Food products from root vegetables

Abstract

A hard cheese analog can be made from products derived from root vegetables. The liquid potato product can be formed from raw potatoes that are subsequently treated and subjected to a high shear processing step that allows for the formation of a liquid potato product that exhibits non-Newtonian rheological properties. The liquid potato product can then be solidified over time to form a hard cheese analog. Unlike certain other dairy-free cheese analogs, the cheese analogs of the present invention can be sliced, cut, shredded, and melted.

Description

[Technical field]

[0001] (Related Applications) This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 311,567, entitled "FOOD PRODUCTS FROM ROOT VEGETABLES," filed on February 18, 2022, the entire disclosure of which is incorporated herein by reference.

[0002] FIELD OF THEINVENTION The present invention relates generally to a potato cheese dairy analog product that can replace certain dairy-based products currently on the market. More generally, the present application relates generally to the production of a solid cheese analog from a liquid potato product. [Background technology]

[0003] There is an increasing emphasis on the production of health food products derived primarily from vegetables and other organic plant-based products. Such products may allow the production of food analogues that can be used to replace certain food products that may cause allergenicity and / or gastrointestinal distress to a large portion of the consumer population. For example, these food products derived from vegetables and other organic plant-based products may be used to produce dairy analogues such as cheese that cannot generally be consumed by people who are sensitive to dairy ingredients or who wish to follow a specific diet (e.g., vegetarians).

[0004] However, these existing food products may exhibit one or more deficiencies, such as poor taste, poor texture, risk of allergies, high production costs, and overall unhealthy formulations. Therefore, there remains a need to identify and efficiently produce healthy food products, such as dairy analogs, from plant-based sources. Summary of the Invention

[0005] One or more embodiments generally relate to a method for producing a dairy analog. Generally, the method includes: (a) providing an initial potato feed comprising a plurality of potatoes; (b) at least partially gelatinizing at least a portion of the initial potato feed, thereby forming a gelatinized potato feed; (c) shearing at least a portion of the gelatinized potato feed at a temperature of at least 50° C. for at least 2 minutes, thereby forming a liquid potato product; and (d) introducing at least a portion of the liquid potato product into a mold and solidifying the liquid potato product in the mold, thereby forming a dairy analog. Further, the shearing occurs in the presence of one or more of the following: (i) at least one oil exhibiting a melting point in the range of 23° C. to 45° C.; or (ii) at least one native and / or modified starch. The dairy analog is generally a cheese analog.

[0006] One or more embodiments generally relate to a method for producing a cheese analog. Generally, the method includes: (a) providing an initial potato feed comprising a plurality of potatoes; (b) at least partially gelatinizing at least a portion of the initial potato feed, thereby forming a gelatinized potato feed; (c) preheating at least a portion of the gelatinized potato feed in the presence of one or more optional additives, thereby forming a preheated potato feed at a temperature of at least 65° C.; (d) shearing at least a portion of the preheated potato feed for at least 2 minutes, thereby forming a liquid potato product; and introducing at least a portion of the liquid potato product into a mold; and (f) allowing the liquid potato product to solidify in the mold for at least 5 days, thereby forming a cheese analog. Further, the shearing occurs in the presence of one or more of the following: (i) at least one oil exhibiting a melting point in the range of 23°C to 45°C; or (ii) at least one native and / or modified starch, wherein the native and modified starches comprise an amylose content of less than 19 weight percent, based on the total weight of the starch.

[0007] One or more embodiments generally relate to a method for producing a dairy analog. Generally, the method includes: (a) providing an initial potato feed comprising a plurality of potatoes; (b) at least partially gelatinizing at least a portion of the initial potato feed, thereby forming a gelatinized potato feed; (c) shearing at least a portion of the gelatinized potato feed at a temperature of at least 25° C., thereby forming a liquid potato product, wherein the shear provides at least 100 kJ / kg of mechanical work when measured over a period of 30 minutes or less; (d) introducing at least a portion of the liquid potato product into a mold; and (e) solidifying the liquid potato product in the mold, thereby forming the dairy analog. Further, the shearing occurs in the presence of one or more of the following: (i) at least one oil, or (ii) at least one native and / or modified starch. Further, the liquid potato product has a particle fineness of less than 125 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020). Additionally, the dairy analog exhibits a maximum load of at least 100 grams measured 15 days after said setting as measured at a constant speed (2 mm / sec) using a Brookfield CTX Texture Analyzer fitted with a TA2 / 1000 probe. The dairy analog is generally a cheese analog.

[0008] One or more embodiments generally relate to a dairy analog, such as a cheese analog, formed from a liquid potato product. Generally, the dairy analog exhibits a maximum load of at least 100 grams measured 15 days after said setting, as measured at a constant speed (2 mm / sec) using a Brookfield CTX Texture Analyzer equipped with a TA2 / 1000 probe. The liquid potato product (a) comprises potatoes and water, and (b) one or more of the following: (i) at least one oil exhibiting a melting point in the range of 23° C. to 45° C., or (ii) at least one native and / or modified starch, the native and modified starch comprising an amylose content of less than 19 percent by weight, based on the total weight of the starch, and (c) has a particle fineness of less than 125 micrometers, as measured with a BYK-Gardner 2512 Metal. [Brief description of the drawings]

[0009] Embodiments of the present invention are described herein with reference to the following drawings. [Figure 1] 1 illustrates an exemplary Liquid P production system that may be used to at least partially convert one or more potato-containing feeds into Liquid P and food products containing Liquid P. [Diagram 2] FIG. 1 is a graph illustrating the rheological profiles from Example 1 at days 0-3 of potato products produced using a conventional shear process. [Diagram 3] 1 is a graph illustrating the rheological profile from Example 1 at days 0-3 of the Liquid P product produced using the shear process of the present invention. [Figure 4] 1 is a graph illustrating shear stress versus shear rate for the samples of Example 1 (Liquid P of the present invention and conventional shear process) on day 0; [Diagram 5] 1 is a graph illustrating shear stress versus shear rate for samples of Example 1 (Liquid P of the present invention and conventional shear process) on day 3. [Figure 6] 1 illustrates a microscopic image (100x magnification) of the cryogenically milled-coarse ground product of Example 2. [Figure 7] 1 illustrates a microscopic image (100x magnification) of the cryogenically milled-fine ground product of Example 3. [Figure 8] 1 illustrates a microscopic image (100x magnification) of the thermally milled-fine ground product of Example 4. [Figure 9] Illustrates texture measurements on day 6 for Examples 2-4. [Figure 10] Illustrates texture measurements on day 16 for Examples 2-4. [Figure 11] 1 illustrates texture measurements on day 2 for Example 5 and Comparative Example 1. [Figure 12] Illustrates texture measurements on day 4 for Example 5 and Comparative Example 1. [Figure 13] 1 illustrates texture measurements at 15 days for Example 5 and Comparative Example 1. [Figure 14] Illustrates texture measurements at 26 days for Example 5 and Comparative Example 1. [Figure 15] 1 illustrates texture measurements at 70 days for Example 5 and Comparative Example 1. [Figure 16] Illustrates day 2 texture measurements for Examples 8-12. [Figure 17] The texture measurements on the second day for Comparative Examples 4 to 8 are shown. [Figure 18] Illustrates texture measurements at day 15 for Examples 6-8. [Figure 19] The texture measurements on the 15th day for Comparative Examples 2 to 4 are shown. [Figure 20] 1 illustrates texture measurements at 23 days for Examples 13 and 14 and conventional Colby Jack cheese. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The inventors have discovered that a specific type of liquid potato product made according to the high shear process described herein can be used to make unique dairy analogs, such as solid cheese analogs. More particularly, the inventors have discovered that hard cheese analogs can be formed from the liquid potato products described herein that can be melted, shredded, crushed, and / or sliced ​​like traditional hard cheeses. As discussed in more detail below, it has been observed that the processes and systems described herein can create a unique liquid potato product, i.e., Liquid P, that can be used to make various types of dairy analogs exhibiting one or more desirable characteristics.

[0011] As used herein, the term "Liquid P" may be used interchangeably with "Liquid Potato Product," both of which contain at least 5 percent by weight potato and are heated at a shear rate of 4. 1 This refers to a substance that has a dynamic viscosity in the range of 70 to 250,000 cP at 1 / sec and temperatures of 12.5°C to 95°C.

[0012] Figure 1 illustrates an exemplary Liquid P production system 10 that may be used to at least partially convert one or more potato-containing feeds into Liquid P and food products containing Liquid P. It should be understood that the Liquid P production system shown in Figure 1 is only one example of a system in which the present invention may be embodied. Thus, the present invention may find application in a wide variety of other systems in which it is desirable to efficiently and effectively produce Liquid P. The exemplary system illustrated in Figure 1 will now be described in more detail.

[0013] 1 above, Liquid P production system 10 can include a potato source 12 for supplying one or more types of potatoes to system 10. Potato source 12 can be, for example, a hopper, a storage bin, a rail car, a trailer, or any other device capable of holding or storing potatoes and other types of vegetables.

[0014] In various embodiments, potato supply 14 derived from potato source 12 can include, consist essentially of, or consist of potatoes. Generally, in various embodiments, the potatoes provided by potato source 12 can include any variety of Solanum tuberosum. Exemplary potato varieties can include, for example, Shepody potatoes, Binche potatoes, American blue potatoes, Royal potatoes, indigenous potatoes, Maris Piper potatoes, Focus potatoes, Yukon Gold potatoes, Lady Balfour potatoes, Kennebec potatoes, Collette potatoes, Chieftain potatoes, Innovator potatoes, Russet Burbank potatoes, Purple potatoes, Russet potatoes, Bamberg potatoes, or combinations thereof.

[0015] In various embodiments, the potatoes from potato source 12 may include whole raw potatoes.

[0016] In various embodiments, the potato feed 14 can include at least 25, 50, 75, 80, 85, 90, 95, or 99 percent by weight of one or more potatoes based on the total weight of the feed stream. In certain embodiments, the initial potato feed 14 can be formed entirely of one or more potatoes, which can be raw potatoes. Additionally or alternatively, the potato feed 14 can include less than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, or 50 percent by weight of one or more potatoes based on the total weight of the stream. Without wishing to be bound by theory, it has been observed that the amount of potatoes in the potato feed can affect the "firmness" of the resulting Liquid P and dairy analog. For example, it has been observed that the higher the potato content of the potato feed 14, the firmer the resulting product.

[0017] In various embodiments, potato supply 14 may include less than 20, 15, 10, 5, 4, 3, 2, 1, 0.5, or 0.1 weight percent added dry potato starch and / or dry rice starch. Additionally or alternatively, potato supply 14 may include at least 0.1, 0.5, or 1 weight percent added dry potato starch and / or dry rice starch. More particularly, in certain embodiments, potato supply 14 may be substantially free of added potato starch and / or rice starch. As used herein, "potato starch" refers to powdered starch previously extracted from potatoes, while "rice starch" refers to powdered starch previously extracted from rice.

[0018] In certain embodiments, potato source 12 may also provide one or more other root vegetables, such as parsnips, celery root, sweet potatoes, yams, onions, red beets, carrots, or combinations thereof. These additional root vegetables may be added to affect the taste and / or color of the resulting cheese analog.

