Method and apparatus for manufacturing an edible product

Abstract

A method of manufacturing an edible product, the method comprising: (a) obtaining a plurality of first edible layers composed of a first edible material, each of the first edible layers having one or more soles defined by being more elastic with respect to shear in a direction transverse to the longitudinal axis than in a direction along the longitudinal axis, each of the first edible layers defining a plane containing the longitudinal axis; (b) obtaining a second edible material having adhesive properties; (c) distributing a portion of the second edible material to form a first adhesive layer on one of the plurality of first edible layers; (d) forming a first stack of the first edible layers with the first adhesive layer between each two first edible layers while the longitudinal axes of most of the first edible layers are substantially parallel to each other; (e) slicing the first stack into a plurality of mats along one or more slicing planes, each slicing plane being parallel to the longitudinal axis and angled with respect to the plane of the first edible layer intersected by the slicing plane, whereby each mat comprises a plurality of elongated sole strands of the first edible material having the second edible material therebetween.

Description

Technical Field

[0001] The present disclosure relates to the manufacture of methods and apparatus for producing edible products, and more particularly to the manufacture of alternative meat products including stacks of edible layers adhered to one another.

Background Art

[0002] Due to environmental and ethical factors, there is a great interest in meat analogs (also referred to herein as alt-meat or alternative meat or meat analogs). More and more people are switching their consumption preferences without actually giving up the taste preference of real meat. The range of desired alternative products starts from minced meat and chicken nuggets and includes whole muscle cuts.

[0003] One of the elements that is difficult to reconstruct in the alt-meat industry is the fibrous nature of meat. In real meat, muscle fibers, together with their connective tissue envelopes, form a highly anisotropic and robust structure that contributes to the chewy texture of whole muscle. Current methods for making meat analogs by additive manufacturing techniques such as WO 2020 / 152689, WO 2021 / 095034, and WO 2021 / 191906 lack the efficiency required to make this manufacturing method operationally suitable. Accordingly, it is an object of the present invention to provide a system and method for mass-producing meat analogs.

Summary of the Invention

[0004] The present invention relates to a system and method for manufacturing a meat-like product. As described below, the term meat relates to any animal tissue of a mammal, fish, seafood, or poultry. The term "meat analog" as referred to below relates to a food having a similar internal arrangement of vegetarian-derived elements that are formed at least partially similarly to animal tissue.

[0005] An exemplary method of manufacturing an edible product is (a) Obtaining a plurality of first edible layers composed of a first edible material, each of the first edible layers having one or more soles defined by being more elastic with respect to shear in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis, and each of the first edible layers defining a plane containing the longitudinal axis; (b) Obtaining a second edible material having adhesive properties; (c) Distributing a portion of the second edible material to form a first adhesive layer on one of the plurality of first edible layers; (d) Forming a first stack of first edible layers with the first adhesive layer between each two first edible layers while the longitudinal axes of most of the first edible layers are substantially parallel to each other; (e) Slicing the first stack into a plurality of mats along one or more slicing planes, each slicing plane being parallel to the longitudinal axis and angled with respect to the plane of the first edible layer intersected by the slicing plane, whereby each mat contains a plurality of elongated sole strands from the first edible material having the second edible material therebetween.

[0006] It should be understood that herein, for the purposes of this description, the longitudinal axis is considered to extend along the fibers of the sole.

[0007] It should be further understood that herein, for the purposes of this description, in some examples, one or more soles can be defined as having a higher tensile strength in a direction transverse to the longitudinal axis, particularly in a direction perpendicular to the longitudinal axis, when measured in the direction along the longitudinal axis. For the purposes of this description, this means that it is easier to tear one or more soles when the soles are stretched in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis.

[0008] It should be further understood that the terms "substantially" and "about" as used herein are to be regarded as indicating tolerances with respect to the corresponding features. For example, "substantially parallel" should be regarded as parallel with a specific tolerance of 0° to 15°. With respect to pressure and / or temperature, "substantially" and / or "about" should be regarded as including a tolerance of 1% to 30% at their respective values. With respect to being at equal distances, "substantially" and / or "about" should be regarded as including a tolerance of 0.1 mm to 5 mm.

