energy for conveying the base material 1 through the container 121 and through the forming system 130 is provided by one or more conveying devices 111 upstream of the container 121. In further embodiments, an additional conveying device 111 can be disposed between the container 121 and the forming system 130 to assist in pumping the treated base material 1 through the forming system 130. In certain embodiments, the supply pressure P f and discharge pressure P d The pressure differential between provides at least 70% of the total energy required to transport the base material 1 through the vessel 121 and the forming system 130.

[0081] 3 shows some further aspects of the system 100 and the process, particularly related to controlling the process and the system 100. In the figure, some examples of controllable elements 181 and measuring (system) elements 171 or sensors 171 are shown. The system 100 includes a measuring system 170 that includes the measuring element 171 and / or is functionally connected to the measuring element 171. The system further includes a control system 180 that includes the controllable elements 181 and the measuring system 170 and / or is functionally connected to them. Some of the controllable elements 181 and measuring elements / sensors 171 are shown, such as an element 181 that controls the conveying system 110, particularly the conveying device 111, an element 181 that controls the shear tool 124, e.g. an element 181 that controls the rotation speed of the high shear tool 124 to control the shear force / specific mechanical energy provided to the base material 1. Additionally, a sensor 171 is shown in the forming system 130 that senses the temperature in the forming system. Additionally, a valve 181 is shown that can control the flow of fluid through the double wall of the forming system 130 .

[0082] The measuring system 170 may in particular measure the (mass and / or volume) flow rate of the base material 1 in the vessel, the shear stage temperature T s , formation temperature T f , the velocity of the base material 1 within the forming system 130, and the specific mechanical energy provided (by the high shear tool 124) to the base material 1. The control system 180 is particularly configured to control the conveying system 110, the high shear device 120, and the forming system 130 substantially independently of one another.

[0083] Based on one or more of the controllable elements 181, the system can control the flow rate of the treated base material 1 in the forming system 130 to be substantially laminar. Such laminar flow can be solidified (cured) to obtain a fibrous structure. However, if the temperature of the product 90 is too high, the product may expand or swell when it leaves the forming system. Thus, if the product 90 leaves the forming system 130 at atmospheric pressure, the forming temperature T f can be particularly controlled to provide fibrous structures at temperatures below 100°C.

[0084] Two further embodiments of a dosing system 160 are shown in Fig. 3, one of which is fluidly connected to the container 121 and the other to the forming system 130. The dosing system 160 can be used to provide additives to the base material 1 in the container 121 and / or the forming system 130. In an embodiment, the use of such a dosing system 160 can make it possible to provide a layer of additives (e.g. fat or fat substitute) at a location between the treated base material 1 and the forming system 130, in particular the wall 133 of the forming element 131.

[0085] The forming system 130 may include a single forming element 131, such as a hollow pipe. However, in an embodiment, the forming system 130 may include multiple elements 131. In FIG. 5, for example, an embodiment of the forming system 130 is shown, which includes multiple forming elements 131 arranged parallel to each other and fluidly connected to each other at the ends of the forming elements 131. It is noted that in other embodiments, different forming elements 131 may also branch off from each other and not necessarily all split and reconnect as in the embodiment of FIG. 5. In such an embodiment, the processed base material 1 from the discharge port 129 may be split across multiple forming elements 131. The processed base material 1 exiting the multiple forming elements 131 may be continuously recombined to provide a product 90 including a fibrous structure at the outlet of the forming system 130.

[0086] The photographs given in figures 6 and 7 show some aspects of the fibrous structure. They do not represent the final product, but show some characteristics of the fibrous structure. In figure 6, the set product is torn in the middle and spread in two. The photograph clearly shows the fixed Hagen Poiseuille (like) flow pattern. The photograph shows that the velocity at the edge of the treated base material 1 was much lower than in the center of the forming system 130. Figure 7 gives another example of a fibrous structure showing fibers that are rather loosely bonded to each other. This results in a texture closer to that of meat than can be produced, for example, using extrusion techniques, which usually result in a rather compact product.

[0087] The term "plurality" refers to two or more than two. Moreover, the terms "plurality" and "several" can be used interchangeably.

[0088] The terms "substantially" or "essentially" and similar terms herein will be understood by those skilled in the art. The terms "substantially" or "essentially" can also include embodiments with "entirely", "completely", "all", etc. Thus, the adjectives "substantially" or "essentially" can also be omitted in embodiments. Where applicable, the terms "substantially" or "essentially" can also relate to 90% or more, such as 95% or more, particularly 99% or more, more particularly 99.5% or more, including 100%. The terms "about" and "approximately" can also relate to 90% or more, such as 95% or more, particularly 99% or more, more particularly 99.5% or more, including 100%. It should be understood that with respect to numerical values, the terms "substantially", "essentially", "about", and "approximately" can also relate to a range of 90% to 110%, such as 95% to 105%, particularly 99% to 101% of the value to which they refer.