[0019] In various embodiments, potato supply 14 can include at least 1, 5, 10, 15, 20, or 25 weight percent, and / or less than 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, or 30 weight percent, of one or more root vegetables based on the total weight of the potato supply. In certain embodiments, potato supply 14 can be substantially free of root vegetables.

[0020] In various embodiments, potato supply 14 may also include additional ingredients such as one or more oils, one or more low amylose starches (e.g., tapioca starch and / or modified starches), one or more gums (e.g., guar, xanthan, and / or Ingredion's Ticagel®), one or more preservatives (e.g., sodium benzoate), one or more salts (e.g., sodium chloride), one or more acids (e.g., lactic acid and / or citric acid), one or more emulsifiers (e.g., lecithin, monoglycerides, diglycerides, and / or EmulsiSMART®), one or more flavorings (e.g., nutritional yeast, seasonings, and / or spices), one or more protein additives (e.g., pea protein and / or potato protein), water, or combinations thereof. Any one of these additional components may be added initially to potato feed 14 (as discussed below) or may be added downstream during the processing of potato feed 14. In one or more embodiments, potato feed 14 can include at least 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, or 45 weight percent of one or more of these additional components, alone or in any combination, based on the total weight of the potato feed. Additionally or alternatively, potato feed 14 can include less than 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of one or more of these additional components, either alone or in any combination, based on the total weight of the potato feed.

[0021] In various embodiments, potato feed 14 may include one or more low amylose starches (e.g., tapioca starch and / or modified starches). These starches may be added initially to potato feed 14 (as discussed below) or may be added downstream during the processing of potato feed 14. In one or more embodiments, potato feed 14 may include at least 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, or 45 weight percent of one or more starches based on the total weight of the potato feed. Additionally or alternatively, potato feed 14 may include less than 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of one or more starches based on the total weight of the potato feed. Without wishing to be bound by theory, it has been discovered that the addition of certain modified starches to a potato feed can result in a dairy analog with excellent texture and melting properties.

[0022] In various embodiments, potato feed 14 may include one or more fats (e.g., oils). These fats may be added initially to potato feed 14 (as discussed below) or may be added downstream during the processing of potato feed 14. Exemplary fats may include, for example, sunflower oil, coconut oil, hydrogenated palm oil, cocoa butter, shea butter, or combinations thereof. Generally, in one or more embodiments, the oils added to gelatinized potato feed 22 may have a melting point that is in the range of 23° C. to 45° C. In one or more embodiments, potato feed 14 may include at least 1, 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, or 45 weight percent of one or more fats (e.g., oils) based on the total weight of the potato feed. Additionally or alternatively, the potato supply 14 may include less than 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, 10, 5, or 1 weight percent of one or more fats (e.g., oils) based on the total weight of the potato supply. Without wishing to be bound by theory, it is believed that the texture of the resulting dairy analog can be altered by varying the fat composition added to the supply. It has been observed that the resulting cheese analog can have a firmer texture when fats having a higher saturated fat fraction content are utilized.

[0023] Referring again to FIG. 1 , potato feed 14 from potato source 12 may be delivered to pre-treatment unit 16 for further processing prior to any subsequent cooking and conversion steps. While in pre-treatment unit 16, potato feed 14 may undergo one or more processes including, for example, freezing, washing, peeling, mashing, water bathing, chelating, microwave heating, radio frequency heating, magnetic heating, electric field pulse heating, cubing, dicing, or combinations thereof. In certain embodiments, potato feed 14 may be washed, peeled, washed again to remove any skin residue, and then diced into defined slices. In one or more embodiments, potatoes and other root vegetables present in potato feed 14 may be diced into pieces having an average width of at least 0.1, 0.15, 0.2, or 0.25 inches, and / or less than 0.75, 0.6, or 0.5 inches.

[0024] In one or more embodiments, all of the potatoes in potato supply 14 may be peeled.

[0025] After exiting pretreatment unit 16, the pretreated potato feed 18 is then introduced into a blanching and gelatinization system 20. While in the blanching and gelatinization system 20, the pretreated potato feed 18 may undergo any known process or technique for at least partially gelatinizing at least a portion of the potatoes in the potato feed. In various embodiments, the blanching and gelatinization system 20 may comprise any system or device that allows the pretreated potato feed 18 to be subjected to a gelatinization process, such as a microwave oven, a water bath, an autoclave, or any other device known in the art.

[0026] Generally, the gelatinization process can include any thermal treatment capable of at least partially gelatinizing the potatoes in pretreated potato supply 18. Such techniques can include, for example, microwave, boiling, scalding, blanching, or combinations thereof.

[0027] In one or more embodiments, the gelatinization process includes blanching. Generally, in various embodiments, the blanching process can include (i) contacting the pretreated potato feed 18 with hot water and / or steam, and (ii) subsequently contacting the cooked potato feed with an aqueous solution, thereby forming a gelatinized feed 22. In certain embodiments, the aqueous solution can include one or more chelating agents and / or pH modifiers, such as citric acid, EDTA, phosphate compounds, or combinations thereof.

[0028] Without wishing to be bound by theory, it is believed that the blanching step may serve to reduce undesirable enzymes in the potato feed, remove skins from the potatoes (if still present), and modify the texture of the potatoes in the potato feed.

[0029] In one or more embodiments, the first step of the blanching process may involve contacting the pretreated potato supply 18 with heated water for a period of at least 1, 2, 3, 4, or 5 minutes, and / or less than 30, 25, 20, 15, or 10 minutes. In such embodiments, this hydrothermal treatment may occur at about atmospheric pressure and at a temperature of at least 50° C., 55° C., 60° C., 65° C., 70° C., 75° C., or 80° C. Additionally or alternatively, in various embodiments, the hydrothermal treatment may occur at a temperature of less than 150° C., 125° C., 100° C., 95° C., 90° C., 85° C., 80° C., 75° C., 70° C., 65° C., 60° C., or 55° C.

[0030] In one or more embodiments, the first step of the blanching process may include contacting the pretreated potato feed 18 with pressurized steam for a period of at least 1, 2, 3, 4, or 5 minutes, and / or less than 30, 25, 20, 15, or 10 minutes. In such embodiments, this steaming may occur at a gauge pressure of at least 10, 25, 50, 75, 100, or 125 psig, and / or less than 300, 250, 200, 175, or 160 psig, and at a temperature of at least 100°C, 125°C, or 150°C, and / or less than 300°C, 250°C, 200°C, or 185°C.

[0031] In one or more embodiments, the second step of the blanching process may occur at a temperature of at least 10° C., 15° C., 20° C., 25° C., 30° C., 35° C., 40° C., 45° C., 50° C., 55° C., 60° C., 65° C., 70° C., 75° C., or 80° C., and / or less than 150° C., 125° C., 100° C., 95° C., 90° C., 85° C., 80° C., 75° C., 70° C., 65° C., or 60° C. Additionally or alternatively, in various embodiments, the second step of the blanching process may occur for a period of less than 10, 5, 4, 3, 2, or 1 minute.

[0032] In one or more embodiments, the blanching process may be used to preheat the pretreated potato feed 18 prior to the downstream shearing step (described below). By preheating the pretreated potato feed 18 during the blanching step, the resulting gelatinized potato feed 22 can be maintained at a temperature that facilitates the downstream high shear processing in the shearing device. In various embodiments, after blanching, the gelatinized potato feed 22 may have a temperature of at least 55°C, 60°C, 65°C, 70°C, 75°C, or 80°C, and / or less than 150°C, 125°C, 100°C, 95°C, or 90°C.

[0033] In certain embodiments, the gelatinization process removes very little water and / or solids from the pretreated potato feed 18. Unlike certain prior art gelatinization techniques that partially dehydrate the potato feed, the gelatinization techniques of the present disclosure may attempt to retain much of the water, moisture, and solids naturally present within the potatoes. For example, in various embodiments, the moisture content (by weight) of the gelatinized potato feed 22 is no more than 50, 45, 40, 35, 30, 25, 20, 15, 10, 9, 8, 7, 6, 5, 4, 3, 2, or 1 percent lower than the moisture content of the pretreated potato feed 18. Additionally or alternatively, the moisture content (by weight) of the gelatinized potato feed 22 may actually be at least 1, 5, 10, 15, or 20 percent higher than the pretreated potato feed 18.

[0034] Additionally or alternatively, in certain embodiments, the moisture content of the gelatinized potato feed 22 may be at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 91, 92, 93, 94, 95, 96, or 97 percent of the moisture content of the pretreated potato feed 18.

[0035] Thus, in various embodiments, the gelatinization process does not dehydrate the potato feed and does not utilize a dehydration process such as drying, or any other process that removes moisture from the potato feed and results in a processed potato feed having less moisture than the initial potato feed.

[0036] Additionally, in various embodiments, the potato feed may also be chemically treated using a chelating agent to eliminate the possibility of subsequent non-enzymatic browning, however, the production processes described herein may not require chelating the potato feed.

[0037] Optionally, in various embodiments, at least a portion of the gelatinized potato feed 22 leaving the gelatinization system 20 may be subjected to freezing prior to downstream processing. Such a freezing step may allow for accumulation of the gelatinized feedstock for downstream processing. If such a freezing step is used, the gelatinized potato feed 22 may be thawed from the frozen state before any additional downstream processing can occur.

[0038] In one or more embodiments, at least one or more additional ingredients may be added to the gelatinized potato feed 22 prior to further downstream processing, such as high shear processing steps. For example, one or more oils, one or more low amylose starches (e.g., tapioca starch and / or modified starches), one or more gums (e.g., guar, xanthan, and / or Ingredion's Ticagel®), one or more preservatives (e.g., sodium benzoate), one or more salts (e.g., sodium chloride), one or more acids (e.g., lactic acid and / or citric acid), one or more emulsifiers (e.g., lecithin, monoglycerides, diglycerides, and / or EmulsiSMART®), one or more flavorings (e.g., nutritional yeast, seasonings, and / or spices), one or more protein additives (e.g., pea protein and / or potato protein), water, or combinations thereof may be added to the gelatinized potato feed 22 at this stage. Exemplary oils may include, for example, sunflower oil, coconut oil, hydrogenated palm oil, cocoa butter, shea butter, or combinations thereof. Generally, in one or more embodiments, the oil added to the gelatinized potato supply 22 may have a melting point in the range of 23°C to 45°C.

[0039] As noted above, in certain embodiments, the gelatinized potato feed 22 leaving the gelatinization system 20 may have a temperature of at least 55° C., 60° C., 65° C., 70° C., 75° C., or 80° C., and / or less than 150° C., 125° C., 100° C., 95° C., or 90° C. However, in additional or alternative embodiments, particularly if an optional freezing step is utilized after the gelatinization system 20, the gelatinized potato feed 22 may be subjected to additional or alternative preheating after leaving the gelatinization system 20 and the blanching step. In such embodiments, at least a portion of the gelatinized potato feed 22 may be subjected to a preheating step prior to the downstream shearing step. For example, at least a portion of the gelatinized potato feed 22 may be subjected to boiling, heating in a water bath, heating in a microwave oven, and / or processing in a Thermomix® processor (i.e., a food processor that heats and refines the feedstock). After these optional pre-heating steps, the gelatinized potato supply 22 may have a temperature of at least 55° C., 60° C., 65° C., 70° C., 75° C., 80° C., 85° C., or 90° C., and / or less than 150° C., 125° C., 110° C., or 100° C. In various embodiments, this pre-heating may occur in a heated jacketed vessel and / or via direct steam injection using pressurized steam at a psi of at least 5, 10, 15, 20, 25, or 30 psi and / or less than 100, 90, 80, 70, 60, 50, or 40 psi.