[0009] In some examples, a gel material, which may optionally contain a colorant, a flavorant, and / or a fat, can be added as an additional layer in addition to, or instead of, the first adhesive layer of the second edible material. In some examples, the second edible material can contain a gel material. The gel material can have adhesive properties.

[0010] In some examples, the adhesive properties of the second edible material (or the first adhesive layer) can be inherent to the respective materials. In some examples, the adhesive properties of the second edible material (or the first adhesive layer) can be generated thereby after further processing and / or after a period of time following its distribution.

[0011] Another aspect of the present disclosure is an apparatus for forming an alternative meat product that is more elastic with respect to shear in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis, a controller processor, a non-transitory memory configured to store computer instructions executed by the controller processor, a first conveyor for receiving and conveying a sole of a first edible material that extends along the longitudinal axis of the sole and is more elastic with respect to shear in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis, a second conveyor for receiving and conveying a stack of soles, A sensor configured to determine the orientation of each sole, generate sole characteristic information related to the orientation of the sole, and transmit the sole characteristic information to a controller processor; A robot arm configured to pick up a sole from a first conveyor and position a plurality of soles in sole layers that substantially overlap each other on a second conveyor under the control of a controller processor, based on the sole characteristic information, wherein each of the sole layers defines a plane including the longitudinal axis; A binder applicator for applying a first adhesive layer on top of each sole layer; The controller processor controls the robot arm and the binder applicator to form each stack formed of a desired number of sole layers and a first adhesive layer. The device relates to this.

[0012] Any one or more of the following characteristic designs and configurations can be applied separately or in combination to any of the aspects of the present disclosure.

[0013] The method (f) obtaining a third edible material having adhesive properties; (g) distributing a portion of the third edible material to form a second adhesive layer on one of the two or more mats; (h) forming a second stack of the mat and the second adhesive layer, maintaining the mats in substantial overlap with each other and maintaining the orientation of the elongated sole strands along the longitudinal axis.

[0014] The stacking of the mats provides an intersecting arrangement of the first and second adhesive layers, providing a more realistic appearance with a more evenly distributed adhesive layer.

[0015] In some examples, the third edible material can include a gelling material, which can optionally include a colorant, a flavorant, and / or a fat. In some examples, the gelling material can be added to the second adhesive layer of the third edible material, or alternatively as an additional layer, in addition to the second adhesive layer of the third edible material. The gelling material can have adhesive properties.

[0016] In some examples, the adhesive properties of the third edible material (or the second adhesive layer) can be inherent to the respective materials. In some examples, the adhesive properties of the third edible material (or the second adhesive layer) can be generated thereby after further processing and / or after a period of time following its distribution.

[0017] The method can (i) dividing the second stack into smaller segments at various acute angles with respect to a plane parallel to the longitudinal axis to produce smaller segments, (j) stacking the smaller segments with either the second edible material or the third edible material sandwiched therebetween to form an alternative meat mass.

[0018] The smaller segments cut at various acute angles allow the meat mass to have a more realistic appearance with the second and third edible materials extending at various angles and lengths.

[0019] The method can (k) further include shaping the alternative meat mass within a press mold.

[0020] The press mold allows the meat mass to be formed into any desired shape or size that provides a more realistic appearance.

[0021] The third edible material can include the second edible material, thereby simplifying the process by allowing the second and third edible materials to be obtained from the same source and have the same appearance.

[0022] One or more slice surfaces may be perpendicular to the layer surface, providing a uniform appearance where the portions of the first edible material surrounded by the second and third edible materials are at right angles to each other. In some cases, the one or more slice surfaces can be two or more slice surfaces that are at approximately equal distances from each other.

[0023] The fat additive can be added between at least two soles and / or mats. The fat additive provides a more realistic appearance and enhances the taste of the product.

[0024] In some examples, the fat additive can include a gel material, and the gel material can optionally include a colorant and / or a flavorant. In some examples, the gel material can be added in addition to or instead of the fat additive as an additional layer.

[0025] The method can further include marinating the sole to add at least one of moisture, fat, color, flavor, and organic or inorganic nutrients between step (a) and step (b). The marinating can provide a more realistic appearance and enhance the taste of the product.