[0089] The term "comprise" also includes embodiments where the term "comprises" means "consists of".

[0090] The term "and / or" specifically refers to one or more of the items listed before and after it. For example, the phrase "item 1 and / or item 2" and similar phrases can refer to one or more of item 1 and item 2. The term "comprising" can refer in one embodiment to "consisting of," while in another embodiment to "containing at least the defined species and optionally one or more other species."

[0091] Moreover, terms such as first, second, third, etc. in the description and in the claims are used to distinguish between similar elements and are not necessarily intended to describe a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances, and that the embodiments of the invention described herein are capable of operating in sequences other than those described or illustrated herein.

[0092] A device, apparatus, or system may be described herein specifically in operation. As will be apparent to one of ordinary skill in the art, the present invention is not limited to methods of operation or to devices, apparatus, or systems in operation.

[0093] The term "further embodiment" and similar terms may refer to an embodiment that includes features of an embodiment discussed above, but may also refer to an alternative embodiment.

[0094] It should be noted that the above embodiments are illustrative rather than limiting of the invention, and that those skilled in the art can design many alternative embodiments without departing from the scope of the appended claims.

[0095] In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim.

[0096] The use of the verb "to comprise" and its conjugations does not exclude the presence of elements or steps other than those stated in a claim. Unless the context clearly requires otherwise, throughout the description and claims, the words "comprise," "comprising," "include," "including," "contain," "containing," and the like, are to be interpreted in their inclusive sense, i.e., "including, but not limited to," rather than in their exclusive or exhaustive sense.

[0097] The article "a" or "an" preceding an element does not exclude the presence of a plurality of such elements.

[0098] The invention can be implemented by means of hardware comprising several distinct elements, and by means of a suitably programmed computer. In a device or apparatus or system claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that several measures are defined in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. The invention also provides a control system capable of controlling a device, apparatus or system or capable of carrying out the methods or processes described herein. Furthermore, the invention also provides a computer program product which, when executed on a computer operatively connected to or configured by the device, apparatus or system, controls one or more controllable elements of such a device, apparatus or system.

[0099] The present invention further applies to a device, apparatus or system comprising one or more of the characteristic features described in the specification and / or shown in the accompanying drawings. The present invention further relates to a method or process comprising one or more of the characteristic features described in the specification and / or shown in the accompanying drawings. Also, where a method or an embodiment of the method is described as being performed in a device, apparatus or system, it will be understood that the device, apparatus or system is suitable for or configured for (performing) the method or an embodiment of the method, respectively.

[0100] The various aspects discussed in this patent may be combined to provide additional advantages. Moreover, those skilled in the art will appreciate that the embodiments may be combined, and that more than two embodiments may be combined. Furthermore, some of the features may form the basis for one or more divisional applications.

Claims

1. A continuous process for producing a product (90) comprising a fibrous structure from a base material (1), said base material (1) being a protein-containing material (5), said process comprising a conveying stage, a high shear stage and a forming stage, The conveying step (i) applies a supply pressure (P ｆ (ii) conveying the base material (10) in a conveying direction (125) through the container (121); and (iii) discharging the treated base material (1) from the container (121), wherein the conveying of the base material (1) and the discharging of the treated base material (1) are performed under the supply pressure (P ｆ ) and discharge pressure (P ｄ ) and the flow rate of the base material (1) in the container (121) is determined based on the pressure difference between the supply pressure (P ｆ ) and discharge pressure (P ｄ ) by controlling the pressure difference between the The high shear stage conveys the base material (1) through the vessel (121) while (i) increasing the shear stage temperature (T ｓ and (ii) treating the base material (1) in the vessel (121) by providing a specific mechanical energy (SME) to the base material (1), wherein the specific mechanical energy provided to the base material (1) is selected from the range of 25 Whr to 800 Whr per kg of base material (1), and the specific mechanical energy is controlled by controlling the shear force provided to the base material (1) as a function of the flow rate of the base material (1); The forming step is performed by adjusting the forming temperature (T ｆ guiding the base material (1) from the container (121) through the forming system (130) while controlling the flow rate of the base material (1) to provide the product (90) at an outlet (139) of the forming system (130). process.

2. Supply pressure (F ｆ ), shear stage temperature (T ｓ ), specific mechanical energy, and forming temperature (T ｆ 2. The process of claim 1, comprising controlling one or more of the following independently of each other:

3. Shear stage temperature (T ｓ 3. The process of claim 1 or 2, comprising controlling the temperature of the reaction mixture in the range of 65 to 150°C.

4. 3. The process according to claim 1 or 2, wherein at least 50% by weight of the base material (1) on dry matter basis comprises protein (2).

5. Shear stage temperature (T ｓ 5. The process of claim 4, wherein the catalyst (2) is selected to at least partially denature the protein (2).