[0040] Additionally or alternatively, after leaving the gelatinization system 20, at least a portion of the gelatinized potato feed 22 may be subjected to a pre-grinding step which involves pureeing at least a portion of the feed. This pureeing step can help to further break down the particle size of the gelatinized potato feed 22 prior to the downstream high shear step. The pureeing may be carried out in a food processor, such as a Thermomix® processor. During the pureeing step, at least a portion of the gelatinized potato feed 22 may be subjected to low shear pureeing in the food processor for at least 5 seconds, 10 seconds, 30 seconds, 1 minute, or 2 minutes, and / or for no more than 10 minutes, 5 minutes, or 3 minutes.

[0041] In certain embodiments where a food processor with a heating source (e.g., a heating jacket), such as a Thermomix® processor or a Stephan Cooker, is utilized, the pureeing and preheating steps may occur simultaneously. Thus, in such embodiments, the pre-grinding step may occur at a temperature within any of the ranges disclosed for the pre-heating step. Additionally, in one or more embodiments, one or more of the aforementioned additives may be added during this pre-grinding step. It has been discovered that grinding the feed prior to or in combination with the pre-heating step can result in improved texture in the final product (i.e., dairy analog) by making the product feel firmer. Without wishing to be bound by theory, it is believed that the grinding and pre-heating steps can allow the potato feed to be better ground and sheared during the subsequent shearing process, thereby producing a Liquid P product with finer particles, thereby resulting in a product with a "firmer" feel.

[0042] Upon leaving the gelatinization system 20, at least a portion of the gelatinized potato feed 22 may be introduced into a shearing device 24. While in the shearing device 24, the gelatinized potato feed 22 may be subjected to specific temperature and shear conditions necessary to produce Liquid P26. Without wishing to be bound by theory, the shearing step may be carried out under specific temperature, pressure, and / or shear conditions such that the starch in the gelatinized potato feed 22 is fully gelatinized, thereby facilitating the formation of Liquid P. Generally, in various embodiments, the temperature of the gelatinized potato feed 22 must reach at least 67° C. during the shearing step to fully gelatinize the starch in the feed. This temperature may come from the shearing process and conditions and / or from an external heating source (e.g., a heating jacket around the shearing device and / or direct injection with pressurized steam, as described above). Thus, in various embodiments, the shearing process may be a form of thermal comminution due to these temperature requirements. As used herein, "shearing" refers to a mechanical process that induces a shear rate through a liquid that changes the underlying microstructure. Thus, for example, shearing may include particle comminution.

[0043] In various embodiments, the gelatinized potato feed 22 has not been subjected to a dehydration process prior to being introduced into the shearing device 24. For example, prior to being introduced into the shearing device 24, the gelatinized potato feed 22 has not been subjected to a dehydration process to previously remove moisture.

[0044] The shearing device 24 may comprise any shearing device known in the art capable of providing the high shear required to produce liquid P26 from the gelatinized potato feed 22. Exemplary shearing devices may include, for example, a food processor, a high shear mixer with an impeller, or a high speed turbine with a shroud. In certain embodiments, the shearing device 24 may comprise a high speed turbine with a shroud, the rpm of the turbine may affect the temperature and time conditions of the shearing process. In specific embodiments, the shearing device may comprise a Stephan-type batch cooker with a high speed impeller and a swept wall scraper, a Vitamix mixer, or a Robot Coupe food processor. In more specific embodiments, the shearing device may comprise a Robot Coupe food processor with at least two blades and at least 1 HP of power. In such embodiments, the shearing device may operate at an RPM of at least 2,500, 3,000, 3,100, 3,200, or 3,300. The shearing process may occur in multiple units that are different from each other. For example, the shearing can be carried out in a separate processing unit such as an off-line or in-line Urschel Comitrol capable of generating very high shear conditions.

[0045] In various embodiments, the shearing step may occur at a temperature of at least 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, 55°C, 60°C, 65°C, or 70°C, and / or less than 150°C, 125°C, 110°C, 100°C, or 90°C, and for a period of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes, and / or less than 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 minutes. Generally, in more specific embodiments, the shearing step may occur at a temperature of at least 65°C for a period of 2-15 minutes. In an exemplary embodiment, the shearing step may occur in a Robot Couple food processor at a temperature of at least 65°C for a period of 2-15 minutes. As would be readily understood by one of ordinary skill in the art, the temperature and duration of the shearing step may be varied slightly outside of the recited ranges disclosed herein, however, such conditions would still fall within the scope of the present disclosure. The temperature may result from the shear rate and conditions, residual heat from the gelatinized potato feed 22 prior to the shearing step, and / or an external heating source (e.g., a heating jacket around the shearing device).

[0046] Additionally or alternatively, in various embodiments, the shearing can include one long shear step (e.g., maintaining a temperature of 80° C. under constant shear for 8 minutes) or can be divided into multiple stages that can be distinguished by different temperatures, shear intensities, and durations. For example, the high shear step may be divided into at least two, three, four, or five different stages, each stage including its own temperature, duration, and shear intensity. The temperature and time parameters for each shear stage can be selected from the temperature and time ranges previously described for the shear process.

[0047] Additionally or alternatively, in various embodiments, the shear may occur at a pressure of at least 1, 5, 10, or 14 psig, and / or less than 1,000, 900, 800, 700, 600, 500, 400, 300, 200, 100, 50, 25, 20, or 15 psig.

[0048] Additionally or alternatively, in various embodiments, the shearing process can provide a set amount of total mechanical work over a period of time. In one or more embodiments, the shearing process can provide mechanical work of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 195, or 200 kJ / kg when measured over a period of 60 minutes or less, 45 minutes or less, 30 minutes or less, or 15 minutes or less. Additionally or alternatively, the shearing step can provide a mechanical work of less than 500, 450, 400, 350, 300, 250, 200, 175, 150, 125, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, or 25 kJ / kg when measured over a period of 60 minutes or less, 45 minutes or less, 30 minutes or less, or 15 minutes or less. In certain embodiments, the shearing step can provide a mechanical work in the range of 4 to 80 kJ / kg over a period of 60 minutes or less, or 30 minutes or less.

[0049] In one or more embodiments, the shearing step can provide a mechanical work of at least 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, 140, 145, 150, 155, 160, 165, 170, 175, 180, 195, or 200 kJ / kg when measured over a period of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes, and / or less than 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 minutes. Additionally or alternatively, the shearing step can provide a mechanical work of less than 500, 450, 400, 350, 300, 250, 200, 175, 150, 125, or 100 kJ / kg when measured over a period of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes, and / or less than 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 minutes.

[0050] As used herein, the total mechanical work per kg may be calculated by the following formula: (kW×sec) / kg, where "kW" refers to the average shaft mechanical power of the shearing device multiplied by the shearing process time in seconds ("sec"), then divided by the batch size in kilograms ("kg"). For the calculation, "kJ" corresponds to (kW×sec) from the above formula. Furthermore, the mechanical shaft power of the shearing device may be measured directly or derived from the device's electric motor based on (i) line voltage and (ii) line amperes drawn, then corrected for conversion losses using manufacturer specified power factor and IE efficiency values, and any other drive chain friction losses from gears and belts.

[0051] Additionally or alternatively, in various embodiments, the shearing may occur with a specified power intensity for a set period of time. The power intensity refers to the peak power input to the product while the product is in the shear zone of the shear device. Generally, this indicates the shear force being applied to the product. In one or more embodiments, the shearing process may apply a power intensity to the product of at least 0.1, 0.5, 1, 2, 3, 4, or 5 kW and / or less than 200, 150, 100, 90, 80, 70, 60, or 50 kW for a time period of less than 5, 4, 3, 2, 1, or 0.5 seconds. The power may be calculated based on the aforementioned mechanical shaft power of the shear device. In certain embodiments, the shearing process may apply a power intensity to the product in the range of 3 to 40 kW for a time period of less than 1 second.

[0052] In various embodiments, one or more fats (e.g., oils), one or more low amylose starches (e.g., tapioca starch and / or modified starches), one or more gums (e.g., guar, xanthan, and / or Ingredion's Ticagel®), one or more preservatives (e.g., sodium benzoate), one or more salts (e.g., sodium chloride), one or more acids (e.g., lactic acid and / or citric acid), one or more emulsifiers (e.g., lecithin, monoglycerides, diglycerides, and / or EmulsiSMART®), one or more flavorings (e.g., nutritional yeast, spices, and / or spices), one or more protein additives (e.g., pea protein and / or potato protein), and / or water may be added to the shearing device 24 along with the gelatinized potato feed 22. Additionally or alternatively, in certain embodiments, one or more oils, one or more low amylose starches (e.g., tapioca starch and / or modified starches), one or more gums (e.g., guar, xanthan, and / or Ingredion's Ticagel®), one or more preservatives (e.g., sodium benzoate), one or more salts (e.g., sodium chloride), one or more acids (e.g., lactic acid and / or citric acid), one or more emulsifiers (e.g., lecithin, monoglycerides, diglycerides, and / or EmulsiSMART®), one or more flavorings (e.g., nutritional yeast, spices, and / or spices), one or more protein additives (e.g., pea protein and / or potato protein), and / or water may be added directly to the gelatinized potato feed 22 prior to introducing the feed 22 into the shearing device 24.

[0053] If added directly to the shearing device 24, the aforementioned additive materials (i.e., oil, starch, salt, acid, emulsifier, gum, protein additive, and / or water) may be added to the shearing device 24 at the same time as the gelatinized potato feed 22 or may be added at different intervals during the shearing process. For example, one or more of the aforementioned additive materials may be added at the transition between one or more shearing stages. Thus, for example, the shearing process may begin with only the gelatinized potato feed 22, however, after the first shearing stage, one or more of the aforementioned additive materials may be added before or during the start of the second shearing stage.

[0054] The oil and water may be useful in producing the desired viscosity of Liquid P and may also enhance certain taste and texture characteristics of the resulting Liquid P. Exemplary oils may include, for example, sunflower oil, coconut oil, hydrogenated palm oil, cocoa butter, shea butter, or combinations thereof. Generally, in one or more embodiments, the oils added to the formulations described herein may have a melting point in the range of 23°C to 45°C, and thus remain in liquid form during shearing. Without wishing to be bound by theory, it is believed that the selection of oils exhibiting a melting point in this range may facilitate downstream production of cheese analogs that can be melted, shredded, sliced, and cut. For example, it has been observed that these oils may help maintain the firm texture of the resulting cheese analogs and provide an improved mouthfeel.

[0055] In one particular embodiment, oil is added to the shearing step, but no water is added, while in yet another embodiment, both water and oil are added to the shearing step along with the gelatinized potato feed 22.