[0026] The sole can have a thickness of 0.4 mm to 15 mm.

[0027] The method can further include a curing step after each step of forming the stack. Each curing step can include curing the stack under a pressure of about 0.5 Kg / cm 2 for 0.5 to 12 hours.

[0028] In some examples, before some or all of the curing steps, the stack can be subjected to repeated application of a high pressure of about 8 to 10 Kg / cm for 1 to 10 seconds in each repetition. This curing can be carried out for about 2 to 6 hours, and in some examples about 4 hours. For example, the stack can be under a pressure of about 8 to 10 Kg / cm for 1 to 10 seconds in each repetition. 2 2It can intermittently receive high pressure, and such curing can completely cure the stack in about 4 hours. Therefore, the curing time is significantly shortened. Furthermore, in such an example, by intermittently receiving high pressure, a "temporary mass" that can be more easily handled for processes including movement and cutting is generated. Additionally, the mass retains its shape under high pressure and can be cut (sliced) without waiting for the curing to be completed.

[0029] The method can be carried out at a temperature of 0°C to 8°C, thereby storing the product.

[0030] Step (h) is to stack a plurality of mats in an overlapping manner to produce an elongated stepped mat, and the third edible material is at least between the overlapping portions of the adjacent overlapping mats, and applying a binding material to the upper surface of the elongated stepped mat, and lifting up the elongated stepped mat to produce a cylindrical meat roll.

[0031] The cylindrical meat roll can be cut at the round part to provide an attractive appearance for offering.

[0032] In an alternative embodiment, step (h) is to arrange a plurality of mats in a continuous manner to produce an elongated mat, and optionally, the third edible material is at least above and / or between the boundary portions of the adjacent mats, and applying a binding material to the upper surface of the elongated stepped mat, and lifting up the elongated stepped mat to produce a cylindrical meat roll.

[0033] The sole source portion in the mat extends from one end to the other end, and the binding material is around and between the sole strands, thereby providing a uniform appearance in the longitudinal direction.

[0034] The method can further include curing each cylindrical meat roll.

[0035] The method can further include covering a plurality of cylindrical meat rolls with an additional binding material and joining the plurality of cylindrical meat rolls to form a block roll while maintaining the elongated sole strands of the plurality of cylindrical meat rolls substantially parallel to each other.

[0036] The first edible layers can be substantially parallel to each other. The first edible layers can be substantially at 0° to 10° with respect to each other. The first edible layers can be substantially at 0° to 20° with respect to each other. The first edible layers can be substantially at 0° to 30° with respect to each other. The first edible layers can be substantially at 0° to 45° with respect to each other. Arranging the first edible layers at different angles enables the cross-section of the product to be arranged to meet the customer's requirements.

[0037] The mats can be substantially parallel to each other. The mats can be substantially at 0° to 10° with respect to each other. The mats can be substantially at 0° to 20° with respect to each other. The mats can be substantially at 0° to 30° with respect to each other. The mats can be substantially at 0° to 45° with respect to each other. Arranging the mats at different angles enables the cross-section of the product to be arranged to meet the customer's requirements.

[0038] The first edible material and / or the second edible material can be simple edibles. The first edible material and / or the second edible material become edible through a preparation process.

[0039] Another aspect is an apparatus for forming an alternative meat product that is more elastic in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis, a controller processor, and a non-transitory memory configured to store computer instructions executed by the controller processor, A first conveyor for receiving and conveying a sole of a first edible material that extends along the longitudinal axis of the sole and is more elastic against shear in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis, A second conveyor for receiving and conveying a stack of soles, A sensor configured to determine the orientation of each sole, generate sole characteristic information related to the orientation of the sole, and transmit the sole characteristic information to a controller processor, A robot arm configured to pick up a sole from the first conveyor and position a plurality of soles on a first edible layer that is substantially overlapped with each other based on the sole characteristic information and is positioned on the second conveyor under the control of the controller processor. Each of the first edible layers defines a layer plane including the longitudinal axis. The robot arm, A binder applicator for applying a first adhesive layer on each sole layer, Relates to an apparatus in which a controller processor controls the robot arm and the binder applicator to form a first stack formed of a desired number of first edible layers and first adhesive layers.