6. In the high shear stage, the shear force (F ｓ 3. The process according to claim 1 or 2, wherein the direction of the slits (125) is selected substantially perpendicular to the conveying direction (125) of the base material (1).

7. Supply pressure (P ｆ ) and discharge pressure (P ｄ 3. The process of claim 1 or 2, wherein a pressure difference between the base material (1) and the container (121) is selected to provide at least 95% of the total energy required to convey the base material (1) through the container (121), the container comprising a high shear tool (124) for providing specific mechanical energy (SME) to the base material (1), and wherein at most 5% of the total energy required to convey the base material (1) through the container (121) is provided by the high shear tool (124).

8. 3. The process of claim 1 or 2, wherein the product (90) exits the forming system (130) at atmospheric pressure.

9. The forming temperature (T ｆ 3. The process of claim 1 or 2, wherein the heating step is controlled to provide a fibrous structure at a temperature below 100°C.

10. 3. The process of claim 1 or 2, wherein the flow rate of the treated base material (1) in the forming system (130) is configured to provide a substantially laminar flow.

11. 3. The process of claim 1 or 2, further comprising adding an additive (9) to the base material (1) during one or more of the high shear stage and the forming stage.

12. 3. The process of claim 1 or 2, wherein the forming system (130) comprises a plurality of forming elements (131), and the forming step comprises dividing the treated base material (1) from an outlet port (129) across the plurality of forming elements (131), and recombining the treated base material (1) exiting the plurality of forming elements (131) to provide a product (90) comprising a fibrous structure at an outlet of the forming system (130).

13. 3. The process according to claim 1 or 2, further comprising a preparation step comprising mixing a base material starter material (3) with a liquid (6) to provide the base material (1) for the conveying step.

14. A system (100) for forming a product (90) comprising a fibrous structure from a protein-containing base material (1), said system (100) comprising: (i) a conveying system (110); (ii) a high shear device (120) comprising a vessel (121) and a temperature control system (126), said vessel (121) comprising a high shear tool (124); and (iii) a forming system (130) comprising a forming temperature control system (136); a first end (132) of the forming system (130) fluidly connected to an outlet port (129) of the container (121), and an outlet (139) of the forming system (130) open; The delivery system (110) (i) supplies a supply pressure (P ｆ ) and conveying the base material (1) through the container (121) and discharging the base material (1) from the container (121) through a discharge port (129) at a discharge pressure (P ｄ (ii) discharging the treated base material (1) at the supply pressure (P ｆ ) and the discharge pressure (P ｄ ) to control the flow rate of the base material (1) in the container (121) by controlling the pressure difference between the The high shear tool (124) is configured to provide specific mechanical energy to the base material (1) in the vessel (121), and the temperature control system (126) controls the shear stage temperature (T ｓ ), wherein the base material (1) is processed in the vessel (121), The high shear tool (124) is configured to be rotatable about an axis of rotation (127), and the high shear tool (124) blocks less than 50% of a cross section (1231) of the vessel (121); The forming temperature control system (136) controls the forming temperature (T ｆ ) configured to control The system (100).

15. 15. The system (100) of claim 14, wherein the rotation axis (127) is configured parallel to the longitudinal axis (128) of the vessel (121), the high shear tool (124) is configured to shear the base material (1) between the wall (123) of the vessel (121) and the high shear tool (124), the high shear tool (124) comprises a shear element (1241) extending along the rotation axis (127), the shear element (1241) is configured at an angle of between -10° and +10° with respect to the longitudinal axis (128) of the vessel (121), and the minimum distance between the shear element (1241) and the wall (123) of the vessel (121) is 0.1 to 20 mm.

16. 16. The system (100) of claim 14 or 15, wherein one or more of the shearing tool (124) and the vessel wall (123) include a temperature control element (1261).

17. 16. The system (100) of claim 14 or 15, wherein the forming system (130) comprises a plurality of forming elements (131) arranged parallel to one another, the forming elements (131) being fluidly connected to one another at their ends.

18. 16. The system (100) of claim 14 or 15, further comprising a dosing system (160), the dosing system (160) being fluidly connected to one or more of the container (121) and the forming system (130) for providing additives to the base material (1) in the container (121) and / or to the processed base material in the forming system (131).

19. The system (100) controls the flow rate of the base material (1) in the vessel (121), the shear stage temperature (T ｓ ), formation temperature (T ｆ ), a velocity of the processed base material (1) in the forming system (130), a specific mechanical energy provided to the base material (1), a density of the base material (1), a moisture content of the base material (1), a pressure in the vessel (121), and a pressure in the forming system (130).

20. 16. The system (100) of claim 14 or 15, further comprising a control system (180) configured to control the conveying system (110), the high shear device (120), and the forming system (130).

21. 16. The system (100) of claim 14 or 15, wherein the vessel (121) comprises a plurality of high shear tools (124) arranged parallel to one another.

22. 3. Vegetarian food product comprising a fibrous structure obtainable by the process according to claim 1 or 2.

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