[0056] Optionally, after the shearing step, the sheared feed may be subjected to additional grinding. For example, the sheared feed may be optionally passed through a grinding machine, such as an Urschel Comitrol or a high pressure homogenizer, one or more times. This optional post-shear grinding step may occur at a temperature within any of the ranges disclosed for the preheating and / or shearing steps. Thus, in such an embodiment, the optional post-shear grinding step may occur at a temperature within any of the ranges disclosed for the preheating and / or shearing steps.

[0057] In various embodiments, at least a portion of the sheared potato feed may be subjected to an optional heat treatment after the shearing treatment. For example, at least a portion of the sheared potato feed may be introduced into a cooking device where it may be subjected to a temperature that increases the temperature of the potato feed to at least 55°C, 60°C, 65°C, 67°C, 70°C, 75°C, 80°C, or 75°C, thereby forming liquid P. In such embodiments, it may be desirable to heat the sheared potato feed to a temperature that will fully gelatinize the starch therein. In various embodiments, this optional post-shearing heat treatment occurs at a temperature of at least 55°C, 60°C, 65°C, 67°C, 70°C, 75°C, 80°C, or 75°C, and / or less than 300°C, 200°C, 150°C, 125°C, or 100°C, and at atmospheric pressure. This optional heat treatment may occur for a period of at least 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 minutes, and / or less than 2 hours, 1 hour, 50 minutes, 40 minutes, or 30 minutes. This heat treatment may be carried out via indirect heating (e.g., a heating jacket on the cooking device) and / or direct heating (e.g., steam injection directly into the sheared potato feed).

[0058] Various features and characteristics of Liquid P are described below. Although all of the following features and characteristics may be listed separately, it is contemplated that each of the following features and / or characteristics of Liquid P are not mutually exclusive and may be combined and present in any combination, so long as such combinations of features are not contradictory. Additionally, it is noted that all weight percentages related to the Liquid P formulation are based on the total weight of the Liquid P formulation, unless otherwise noted.

[0059] Due to the unique shear process described herein, the resulting Liquid P can be formulated to form dairy analogs, particularly cheese analogs, with excellent texture and contain a desirable grind gauge particle size range. In various embodiments, Liquid P may comprise a particle fineness of less than 250, 240, 230, 220, 210, 200, 190, 185, 180, 175, 170, 165, 160, 155, 150, 145, 140, 135, 130, 125, 120, 115, 110, 105, 100, 95, 90, 85, 80, 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020). Additionally or alternatively, Liquid P may comprise a particle fineness of at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020). For example, Liquid P may comprise a particle fineness in the range of 1 to 250, 1 to 200, 1 to 150, 1 to 130, 1 to 125, 1 to 100, 1 to 80, 1 to 60, 1 to 50, 1 to 40, 1 to 30, 1 to 25, 1 to 20, or 1 to 15 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020). Note that ISO 1524(2020) was done with the gauge plate at room temperature (20-25°C) because recipes containing higher melting point oils had difficulty measuring if the gauge plate was too cold.

[0060] In various embodiments, Liquid P comprises at least 5, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 25, 30, 35, or 40 weight percent, and / or less than 99, 95, 90, 85, 80, 75, 70, 65, 60, 55, or 50 weight percent potatoes, such as those originally added in the initial potato feed, based on the total weight of the Liquid P composition.

[0061] In various embodiments, the oil is added in a sufficient amount such that Liquid P comprises at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, or 15 percent by weight of one or more oils, based on the total weight of the Liquid P composition. Additionally or alternatively, the oil is added in a sufficient amount such that Liquid P comprises less than 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10 percent by weight of one or more oils, based on the total weight of the Liquid P composition. In general, the oil may comprise coconut oil, sunflower oil, cocoa butter, shea butter, or a combination thereof.

[0062] In specific embodiments, Liquid P comprises (i) sunflower oil and (ii) coconut oil or cocoa butter. In such embodiments, Liquid P may comprise sunflower oil in the range of 1 to 10, 2 to 8, or 3 to 7 weight percent, and coconut oil or cocoa butter in the range of 5 to 45, 7 to 40, or 9 to 35 weight percent, based on the total weight of the Liquid P composition.

[0063] In various embodiments, one or more specific starches and / or gums may be added in sufficient amounts during the process such that Liquid P comprises at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, or 20 percent by weight of at least one low amylose starch, e.g., tapioca starch, modified starch, or combination thereof, based on the total weight of the Liquid P composition. Additionally or alternatively, Liquid P may comprise no more than 50, 45, 40, 35, 30, 25, 20, 19, 18, 17, 16, 15, 10, 5, or 1 percent by weight of at least one low amylose starch, e.g., tapioca starch, modified starch, or combination thereof, based on the total weight of the Liquid P composition. As used herein, "low amylose starch" refers to starch that contains less than 19 weight percent amylose, based on the total weight of the starch. Thus, low amylose starch is typically not native potato starch, specific rice starch, or native corn starch. Generally, in one or more embodiments, low amylose starch as used herein includes an amylose content of less than 19, 18.5, 18, 17.5, or 17 weight percent. Without wishing to be bound by theory, it is believed that the use and incorporation of appropriate starches into the Liquid P formulation can improve the resulting properties of the cheese analogs produced according to the present disclosure. For example, it has been observed that the use of tapioca starch and modified starches can enhance the melting properties of the cheese analogs described herein.

[0064] In various embodiments, one or more gums are added in a sufficient amount such that Liquid P comprises at least 0.1, 0.5, 1, 2, 3, or 4 weight percent, and / or less than 10, 9, 8, 7, 6, or 5 weight percent gums, based on the total weight of the Liquid P composition. Exemplary gums may include, for example, guar, xanthan, Ingredion's Ticagel®, or combinations thereof.

[0065] In various embodiments, one or more gums are added in a sufficient amount so that Liquid P comprises at least 0.1, 0.5, 1, 2, 3, or 4 weight percent, and / or less than 10, 9, 8, 7, 6, or 5 weight percent of one or more protein additives (e.g., pea protein and / or potato protein), based on the total weight of the Liquid P composition.

[0066] In various embodiments, water is added in a sufficient amount so that Liquid P contains at least 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10 weight percent water, and / or less than 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 20, or 15 weight percent water, based on the total weight of the Liquid P composition.

[0067] In various embodiments, Liquid P can optionally include one or more additional complex carbohydrates, such as up to 50 weight percent of root vegetables other than potatoes. In certain embodiments, the optional complex carbohydrates can have a higher fiber content than the potatoes used to make Liquid P. Examples of additional complex carbohydrates suitable for use in Liquid P include root vegetables, such as parsnips, celery root, sweet potatoes, onions, red beets, carrots, or combinations thereof. For example, in various embodiments, Liquid P includes at least 1, 2, or 5 weight percent, and / or less than 60, 55, 50, 45, 40, 35, 30, 25, 20, 15, or 10 weight percent of one or more root vegetables, based on the total weight of the Liquid P composition.

[0068] In various embodiments, one or more preservatives (e.g., sodium benzoate) are added in a sufficient amount such that Liquid P comprises at least 0.001, 0.005, 0.01, or 0.02 weight percent, and / or less than 1, 0.5, 0.4, 0.3, 0.2, or 0.1 weight percent of the one or more preservatives, based on the total weight of the Liquid P composition.

[0069] In various embodiments, optional flavors, optional additives, and other optional vegetables and fruits may be added to the shearing device 24 along with the gelatinized potato feed 22. These flavors may include, for example, spices, meats, cheeses, herbs, other flavors desired in the final food product, or combinations thereof. Exemplary additives that may be added may include, for example, protein supplements (e.g., chickpeas, soy, or combinations thereof), dietary fiber supplements, vitamins, minerals, or combinations thereof. Other vegetables and fruits that may be added at this stage may include, for example, peppers (including bell and hot peppers), onions, spinach, kale, mushrooms, mangoes, artichokes, legumes, corn, olives, tomatoes, or combinations thereof. In various embodiments, the flavorings, additives, and other vegetables and fruits are added in sufficient amounts so that Liquid P contains at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, or 20 weight percent, and / or less than 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 15, 10, or 5 weight percent of flavorings, additives, other vegetables, and / or other fruits, based on the total weight of the Liquid P composition. Alternatively, in certain embodiments, Liquid P may not contain any added water and / or flavorings.

[0070] Due to the inherent shear process and additives, liquid P26 may be in the form of a viscous, flowable liquid with a glossy, smooth appearance.

[0071] In various embodiments, the resulting liquid P26 can exhibit a viscosity at 12.5°C or 25°C of at least 100, 250, 500, 1,000, 1,500, 2,000, 2,500, 3,000, 3,500, 4,000, 4,500, or 5,000 cP, and / or less than 250,000, 200,000, 150,000, 100,000, 90,000, 80,000, 70,000, 60,000, 50,000, 40,000, 30,000, 25,000, or 20,000 cP.

[0072] Without wishing to be bound by theory, it is believed that the high shear conditions used in the preparation of Liquid P help to shape its unique rheological profile. In general, Liquid P is a non-Newtonian fluid that has a non-linear relationship between shear stress and shear rate. Liquid P can exhibit its non-Newtonian properties by maintaining its non-linear relationship between shear stress and shear rate after long-term storage of 24 hours, 48 ​​hours, and 72 hours.

[0073] In various embodiments, the liquid P is 0, 5, 10, 15, or 20 1 / sec shear rate of at least 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 75, 100, 125, 150, 175, 200, 225, 250, 275, 300, 325, 350, 375, 400, 425, or 450 dynes / cm 2 Additionally or alternatively, in various embodiments, liquid P may exhibit a shear stress at 12.5° C. of 0, 5, 10, 15, or 20 1 / sec shear rate of 900, 800, 700, 600, 500, 450, 400, 350, 300, 250, 200, 150, 125, 100, 75, or 50 dynes / cm 2 It should be noted that these above rheological measurements may be applicable immediately after preparation of Liquid P, or after storage at 6° C. for 24 hours ("Day 1"), 48 hours ("Day 2"), or 72 hours ("Day 3"). As noted above, the high shear process utilized herein enables Liquid P to exhibit and maintain its non-Newtonian profile after storage at 6° C. for 24 hours ("Day 1"), 48 hours ("Day 2"), or 72 hours ("Day 3").

[0074] In various embodiments, Liquid P may exhibit one of the following shear stress profiles at 12.5° C. after storing Liquid P at 6° C. for 24 hours ("Day 1"), 48 hours ("Day 2"), or 72 hours ("Day 3"): i. 5 when Liquid P does not contain complex carbohydrate materials such as other root vegetables or contains less than 10, 8, 6, 4, 2, or 1 weight percent of complex carbohydrate materials such as other root vegetables; 1 / sec shear rate of at least 15, 20, 25, 30, 35, 40, 45, 50, 75, 100, 125, or 150 dynes / cm 2 shear stress, 10 1 / sec shear rate of at least 25, 30, 35, 40, 45, 50, 75, 100, 125, or 150 dynes / cm 2 Shear stress, 15 1 / sec shear rate of at least 35, 40, 45, 50, 75, 100, 125, or 150 dynes / cm 2 shear stress, and / or 20 1 / sec shear rate of at least 40, 45, 50, 75, 100, 125, 150, 175, 200, 225, 250, 275, 300, 325, 350, 375, or 400 dynes / cm 2 shear stress.