[0040] The apparatus can further include a mold attached on a second conveyor configured to receive a first edible layer. The mold can be formed having an open top. The binder applicator is movable relative to the second conveyor and is configured to pass back and forth over the mold to apply a first adhesive layer on each first edible layer. The mold can ensure a uniform product structure without leakage or bleeding of the layer. By moving the binder applicator, further control for applying a uniform layer of the adhesive material becomes possible.

[0041] The apparatus can further comprise a mold mounted on a second conveyor configured to receive a first edible layer, and the second conveyor can be configured to reciprocate the mold under a binder applicator to apply a first adhesive layer over each sole layer. The mold can ensure a uniform product structure without leakage or bleeding of the layers. By moving the second conveyor, the binder applicator can be stably held, ensuring a uniform layer of adhesive material.

[0042] The apparatus can further comprise a cutting unit configured to supply a required number of half-soles or partial soles, and the robot arm can be configured to pick up from the cutting unit and place into the mold as needed to complete each sole layer.

[0043] The apparatus can further comprise a block manufacturing device configured to cut a first stack into mats and stack the mats onto a second stack, and the block manufacturing device comprises a slicer configured to receive the first stack from the second conveyor and slice the first stack into mats, an operator configured to supply the first stack to a meat slicer and / or direct the mats out from the meat slicer, a third conveyor configured to receive the mats from the slicer and transfer them, a first applicator disposed above the third conveyor and configured to apply a second adhesive layer to each of the mats traveling thereunder, and a mat stacker configured to receive the mats from the third conveyor and stack them, the mat stacker being configurable to continuously weigh the second stack of mats and release the second stack when the second stack reaches a target weight.

[0044] The stacking of the mats provides an alternating arrangement of the first and second adhesive layers, providing a more realistic appearance with a more uniformly distributed adhesive layer.

[0045] The apparatus may further comprise a second applicator provided on a third conveyor configured to dispense a fat additive. The fat additive can provide a more realistic appearance and enhance the taste of the product. In some examples, the fat additive can include a gelling material, which can optionally include a colorant and / or a flavorant. In some examples, the gelling material can be added to the fat additive or, alternatively, added as an additional layer in addition to or instead of the fat additive.

[0046] The apparatus may further comprise a waste removal tray configured to collect at least a first slice of the first stack and discard it or reuse it in some other product.

[0047] The apparatus may further comprise a press mold configured to shape the second stack into a desired shape, and a buffer conveyor extending from the mat stacker for transferring the stacked pile to the press mold.

[0048] It should be understood herein that the press mold can be configured to process the stack according to any of the curing processes described herein.

[0049] The apparatus may further comprise a conveyor cleaning box configured to wash excess waste from the third conveyor. In other embodiments, the cleaning element and / or system can be adjacent to other parts of the apparatus, including other conveyors, dispensers, cutting elements, etc., in the same manner.

[0050] Another aspect relates to an alternative meat product manufactured by any one of the methods or apparatuses described above.

Brief Description of the Drawings

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DETAILED DESCRIPTION OF THE INVENTION

[0052] The present invention relates to a method and system for producing alternative meat-like food products. In some cases, the alternative meat-like food products may be purely vegan, and in other cases, the alternative meat-like food products may be vegetarian. In still other cases, the meat-like food products can include non-vegan additives. The way in which the food products resemble animal tissue is by having an internal orientation of a plurality of discrete elements adhered to one another, with each of the plurality of discrete elements being configured to have the same orientation as the other elements and being held together with the other discrete elements in a manner similar to the way muscle fibers are arranged and held together in animal tissue.

[0053] Generally, the food products are formed by stacking a first layer of food materials and joining them together to form an arrangement of stacked layers adhered to one another. The stack can be subjected to cutting to form a plurality of second layers, each having high-protein strands joined to one another. The produced second layers mimic the structure of muscle fibers along a two-dimensional array, and all the strands of the first layer have substantially the same orientation, like the muscle tissue of meat, and are connected to one another, for example by an adhesive material, like the connective tissue of meat.