[0075] As noted above, the liquid P may be a non-Newtonian fluid and thus exhibit a non-linear rheological profile. As used herein, "Y1", "Y5", "Y 10 ","Y 15 ","Y 20 ","Y 30 " and "Y 40 " are 1, 5, 10, 15, 20, 30, and 40, respectively. 1 / sec shear stress value (dyne / cm) of liquid P at 12.5°C 2 Furthermore, as used herein, "Y 1-5 ","Y 5-10 ","Y 10-15 ","Y 15-20 ","Y 1-10 ","Y 10-20 ","Y 20-30 " and "Y 30-40 " are Y1 to Y5, Y5 to Y 10 , Y 10 ~Y 15 , Y 15~Y 20 , Y1~Y 10 , Y 10 ~Y 20 , Y 20 ~Y 30 , and Y 30 ~Y 40 represents the change in shear stress value.

[0076] In various embodiments, the liquid P has the following rheological properties: iY 1-5 ≠ Y 5-10 ≠ Y 10-15 ≠ Y 15-20 , ii.Y 10 is Y 10-15 and / or Y 15-20 is at least 50, 100, 150, 200, 250, or 300 percent greater than iii.Y 1-5 is Y 5-10 , Y 10-15 and / or Y 15-20 is at least 50, 100, 150, 200, 250, or 300 percent greater than iv.Y 5-10 is Y 10-15 and / or Y 15-20 is at least 50, 100, 150, 200, 250, or 300 percent greater than vY 1-5 is Y 10-20 , Y 20-30 and / or Y 30-40 and / or vi.Y 1-10 is Y 10-20 , Y 20-30 and / or Y 30-40 In some embodiments, the present invention may exhibit at least one, two, three, four, five, or six of at least 25, 50, 75, 100, 125, or 150 percent greater than the above.

[0077] It should be noted that these above rheological measurements may be applicable immediately after production of Liquid P, or after Liquid P has been stored at 6° C. for 24 hours ("day 1"), 48 hours ("day 2"), or 72 hours ("day 3"). Furthermore, the above rheological properties may be measured at 12.5° C. When rheological property measurements and more than one storage standard are asserted herein (e.g., "the rheological properties are measured either after storing the liquid potato product for 24 hours at 6° C., 48 hours at 6° C., or 72 hours at 6° C."), infringement of the claimed rheological properties may be met if the infringing product exhibits the recited rheological properties at any one of the recited storage standards (e.g., after 24 hours of storage at 6° C.). In other words, to determine infringement of the above hypothetical claims, rheological testing would need to be performed at each of the recited storage criteria (e.g., after 24 hours of storage at 6°C, after 48 hours of storage at 6°C, and after 72 hours of storage at 6°C).

[0078] Due to the high shear process described herein, Liquid P formulations may exhibit a unique particle portfolio that results directly from the shear process. Upon microscopic examination using an OMAX M834SL PLAN-C50U3 compound microscope in bright field mode, samples of Liquid P stained with Lugol's solution may be characterized by the presence of fewer and smaller starch particles as well as a continuous non-particulate starch matrix. In contrast, low shear conventional potato products contain numerous visible starch particles in the size range of 100-600 μm and no continuous non-particulate starch matrix.

[0079] As shown in Figure 1, at least a portion of Liquid P26 can be transferred to a food production plant 28, where Liquid P26 can be used to produce a variety of food products. As noted above, Liquid P can be used to form dairy analogs, such as cheese analogs. As used herein, "cheese analog" refers to a food product that can be used in the same volumes as cheese products, but does not contain any milk-derived materials.

[0080] Generally, in various embodiments, Liquid P may be directly introduced into a food production plant (i.e., without any intervening steps) and formed into the desired dairy analog immediately after Liquid P is produced, or after Liquid P has been subjected to storage for 24, 48, or 96 hours at 0° C.-7° C., generally at about 6° C. More particularly, after producing Liquid P as described above, Liquid P may be used directly to form the desired food product without any intervening processing steps therebetween (e.g., dehydration and / or rehydration). In certain embodiments, Liquid P may not be subjected to dehydration and rehydration prior to forming the desired dairy analog, such as a cheese analog.

[0081] In various embodiments, a dairy analog, such as a cheese analog, may comprise at least 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 percent by weight Liquid P, based on the total weight of the dairy analog. Additionally or alternatively, in various embodiments, a dairy analog, such as a cheese analog, may comprise less than 99, 95, 90, 85, 80, or 75 percent by weight Liquid P, based on the total weight of the dairy analog. In certain embodiments, a dairy analog, such as a cheese analog, may be formed entirely from Liquid P.

[0082] In one or more embodiments, hard and solid cheese analogs can be made from Liquid P. Such cheese analogs can contain at least 1, 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, or 99 percent by weight of Liquid P, based on the total weight of the cheese analog. More particularly, in various embodiments, the cheese analogs can be formed entirely from Liquid P.

[0083] Prior to forming the dairy analog, additional flavors, additives, vegetables, and / or fruits may be added to the liquid P to enhance and modify the flavor and texture of the resulting dairy analog. These flavors may include, for example, spices, meat, cheese, herbs, or combinations thereof. Exemplary additives that may be added may include, for example, protein supplements (e.g., chickpeas, soy, or combinations thereof), dietary fiber supplements, vitamins, minerals, or combinations thereof. Other vegetables and fruits that may be added at this stage may include, for example, peppers (including bell peppers and hot peppers), onions, spinach, kale, mushrooms, mangoes, artichokes, legumes, corn, olives, tomatoes, or combinations thereof. In various embodiments, the flavorings, additives, and other vegetables and fruits are added in sufficient amounts so that the dairy analog contains at least 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, or 20 weight percent, and / or less than 75, 70, 65, 60, 55, 50, 45, 40, 35, 30, 25, 15, 10, or 5 weight percent of flavorings, additives, other vegetables, and / or other fruits, based on the total weight of the dairy analog. Note that these weight percentages do not include the amount of Liquid P in the dairy analog, and these additional materials are considered separately from Liquid P if added after the formation of Liquid P.

[0084] The cheese analog can be formed by allowing Liquid P to develop and solidify in a mold for an extended period of time. More specifically, the process for forming the cheese analog comprises: (a) filling a mold (e.g., any geometric shape that you want the final product to have) with liquid P and any other optional additives; (b) storing the Liquid P and other optional additives in the mold for an extended period of time to develop a gel in the Liquid P and solidify the resulting product.

[0085] It should be noted that the "mold" can include a temporary mold for forming the cheese analog, from which the cheese analog is removed prior to final packaging. Alternatively, the "mold" can be the final commercial packaging in which the cheese analog is packaged and sold commercially. In various embodiments, Liquid P must be stored in the mold at a temperature of at least 1° C., 2° C., 3° ​​C., 4° C., 5° C., or 6° C., and / or less than 20° C., 18° C., 16° C., 15° C., 14° C., 13° C., 12° C., 11° C., 10° C., 9° C., 8° C., or 7° C. for at least 1 day (24 hours), 2 days (48 hours), 3 days (72 hours), 4 days (96 hours), 5 days (120 hours), 6 days (144 hours), or 7 days (168 hours) to form the cheese analog. Generally, in one or more embodiments, Liquid P must be stored in a mold at 1° C.-20° C., 2° C.-20° C., 3° ​​C.-20° C., 1° C.-15° C., 1° C.-10° C., 2° C.-10° C., 1° C.-9° C., 2° C.-9° C., 2° C.-10° C., 3° ​​C.-10° C., or 4° C.-10° C., typically at 6° C., for at least 1 day (24 hours), 2 days (48 hours), 3 days (72 hours), 4 days (96 hours), 5 days (120 hours), 6 days (144 hours), or 7 days (168 hours) to form the cheese analog. In certain embodiments, the cheese analog is formed after storing Liquid P in a mold at 4-6° C. for at least 7 days (168 hours). During this time, the starch in Liquid P can at least partially develop and aid in the formation of a solidified texture.

[0086] During the storage and solidification phase, in various embodiments, Liquid P may be subjected to a cooling rate of at least 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.1, or 1.2 Watts, and / or less than 150, 125, 100, 90, 80, 70, 60, 50, 40, 30, 20, 15, 10, or 5 Watts, as measured over a 1 hour, 12 hour, or 24 hour period.

[0087] The molds used to form the cheese analogs can be configured to any desired geometric shape and any desired thickness, which can provide an advantage over traditional cheeses because it can be easier to configure the shape and thickness of the cheese analog as desired.

[0088] Liquid P may be poured into molds immediately after the shearing step described herein. Alternatively, Liquid P may be used to form a cheese analog after storage at 6° C. for 24, 48, or 96 hours.

[0089] The resulting cheese analogs may have a solid texture and may be cut, shredded, crushed, and / or sliced ​​in the same manner as traditional hard cheeses such as Cheddar or Parmesan. The cheese analogs may have a cohesive texture in the mouth and may be easily broken down and dispersed when chewed. Due to their solid texture, cheese analogs are typically not spreadable. Additionally, in certain embodiments, the cheese analogs may melt when heated.

[0090] Dairy analogs, such as cheese analogs, may exhibit excellent texture due to the inherent microstructure of sheared potatoes resulting from the shearing techniques described herein. In various embodiments, the dairy analogs, such as cheese analogs, exhibit a texture that is at least 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, 95, 100, 105, 105, 150, 20, 25, 26, 30, 35, 40, 45, 50, 55, 60, 65, or 70 days after manufacture and subsequent storage at 1-10° C., 2-8° C., 3-7° C., or 4-6° C. , 110, 120, 130, 140, 150, 160, 170, 180, 190, 200, 205, 210, 215, 220, 225, 230, 235, 240, 250, 260, 270, 280, 290, 300, 325, 350, 375, 400, 425, 450, 475, 500, 525, 550, 575, 600, 625, 650, 675, 700, 725, or 750 grams. Additionally or alternatively, a dairy analog, such as a cheese analog, may exhibit a maximum load of less than 900, 850, 800, 750, 700, 650, 600, 550, 500, 450, 400, 350, 300, 250, 225, 200, 175, 150, 140, 130, 120, 110, or 100 grams when measured at 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 26, 30, 35, 40, 45, 50, 55, 60, 65, or 70 days after manufacture and subsequent storage at 1-10°C, 2-8°C, 3-7°C, or 4-6°C.

[0091] Texture measurements are performed using a Brookfield CTX Texture Analyzer fitted with a CTX050 load cell and a TA2 / 1000 probe. Samples may be removed from a refrigerator, which stores the samples at approximately 4°C, and then allowed to warm to 5-10°C for testing. Data measurements are analyzed using Texture Pro 1.0.14 software. The load recorded corresponds to the mass applied to the sample to press the probe into the product at a constant rate (2mm / sec) until the probe has traveled a predetermined distance of 10mm, and then to withdraw the probe at a constant rate (2mm / sec).

[0092] Before and / or after forming the cheese analog, at least a portion of the Liquid P forming the cheese analog and / or at least a portion of the formed cheese analog itself can be subjected to additional processing to further improve the safety and / or properties of the resulting cheese analog. For example, at least a portion of the Liquid P (before forming the dairy analog) and / or at least a portion of the dairy analog (e.g., cheese analog) may be subjected to pasteurization / sterilization via any technique known in the art. Additionally or alternatively, at least a portion of the Liquid P (before forming the dairy analog) and / or at least a portion of the dairy analog (e.g., cheese analog) may be subjected to irradiation and / or electromagnetic radiation to inhibit any undesirable microbial growth in the resulting dairy analog. In yet other embodiments, at least a portion of the Liquid P (before forming the dairy analog) and / or at least a portion of the dairy analog (e.g., cheese analog) may be subjected to vibration and / or ultrasonic treatment to remove any entrapped air and / or to change the microstructure of the product. In yet other embodiments, at least a portion of Liquid P (prior to forming the dairy analog) and / or at least a portion of the dairy analog (e.g., a cheese analog) may be subjected to aeration to add desired air bubbles to the final dairy analog for textural purposes.

[0093] In various embodiments, the formed cheese analog may be subjected to stretching to enhance and manipulate the texture of the resulting cheese analog.

[0094] In various embodiments, the cheese analogue can be further processed in a Natec FreePack or conventional Hot Pack packaging machine in the same manner as processed cheese to form individually packaged sliced ​​cheese analogue products.

[0095] The resulting cheese analog can be consumed directly (e.g., as a snack cheese). Alternatively, the cheese analog can be used in the same volumes that any hard cheese, such as cheddar or parmesan, is typically used. For example, the cheese analog may be used as a topping for hamburgers, pizza, salads, or generally any other food item that uses sliced ​​cheese. Additionally, in certain embodiments, the cheese analog can be used to replace the cheese component in macaroni and cheese.

[0096] The present invention can be further illustrated by the following examples of this embodiment, although it will be understood that these examples are included for illustrative purposes only and are not intended to limit the scope of the invention unless specifically stated. EXAMPLES

[0097] Example 1 The Liquid P manufacturing method of the present invention was tested and compared to a conventional process for producing a potato-based food product ("Comparative Example A"). Both procedures used the same formulation, outlined in Table 1 below.

[0098] [Table 1]

[0099] The initial potato material was diced into 3 / 8 inch cubes. Additionally, the potato cubes were pre-blanched, pre-gelatinized, treated with citric acid, and frozen. The potatoes were then gently thawed in a microwave oven (1200W 110v Panasonic Rotary model NSD997S). Afterwards, the diced, thawed potatoes were then mixed with the oil and water fractions and poured into a Vitamix blender (Vitamix 5200 model VM0103 11.5amp 110v with variable speed). It was at this point that the traditional process and the inventive process described herein began to diverge.

[0100] In the conventional method (Comparative Example A), the Vitamix was run on a low speed setting (3-4 on the dial) for 2-3 minutes until a consistent, uniform puree was obtained. The shearing process was gentle enough to ensure there was no appreciable temperature increase. The product was then heated in a microwave oven with stirring to obtain a temperature of 165-170°F (74-77°C).

[0101] In the present (i.e., Liquid P) method, the Vitamix was run on a high speed setting (10 on the dial) for 5-10 minutes until there was a characteristic appearance change in which the product became glossy with a distinct sheen and the power was sucked up due to a significant increase in the motor. The temperature increased with the amount of mechanical work applied to the product to approximately 170-180°F (77-82°C) by the end of the shearing process.

[0102] For both methods, the completed product was allowed to sit at room temperature for 30 minutes and then a portion was transferred to the rheometer sample chamber (Brookfield DV3TRVTJ equipped with a small sample adapter kit using an SC4-28 spindle and a TC-650AP controller water bath) and placed in a temperature controlled water bath (set at 12.5°C). The rheometer spindle was then positioned within the product. This represents the "Day 0" product. The remaining product was kept in a refrigerator (4-8°C) and samples were removed for measurement in the rheometer after 24, 48, and 72 hours, representing "Day 1", "Day 2", and "Day 3", respectively.

[0103] Once the sample had reached a temperature of 12.5°C, the rheometer ran a predefined program. During this program, the spindle rotated at a defined rpm, creating a defined shear rate within the sample, along with the wall-to-wall distance between the spindle and the chamber. As a result, the corresponding torque could be measured, which is directly converted to the shear stress experienced (dynes / cm). The program went through a series of rotational speeds at 30 second intervals, ranging from 0 to 67.2. 1 A range of shear rates was created spanning 67.2 / sec. 1After reaching the maximum shear rate of 100 / sec, the program reduced the spindle rotational speed in 30 second intervals until it returned to zero (as shown in Tables 2-4 below). This therefore resulted in two sets of data, one "top" and one "bottom". The resulting shear stress values ​​were then plotted against shear rate for both sets of data (i.e., samples from the conventional method and the inventive method). Tables 2 and 3 below provide the "top" and one "bottom" shear stress values ​​at days 0, 1, 2, and 3 for samples produced from the conventional process and the inventive Liquid P process described herein. Figures 2 and 3 illustrate the rheological profiles of the conventional sample and Liquid P at days 0 through 3, respectively.

[0104] [Table 2]

[0105] [Table 3]

[0106] Table 4 also provides a direct comparison of the measured shear stress values ​​for the day 0 and day 3 samples of the conventional and Liquid P processes.

[0107] [Table 4]

[0108] FIG. 4 illustrates a graph comparing shear stress versus shear rate for samples on day 0, while FIG. 5 illustrates a graph comparing shear stress versus shear rate for samples on day 3. As shown in FIG. 4, the Liquid P product produced by the method of the present invention exhibited higher viscosity and slightly non-Newtonian rheology versus the product produced by the conventional method on day 0. As shown in FIG. 5, the rheological differences between the Liquid P product and the conventional product became much more evident on day 3. More particularly, FIG. 5 shows that the Liquid P product was able to achieve a much higher viscosity (indicated by a higher shear stress) versus the conventional product, which decreased substantially from day 0 to day 3. Furthermore, the Liquid P product exhibited a higher viscosity at lower shear rates (10 1 The Liquid P product demonstrated a distinct non-Newtonian rheology at shear rates below 1 / sec. Thus, the Liquid P product exhibited and was able to achieve a much more desirable rheological profile over time versus conventional products. Without wishing to be bound by theory, it is believed that this rheological profile of the Liquid P product may result at least in part from the high shear conditions used in its production.

[0109] Thus, Figures 4 and 5 demonstrate how the Liquid P product exhibits and retains desirable rheological properties at 12.5°C that closely reflect the desirable rheological profile of a particular food product.

[0110] Example 2 - Rough grinding (low temperature grinding) A potato feed according to the formulation illustrated in Table 5 below was subjected to cryogenic milling and coarse grinding. All percentages presented in Table 5 correspond to the weight percent of the indicated material based on the total weight of the sample.

[0111] [Table 5]

[0112] First, the sodium benzoate and potassium sorbate were dispersed in a small amount of water. Additionally, the potato material was pre-diced, blanched, chelated, and frozen prior to making the potato feed.

[0113] Frozen potato cubes, sunflower oil, and water were then premixed in a container to a total recipe weight of 12.5 kg and added to a Groen kettle (20 L volume) containing a heating jacket and swept-wall stirrer. The mixture was gently warmed (<10° C.) in the Groen kettle until the potato pieces were completely thawed.

[0114] The mixture was then poured into an Urschel Comitrol® (Model 1700) mill fitted with a 190084-1° head (i.e., a relatively coarse grinding head with a 389 micrometer opening) operating at 9,390 rpm. Flow to the mill was maintained to ensure that the current drawn by the motor was approximately 25 amps. 12.5 kg of the mixture was processed in less than 60 seconds.

[0115] The temperature of the product mix going into the mill was 2°C, and the temperature of the mix exiting the mill was 5°C. Part of this temperature increase was due to the mechanical work done to the mix, but also due to heat transfer from the room temperature (approximately 20°C) steel of the mill to the mix. Thus, the potatoes in the mix were ground (i.e., cryo-ground) before the native starch was fully gelatinized.

[0116] Immediately after grinding the mixture, the fineness of the mixture was measured using a BYK-Gardner 2512 Metal Grind Gauge #PD-250 using the method described in ISO 1524 (2020). The fineness size was observed to be 225 micrometers. The resulting ground mixture was in the form of a white, free-flowing slurry.

[0117] The ground mixture was also examined under a microscope (100x magnification, under bright field mode, unpolarized illumination, stained with Lugol's solution (iodine)). Figure 6 is a photograph of this microscope image.

[0118] A portion of the ground mixture was removed and indirectly heated to 84°C for 3 minutes. As the product warmed, the rheology changed and the ground product thickened as the native potato starch gelatinized, becoming a thick, flowable, and cohesive mass. The hot cooked product was then poured into containers and allowed to cool in a refrigerator at 4°C and then stored.

[0119] After cooling, the milled product became a firm gel. As discussed above, the texture development of this gel was followed at a constant speed (2 mm / sec) using a Brookfield CTX Texture Analyzer equipped with a CTX050 load cell and a TA2 / 1000 probe. The texture analysis was performed immediately after removing the product from the refrigerator while the product was at a temperature of 5-10°C.

[0120] Example 3 - Fine grinding (cryogenic grinding) A potato feed mixture according to Table 5 above was prepared according to the procedure described in Example 2.

[0121] The mixture was poured into an Urschel Comitrol® (Model 1700) mill fitted with a 218084-0° head (i.e., a fine grinding head with a 64 micrometer opening) operating at 9,390 rpm. The flow rate to the mill was maintained to ensure that the current drawn by the motor was less than 80 amps, and generally remained at about 60 amps, thereby representing a significantly higher level of work relative to the coarse grinding head of Example 2. 12.5 kg of the mixture was processed in less than 60 seconds.

[0122] The temperature of the product mix into the mill was 3°C, and the temperature of the mix exiting the mill was 13°C. Part of this temperature increase was due to the mechanical work done on the mix, but also due to heat transfer from the room temperature (approximately 20°C) steel of the mill to the mix. Thus, the potatoes in the mix were ground (i.e., cryo-ground) before the native starch was fully gelatinized.

[0123] Immediately after grinding the mixture, the fineness of the mixture was measured using a BYK-Gardner 2512 Metal Grind Gauge #PD-250 using the method described in ISO 1524 (2020). The fineness size was observed to be 125 micrometers. The resulting ground mixture was in the form of a heavy, free-flowing white slurry, which was significantly thicker than the ground mixture from Example 2.

[0124] The ground mixture was also examined under a microscope (100x magnification, under bright field mode, unpolarized illumination, stained with Lugol's solution (iodine)). Figure 7 is a photograph of this microscope image.

[0125] A first portion of the ground mixture was removed and indirectly heated to 80°C for 3 minutes ("Sample 3a"), and a second portion of the ground mixture was removed and indirectly heated to 95°C for 3 minutes ("Sample 3b"). As the product warmed, the rheology changed and the ground product thickened as the native potato starch gelatinized, becoming a thick, flowable, and cohesive mass. These hot cooked products were then poured into containers and cooled in a refrigerator at 4°C before they were stored.