[0054] Referring to FIGS. 1 to 5, in the first step, a plurality of first edible "sole" layers 12 (hereinafter referred to as the first edible layer 12 or the sole layer 12 interchangeably in this specification) composed of a first edible material are obtained, hereinafter referred to as "sole", each having one or more soles 11. Each sole 11 is defined by exhibiting anisotropic physical properties when measuring physical parameters from its three different essentially orthogonal directions. In some cases, the physical parameters can be anisotropic texture properties such as hardness, adhesiveness, chewiness, Young's modulus, and cohesiveness. In a particular case, the physical parameter is more elastic with respect to shear in a direction transverse to the longitudinal axis LA than in the direction along the longitudinal axis LA. In an example of the subject matter of the present disclosure, each sole 11 can include a plurality of edible protein fibers (F) extending mainly along an axis parallel to the longitudinal axis LA. Each of the first edible "sole" layers 12 defines a plane including the longitudinal axis LA. In some examples, the first edible material forming the first edible layer is a texturized vegetable protein.

[0055] A second edible material having cohesive properties is also obtained to form the first adhesive layer or binder layer 14. The second edible material can be configured to mechanically or chemically sufficiently adhere and / or bond the first edible "sole" layer 12 to each other at various temperatures and conditions, such that portions of the first edible "sole" layer 12, after being cut, are prevented from separating from each other after being held together by the second edible material. In some examples, the second edible material can include a gel material, which can optionally include a colorant, a flavorant, and / or a fat, and / or can have cohesive properties, and can be added as an additional layer in addition to, or as an alternative layer to, the first adhesive layer of the second edible material. In some examples, the first adhesive layer can be composed of two or more layers, and one or more of these layers can include the gel material described above. In some examples, the cohesive properties of the second edible material (or the first adhesive layer 14) can be inherent to the respective materials. In some examples, the cohesive properties of the second edible material (or the first adhesive layer 14) can be generated thereby after further processing and / or after a period of time following its distribution.

[0056] As shown in FIG. 1A, in some embodiments, individual pieces of the first edible material may be immersed in a marinade 20, such as a vat 21, etc., a suitable container, to add at least one of moisture, fat, color, and flavor. The sole 11 can have a thickness of 0.4 mm to 15 mm, preferably 2 mm to 8 mm, more preferably 2 mm to 5 mm. If the raw sole 11 is too thick, any step of cutting the raw sole 11 to produce a sole having the desired thickness may be added. Each sole 11 is defined as being more resilient to shear in a direction transverse to the longitudinal axis than in the direction along the longitudinal axis. In some embodiments, each sole 11 is composed of elongated sole strands extending along or parallel to the longitudinal axis.

[0057] Referring to FIG. 1B, a plurality of soles 11 are stacked on a plurality of sole layers 12 (alternatively referred to herein as a first edible layer) within an oriented stack 13 (alternatively referred to herein as a first stack) having a first adhesive layer 14 between each of the plurality of sole layers 12. Each adhesive layer 14, for example, gluten or a gluten-based substance, is added between each sole layer 12 during the preparation of the stack 13. Typically, 4 to 12% by weight of the stack 13 is constituted by the adhesive layer 14. The adhesive layer 14 can typically be added by spreading, spraying, atomizing, dripping, or placing a complete adhesive panel having a thickness of 0.01 to 1 mm.

[0058] Stack 13 may be constructed as a single or multiple adjacent columns of soles 11, or with the sole layer 12 offset inside a dedicated type 15 (e.g., classifiable as type 15a or 15b shown in FIGS. 2A and 2B, respectively) which may be referred to as an enlarged cartridge, as shown in FIGS. 2A and 2B, to form a wider stack 13' (FIG. 2A) or 13'' (FIG. 2B). Each first edible "sole" layer 12 in the wider stack 13' or 13'' includes a plurality of soles, e.g., 4 to 8 soles, arranged and aligned side by side, with, for example, a flat side facing down and the abutting planar edge being the longer side. As used herein, the terms "wide" and "wider" are to be understood as being used herein to indicate that stacks 13' and 13'' are wider than stack 13 formed by a plurality of adjacent columns of soles 11. In some embodiments, each sole layer 12 is composed of an elongate sole strand from each sole 11 extending along or parallel to the longitudinal axis and to each other. If the number of soles 11 required to fill the sole layer 12 within type 15b is an integer, one sole layer 12 may be made from all the soles 11, and the next sole layer 12 may have half soles 11 at each end (or any other ratio, as long as the total length of both cut soles is one sole). If the number of soles 11 is not an integer within type 15a, each sole layer 12 may be arranged such that all the soles 11 are adjacent to each other, and then, to complete the sole layer 12, soles 11 cut at one end may be arranged. The cut soles 11 may have ends alternating with the adjacent stacked sole layers 12. Each of the first edible layers defines a plane including the longitudinal axis of each sole 11.