[0126] After cooling, the milled products became firm gels. As discussed above, the texture development of these gels was followed at a constant speed (2 mm / sec) using a Brookfield CTX Texture Analyzer fitted with a CTX050 load cell and a TA2 / 1000 probe. Texture analysis was performed immediately after removing the products from the refrigerator while they were at a temperature of 5-10°C.

[0127] Example 4 - Fine grinding (thermal milling) A potato feed mixture according to Table 5 above was prepared according to the procedure described in Example 2, except that the mixture was warmed to 85° C. in a Groen kettle before grinding until the potato pieces were fully cooked.

[0128] The mixture was then poured into an Urschel Comitrol® (Model 1700) mill fitted with a 218084-0° head (i.e., a fine grinding head with a 64 micrometer opening) operating at 9,390 rpm. The flow rate to the mill was maintained to ensure that the current drawn by the motor was less than 80 amps, and generally remained at about 50 amps, thereby representing a significantly higher level of work relative to the coarse grinding head of Example 2. 12.5 kg of the mixture was processed in less than 60 seconds.

[0129] The temperature of the product mix entering the mill was about 85° C. and the temperature of the mix exiting the mill was approximately the same. Thus, the potatoes in the mix were ground (i.e., hot ground) with complete gelatinization of the native starch.

[0130] Immediately after grinding the mixture, the fineness of the mixture was measured with a BYK-Gardner 2512 Metal Grind Gauge #PD-250 using the method described in ISO 1524 (2020). The fineness size was observed to be 15 micrometers. The resulting ground mixture was in the form of a smooth, free-flowing white liquid.

[0131] The ground mixture was also examined under a microscope (100x magnification, under bright field mode, unpolarized illumination, stained with Lugol's solution (iodine)). Figure 8 is a photograph of this microscope image.

[0132] A portion of the ground mixture was removed and indirectly heated to 80° C. for 3 minutes and then further heated to 95° C. As the product warmed, the rheology changed and the ground product thickened as the native potato starch gelatinized, becoming a thick, flowable and cohesive mass, but less viscous than the cold ground products of Examples 2 and 3. This hot cooked product was then poured into containers and allowed to cool in the refrigerator at 4° C. and then stored.

[0133] After cooling, the milled product became a firm gel. As discussed above, the texture development of this gel was followed at a constant speed (2 mm / sec) using a Brookfield CTX Texture Analyzer equipped with a CTX050 load cell and a TA2 / 1000 probe. The texture analysis was performed immediately after removing the product from the refrigerator while the product was at a temperature of 5-10°C.

[0134] As shown in Figures 6-8, the microscopic images of Examples 2-4 clearly demonstrated the effect that different grinding conditions had on the starch granules obtained from potatoes. More specifically, cryo-grinding with a coarse grind of Example 2 generally resulted in larger and fewer starch particles relative to cryo-grinding with a fine grind of Example 3. Furthermore, there did not appear to be any intact native starch granules in the coarse ground sample of Example 2.

[0135] There was a significant difference between the finely ground sample from cryo-milling (Example 3) and the finely ground sample from thermal milling (Example 4). The thermally ground sample had a significantly smaller particle size and did not contain any dense starch granules.

[0136] Texture measurements for Examples 2-4 were performed on days 6 and 16 (the date of manufacture being day 0) and are illustrated in Figures 9 and 10, respectively. The graphs in Figures 9 and 10 demonstrate the load recorded as the probe was pressed into the product at a constant rate (i.e., compressive stress) until it had traveled a predetermined distance of 10 mm, after which the probe was withdrawn.

[0137] As shown in Figure 9, texture measurements on day 6 revealed that the coarse cryogenically ground product (Example 2) exhibited the lowest level of firmness, achieving a maximum load of 54 g. This was closely followed by Sample 3a of Example 3 (i.e., the first portion of the fine cryogenically ground product heated to 80°C), which achieved a maximum load of 62 g. Both Sample 3b of Example 3 (i.e., the second portion of the fine cryogenically ground product heated to 95°C) and the fine thermally ground product of Example 4 exhibited significantly superior firmness values ​​with maximum loads of 88 g and 102 g, respectively.

[0138] As shown in Figure 10, texture measurements at 16 days revealed that all products became harder, but also began to diverge more significantly in terms of texture properties. The coarse cryogenically ground product (Example 2) still exhibited the lowest level of firmness with an increased load of 78g. Sample 3a of Example 3 (i.e., the first portion of the fine cryogenically ground product heated to 80°C) was also significantly firmer with a maximum load of 140g. Meanwhile, Sample 3b of Example 3 (i.e., the second portion of the fine cryogenically ground product heated to 95°C) exhibited a maximum load of 190g. Finally, the fine thermally ground product of Example 4 exhibited the best texture properties with a maximum load of 240g.

[0139] It has therefore been shown that the combination of thermal milling and fine grinding leads to the formation of a product with excellent textural properties.

[0140] Example 5 and Comparative Example 1 - Inventive Shear vs. Conventional Shear When Hot Potato feeds were made for these test samples according to the formulations illustrated in Table 6 below. All percentages listed in Table 6 correspond to the weight percent of the indicated ingredients, based on the total weight of the sample.

[0141] [Table 6]

[0142] Sodium benzoate and potassium sorbate were added to a portion of the water and allowed to hydrate and disperse for at least 5 minutes. Both of these materials acted as preservatives and had no function related to the texture properties of the final product. The purpose of these additives was to act as preservatives to limit the growth of mold and other spoilage microorganisms in the product, so that the texture development could be monitored over a period of weeks.

[0143] The oil and water were first blended and gently heated in a microwave oven (1200W, 110v Panasonic Rotary Model NSD997S) to 85° C. Frozen IQF diced potatoes were then added to the oil / water blend to form a reaction mixture which was then heated again to 85° C. in the microwave.

[0144] The reaction mixture was then placed hot into a Robot Coup Blixer 2 (2.9 L capacity) industrial food blender. The batch size was 1,400 g. The blender was then run on a low speed setting until the product was pureed into a smooth, homogenous mass with no diced potato pieces remaining.

[0145] At this point the mass was split in half into batches of Example 5 and Comparative Example 1 so that the hot-grinding process could be compared to the "conventional" process.

[0146] In Comparative Example 1, half of the pureed mass was placed in a silicone mold, sealed, and placed in the refrigerator to demonstrate the conventional process.

[0147] In Example 5, the remaining half of the pureed mass was further ground in a Robot Coupe at high speed for at least 10 minutes. During this time, the mixture gained a glossy appearance. The mixture was then poured into a silicone mold, sealed, and placed in the refrigerator.

[0148] Both Comparative Example 1 and Example 5 were allowed to cool for at least 24 hours to ensure the molds were completely cooled. For texture testing, the formed blocks were removed from the refrigerator and warmed to room temperature to about 15° C. before opening. This was done to minimize any condensation on the product surface that could interfere with the results.

[0149] The texture of the products was measured at a constant speed (2 mm / sec) using a Brookfield CTX Texture Analyzer fitted with a CTX050 load cell and a TA2 / 1000 probe. The probe was pressed into the product at a constant speed (2 mm / sec) until it had travelled a predetermined distance of 10 mm (i.e. compressive stress) and then the load was recorded as the probe was withdrawn at a constant speed (2 mm / sec) and the results were captured digitally using the accompanying Texture Pro 1.0.14 software.

[0150] As shown in Figures 11-15, texture measurements were performed over several days (i.e., days 2, 4, 15, 26, and 70). The texture measurements revealed that Example 5 always exhibited higher firmness versus Comparative Example 1; however, for both Example 5 and Comparative Example 1, firmness increased for both products as they aged.

[0151] As evidenced by Figures 11-15, the products begin to increase in firmness as they age. At day 1, the firmness of Comparative Example 1 was not measurable due to lack of firmness. As shown in Figures 11-15, the product made according to Example 5 exhibited significantly superior firmness to the product made according to Comparative Example 1. Even by day 2, the two processes show a particularly clear difference in firmness, as shown by Figure 11. Although both products also increased in firmness over time, the product made according to Example 5 increased in firmness at a faster rate and remained firmer over the extended period of 70 days, as shown in Figure 15. Without wishing to be bound by theory, it is believed that the product made according to Example 5 had a different and superior microstructure to the product made according to Comparative Example 1, which contributed to the superior texture development and retention of the samples over time.

[0152] Examples 6 to 12 and Comparative Examples 2 to 8 - Recipe and Variation in Texture Hardness To observe the effect of recipe variability on the textural properties of the resulting molds, various molded samples were prepared based on the formulations in Tables 7 and 8 below and following the milling and molding procedures used in Example 5 and Comparative Example 1. All percentages presented in Tables 7 and 8 correspond to the weight percent of the indicated ingredients based on the total weight of the sample. Examples 6-12 were made according to the process used to make Example 5, and Comparative Examples 2-8 were made according to the process used to make Comparative Example 1.

[0153] [Table 7]

[0154] [Table 8]

[0155] As shown in Figures 16-19, for the same levels of potato material, the formed products of Examples 6-12 made with the inventive process used in Example 5 exhibited higher levels of firmness than Comparative Examples 2-8 made with the conventional process used in Comparative Example 1. The difference in firmness between the two processes becomes less pronounced at higher levels of potato material, but is still evident at these higher levels. In general, the higher levels of potato exhibited higher levels of firmness. Firmness was measured using the same procedure as described above for Example 5.

[0156] Additionally, as shown in Figures 16-19, Examples 6-8 and Comparative Examples 2-4, which contained lower levels of potato, were less firm, formed slower, and were more easily measured by Day 15. Nevertheless, they still exhibited the benefits of the inventive thermal grinding process described herein (i.e., excellent texture).

[0157] Examples 13 and 14 - Composite recipes with improved cheese properties As noted above, ingredients other than potatoes, oil, and water can be added to improve the flavor, color, mouthfeel, melting properties, cost, and shelf life of the product. To demonstrate the impact of additional additives and their effect on the cheese-like properties of the resulting product, two separate potato feeds (1 kg each) were prepared according to the recipes listed in Table 9 below. All percentages presented in Table 9 correspond to the weight percent of the indicated ingredients based on the total weight of the sample.

[0158] [Table 9]

[0159] Sodium benzoate was added to a portion of the water and allowed to hydrate and disperse for at least 5 minutes. In addition, frozen potatoes and coconut were gently heated in a microwave oven to thaw and melt, respectively, raising their temperature to 85°C. The potatoes and water phase were then added to a Robot Coupe Blixer 4 (4.5L capacity 1.5HP / 1.12KW motor) and blended for 2 minutes at maximum speed (3,500RPM). Then, the oil Emulismart / Nutrava and lactic acid were added to the Blixer and blended for 1 minute at maximum speed. The temperature of the resulting mixture was 40°C.

[0160] At this point, the remaining ingredients, except for the native / modified starch, were added to the Blixer and blended at maximum speed for 6-10 minutes. The temperature of the resulting mixture was 60°C. The native / modified starch was then slowly added to the Blixer while blending. The temperature of the mixture rose to approximately 75-80°C and began to thicken as the motor of the Blixer began to overload and trip. At this stage, the mixture was a cohesive and viscous mass which was then poured into containers, sealed, and placed in the refrigerator for cooling and storage. Once cooled, the mixture was stiff enough to be removed from the container.

[0161] The texture of the formed mixtures was measured according to the procedure described above in Example 5. For comparison purposes, samples of Examples 13 and 14 were compared to store-bought Colby Jack (Kroeger). Figure 20 illustrates the texture measurements of all three samples at day 23. As shown in Figure 20, Examples 13 and 14 had very similar textural characteristics to traditional Colby Jack cheese.

[0162] Example 15 - Composite recipe with improved cheese properties As noted above, ingredients other than potatoes, oil, and water can be added to improve the flavor, color, mouthfeel, melting properties, cost, and shelf life of the product. To demonstrate the impact of additional additives and their effect on the cheese-like properties of the resulting product, three separate potato feeds (75 kg) were prepared according to the formulations listed in Table 10 below. All percentages presented in Table 10 correspond to the weight percent of the indicated ingredients based on the total weight of the sample. These samples were labeled Samples 15a, 15b, and 15c, and all three contained the same formulation.

[0163] [Table 10]

[0164] First, in preparation for the experiment, coconut oil was melted at 45°C. Water was then added to a Stephan Universal Batch Cooker UM200, which utilized direct steam injection for product heating. The water was heated to 80°C. Frozen root vegetables (i.e., potato and sweet potato) and carrot puree were then added to the Cooker and stirred for approximately 5 minutes to thaw the frozen vegetables. If necessary, the temperature of the mixture was increased to 40°C using direct steam injection.

[0165] At this stage, the stirring blade speed was increased to 50% for sample 15a, 75% for sample 15b, and 100% for sample 15c, and Cooker maintained these speeds for 6 minutes. At this stage, samples were taken from samples 15a, 15b, and 15c to measure fineness ("Fineness Measurement A"). Fineness was measured as described in Examples 2-4.

[0166] The powdered ingredients and lactic acid were then added to the mixture in the Cooker, and the mixer was run at 100% speed for 2 minutes to thoroughly mix all ingredients. Another sample was taken from each of the mixtures to measure the fineness ("Fineness Measurement B").

[0167] The melted coconut oil was then added to the mixture and the agitator was run at 100% speed for 2 minutes to effect final break-up and emulsification of the oil phase. Direct steam injection was used to raise the temperature of the mixture to 85° C. The mixtures were held at this temperature in the Cooker and another sample was once again taken from each of the mixtures to measure fineness ("Fineness Measurement C").

[0168] At this stage, all three samples were poured into molds and refrigerated. Depending on the mold dimensions, the product can be demolded, sliced ​​and / or grated within 1-20 days.

[0169] The samples taken for fineness measurements A, B, and C were tested for fineness using the grinding gage technique described in Example 2 so that the level of grain size reduction during the process could be analyzed. The results of these analyses are provided below in Table 11.

[0170] [Table 11]

[0171] As shown in Table 11, the most significant particle size reduction occurred during thermal milling in the presence of oil (stage C, i.e., fineness measurement C), however, the total shear experienced is estimated to be cumulative across all three milling stages, which is supported by the different hardness measurements of the final products.

[0172] Additionally, samples 15a, 15b, and 15c were tested for sample firmness 41 days after manufacture using a texture analyzer (TA.XT-Plus from Stable Micro Systems) in compression mode fitted with a metal knife-type probe (Extended Craft knife A / ECB). During this test, the knife cut the product at a speed of 2 mm / sec, and the force required during the movement of the knife through the product was digitally captured by the unit. Samples were analyzed immediately after removal from the refrigerator (approximately 4° C.), with three replicate measurements made for each sample. The results of these tests are provided in Table 12 below.

[0173] [Table 12]

[0174] Penetration through all samples proceeded smoothly without disruption of the product, thereby leaving a smooth cut surface, indicating that the product is ideal for slicing and grating in the same manner as many cheeses.

[0175] As shown in Table 12, the results of the texture measurements for Samples 15a, 15b, and 15c indicate that higher levels of shear force used during the cryogenic grinding of potatoes (as represented by 100% and 75% agitator speed) produced a firmer product.

[0176] Additionally, the microstructures of Samples 15a, 15b, and 15c were analyzed after formation of their respective products. 3 Cubes of 1000g ...

[0177] definition It should be understood that the following is not intended to be an exhaustive list of defined terms. Other definitions may be provided in the preceding description, for example, as they accompany the use of a defined term in context.

[0178] As used herein, the terms "a," "an," and "the" mean one or more.

[0179] As used herein, the term "and / or," when used in a list of two or more items, means that any one of the listed items may be used alone, or any combination of two or more of the listed items may be used. For example, if a composition is described as containing components A, B, and / or C, the composition can contain only A, only B, only C, a combination of A and B, a combination of A and C, a combination of B and C, or a combination of A, B, and C.

[0180] As used in this specification, the terms "comprising," "comprises," and "comprise" are open-ended transitional terms used to transition from the subject matter described before the term to one or more elements described after the term, and the element or elements listed after the transitional term are not necessarily the only elements that make up the subject matter.

[0181] As used herein, the terms "having," "has," and "have" have the same open-ended meaning as "comprising," "comprises," and "comprise" provided above.

[0182] As used in this specification, the terms "including," "include," and "included" have the same open-ended meaning as "comprising," "comprises," and "comprise" provided above.

[0183] As used herein, the term "potato ingredients" refers to ingredients in a potato supply that are derived solely from potatoes.

[0184] As used herein, the term "dairy analog" refers to a food product that can be used in the same volumes as the referenced dairy food product, but does not contain any materials derived from milk.

[0185] As used herein, "modified starch" refers to starch derivatives produced by physically, enzymatically, or chemically modifying original starch.

[0186] Number range This description uses numerical ranges to quantify certain parameters related to the present invention. When numerical ranges are provided, it should be understood that such ranges are interpreted as providing literal support for claim limitations that recite only the lower limit of the range, as well as for claim limitations that recite only the upper limit of the range. For example, a disclosed numerical range of 10 to 100 provides literal support for claims that recite "greater than 10" (no upper limit) and claims that recite "less than 100" (no lower limit).

[0187] The claims are not limited to the disclosed embodiments. The above male preferred embodiment of the present invention should be used only as an example and should not be used in a limiting sense to interpret the scope of the present invention. Modifications to the above exemplary embodiment can be easily made by those skilled in the art without departing from the spirit of the present invention.

[0188] The male inventors hereby state their intention to rely on the doctrine of equivalents to determine and evaluate the reasonably fair scope of the present invention as it relates to devices that are outside, but do not materially depart from, the literal scope of the invention as set forth in the following claims.

Claims

1. 1. A method for producing a dairy analog comprising: (a) providing an initial potato supply comprising a plurality of potatoes; (b) at least partially gelatinizing at least a portion of said initial potato feed, thereby forming a gelatinized potato feed; (c) shearing at least a portion of said gelatinized potato feed at a temperature of at least 50° C., thereby forming a liquid potato product; providing a mechanical work of at least 20 kJ / kg when the shear is measured over a period of 15 minutes or less; The shear is as follows: (i) at least one oil exhibiting a melting point in the range of 23° C. to 45° C.; or (ii) formation occurring in the presence of at least one native starch and / or one or more modified starches; (d) introducing at least a portion of the liquid potato product into a mold; (e) solidifying the liquid potato product in the mold, thereby forming the dairy analog.

2. 10. The method of claim 1, wherein the partially gelatinizing comprises blanching, and the shearing occurs for a period of at least 2 minutes and at a temperature of at least 55°C.

3. The method of claim 1 , wherein the shearing comprises multiple shear stages, each of the shear stages comprising different shear times and conditions.

4. 2. The method of claim 1, wherein the shear occurs in the presence of the oil, the oil comprising coconut oil, hydrogenated palm oil, cocoa butter, shea butter, or a combination thereof.

5. The method of claim 1 , wherein the shearing occurs in the presence of the native starch and / or the modified starch.

6. The method of claim 1, wherein the solidifying comprises maintaining the liquid potato product in the mold at 1° C. to 20° C. for at least 5 days.

7. 10. The method of claim 1, further comprising preheating the initial potato feed and / or the gelatinized potato feed to a temperature of at least 65°C prior to said shearing.

8. 10. The method of claim 1, wherein the dairy analog exhibits a maximum load of at least 100 grams measured 15 days after said setting when measured with a Brookfield CTX Texture Analyzer equipped with a TA2 / 1000 probe.

9. 10. The method of claim 1 , wherein the liquid potato product has a particle fineness of less than 125 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020).

10. A dairy analog produced by the method of claim 1.

11. 1. A method for producing a dairy analog comprising: (a) providing an initial potato supply comprising a plurality of potatoes; (b) at least partially gelatinizing at least a portion of said initial potato feed, thereby forming a gelatinized potato feed; (c) shearing at least a portion of said gelatinized potato feed at a temperature of at least 25° C., thereby forming a liquid potato product; providing a mechanical work of at least 100 kJ / kg when the shear is measured over a period of 30 minutes or less; The shear is as follows: (i) at least one oil; or (ii) occurring in the presence of at least one native starch and / or one or more modified starches; forming a liquid potato product having a particle fineness of less than 125 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020); (d) introducing at least a portion of the liquid potato product into a mold; (e) solidifying the liquid potato product in the mold, thereby forming the dairy analog; The method wherein said dairy analog exhibits a maximum load of at least 100 grams measured 15 days after said setting when measured with a Brookfield CTX Texture Analyzer fitted with a TA2 / 1000 probe.

12. 12. The method of claim 11, wherein the partially gelatinizing comprises blanching, and the shearing occurs for a period of at least 2 minutes and at a temperature of at least 55°C.

13. The method of claim 11 , wherein the shearing comprises multiple shear stages, each of the shear stages comprising different shear times and conditions.

14. 12. The method of claim 11, wherein the shear occurs in the presence of the oil, the oil comprising coconut oil, hydrogenated palm oil, cocoa butter, shea butter, or a combination thereof.

15. The method of claim 11 , wherein the shearing occurs in the presence of the native starch and / or the modified starch.

16. 12. The method of claim 11, wherein the solidifying comprises maintaining the liquid potato product in the mold at 1° C. to 20° C. for at least one day.

17. 11. The method of claim 10, further comprising preheating the initial potato feed and / or the gelatinized potato feed to a temperature of at least 65°C prior to said shearing.

18. A dairy analog produced by the method of claim 11.

19. a dairy analog formed from a liquid potato product, said dairy analog exhibiting a maximum load of at least 100 grams measured 15 days after said setting when measured with a Brookfield CTX Texture Analyzer fitted with a TA2 / 1000 probe; The liquid potato product comprises: (a) a composition comprising potatoes and water; (b) Below, (i) at least one oil exhibiting a melting point in the range of 23° C. to 45° C.; or (ii) at least one native starch and / or modified starch, the native and modified starches comprising an amylose content of less than 19 percent by weight, based on the total weight of the starch; (c) A dairy analog having a particle fineness of less than 125 micrometers as measured with a BYK-Gardner 2512 Metal Grind Gauge (PD-250) in accordance with ISO 1524 (2020).

20. 20. The dairy analog of claim 19, wherein the liquid potato product comprises the oil, the oil comprising coconut oil, hydrogenated palm oil, cocoa butter, shea butter, or combinations thereof.

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