[0059] In some embodiments, the first edible layers, i.e., the sole layers 12, are substantially parallel to each other. Alternatively, the first edible layers, i.e., the sole layers 12, are substantially 0° to 10°, substantially 0° to 20°, substantially 0° to 30°, or substantially 0° to 45° to each other. Arranging the first edible layers at different angles allows the cross-section of the product to be arranged to meet the customer's desires.

[0060] In some embodiments, each adhesive layer 14 can consist of gluten only or a gluten-based adhesive. In other embodiments, each adhesive layer can include different adhesive materials and can be mixed with other materials, such as pea protein, egg protein, starch, and vitamin C, to provide stronger adhesion or enhance flavor and / or nutritional value. The amount of adhesive added is typically calculated to be 5-15% of the weight of the previous sole layer, and in some examples 7-12%. However, depending on the added chemicals, the amount of adhesive can be reduced to 0-6% of the weight of the previous sole layer.

[0061] In some embodiments, the first edible material and / or the second edible material is a simple edible. However, in alternative embodiments, the first edible material and / or the second edible material becomes edible through a preparation process.

[0062] At any step, stack 13 can be set aside for the "curing" of the adhesive within adhesive layer 14. In the case of pure gluten, the curing time can be 0.5-12 hours in a temperature range of approximately -10°C to 16°C. The inventors have found that curing in a temperature range of approximately -7°C to 4°C can reduce over-freezing on one side of the mass and minimize contamination on the other side. This rate may vary considering the size, weight, and composition of the stack, as well as other variables, to optimize the curing of stack 13. Stack 13 can also be left to cure under moderate pressure, for example, typically 0.5 Kg / cm 2 and may be left to cure under this pressure.

[0063] In some examples, prior to curing, the stack can be subjected to repeated application of high pressure of about 8-10 Kg / cm 2 for 1-10 seconds in each repetition. This curing can be carried out for about 2-6 hours, and in some examples about 4 hours. For example, the stack can be subjected to repeated application of high pressure of about 8-10 Kg / cm 2It can intermittently receive high pressure, and such curing can completely cure the stack in about 4 hours. Therefore, the curing time is significantly shortened. Furthermore, in such an example, by intermittently receiving high pressure, a "temporary mass" that can be more easily handled for processes including movement and cutting is generated. Additionally, the mass holds its shape under high pressure and can be cut (sliced) without waiting for the curing to be completed.

[0064] Next, the compressed pile may be cooled until the core of the stack 13 reaches a temperature of 0°C to 8°C, preferably about 4°C. Time and pressure are required for the adhesive to be effective.

[0065] Referring to FIG. 3, an automatic sole stacking system 31 comprises a first conveyor 32 for receiving and transporting individual soles 11 to form, for example, an apparatus for forming alternative meat products as described above in this specification. The first conveyor 32 transports each sole 11 under a vision sensor 33, which identifies, measures, determines the orientation of each sole 11, and transmits sole characteristic information to a controller processor 35, optionally along with additional characteristic information of each sole 11. The controller processor 35 executes computer instructions stored in a non - transitory memory 36 configured to control the sole stacking system 31. At least one robot arm 37, under the control of the controller processor 35, picks up one or more of the soles 11 at a time, and positions each of the picked - up soles 11 onto one of a dedicated surface and / or mold 15 positioned on a second conveyor 38 to form a sole layer 12 (referred to interchangeably herein as the first edible layer 12). After each sole layer 12 is completed, the controller processor 35 then moves the mold 15 and activates a binder applicator 39 to apply an adhesive layer 14 (referred to interchangeably herein as the first adhesive layer 14) over each sole layer 12. The binder applicator 39 may be mounted on a linear rail such that the binder applicator 39 can pass back and forth over the mold 15 to apply the adhesive layer 14, or the second conveyor 38 may transport and position the mold 15 under the binder applicator 39 to apply the adhesive layer 14. After each sole layer 12 and adhesive layer 14 are formed, the controller processor 35 may repeat these steps for subsequent sole layers 12 and adhesive layers 14 until a stack 13 having a desired dimension (e.g., height) and / or number of sole layers 12 is formed. The complete mold 15 may then be transported via the second conveyor 38. In the case of molds 15a or 15b that require half - soles or partial soles 11, a cutting unit 40 is provided to supply the required number of half - soles or partial soles 11, and the robot arm 37 picks up from the cutting unit and positions them within the mold 15 as required to complete the sole layer 12.

[0066] Referring to FIG. 4, each stack 13 of the sole layer 12 is rotated by 90° and arranged on a slicing machine. Each stack 13 is sliced at an angle, for example perpendicularly, with respect to the plane of the sole layer 12 and the adhesive layer 14, while still maintaining an alternating sole layer 12 and adhesive layer 14 pattern, to produce a plurality of fiber mats 41. Each mat 41 has a length of 80 mm to 150 mm, preferably 110 mm to 130 mm, and a width of 50 mm to 160 mm, preferably 55 mm to 100 mm. The thickness of each mat 41 may be 0.5 mm to 5 mm.

[0067] In another embodiment of the subject matter of the present disclosure, each of the second layers is joined to another second layer to form a second stack of a three-dimensional array of sole strands connected by an adhesive material, thereby further mimicking the structure of actual animal tissue. In some cases, the second layers of the second stack can have different arrangements of the sole strands and the adhesive material to provide further diversity to the formed meat substitute.

[0068] An example of the formation of the second stack is shown in FIG. 5. The first exemplary finishing process includes re-stacking the mats 41 on top of each other in parallel, with all strands being in substantially the same direction, to form a stacked pile 42 (alternatively referred to herein as the second stack 42). A second plurality of adhesive layers 44, composed of a third edible material, such as an adhesive like gluten, are disposed between each adjacent pair of stacked mats 41. In some embodiments, a fat additive 45 is added between the mat 41 layers during the stacking process. The fat additive 45 may be incorporated into the second adhesive layer 44, deposited as an independent layer parallel to the adhesive layer 44, or incorporated into the stacked pile 42 in some other suitable manner. The first adhesive layer 14 may extend perpendicular to the second plurality of adhesive layers 44, or at any suitable or desired angle. As described with reference to FIG. 3, the same stacking process and machinery as when stacking the sole layer 12 can be used to stack the mats 41. Typical amounts of the fat additive and the adhesive include 2% to 15%, preferably 8% to 12% of the weight of each mat 41.

[0069] In some examples, the third edible material can include a gel material, which can optionally include a colorant, a flavorant, and / or a fat, and / or can have adhesive properties, and can be added as an additional layer or as an alternative layer in addition to the second adhesive layer of the third edible material. In some examples, the second adhesive layer can be composed of two or more layers, and one or more of these layers can include the gel material described above.

[0070] In some examples, the adhesive properties of the third edible material (or the second adhesive layer 44) can be inherent to the respective materials. In some examples, the adhesive properties of the third edible material (or the second adhesive layer 44) can be generated thereby after further processing and / or after a period of time following its dispensing.

[0071] In some examples, the fat additive can include a gelling material, which can optionally include a colorant and / or a flavorant, and can be added as an additional layer in addition to, or as an alternative layer to, the fat additive layer. In some examples, the fat additive layer can be composed of two or more layers, and one or more of these layers can include the gelling material described above.

[0072] The stacked pile 42 may be cured as described above. Alternatively, the stacked pile 42 can undergo a two-stage curing. The first step includes a partial curing as described above. In the second step, the stacked pile 42 is inserted into a press mold 51 that presses and shapes the stacked pile into a specific shape. Then, the press mold 51 is inserted into a cooling environment for additional curing. In some cases, the additional curing can include cooling the mold at 4 °C for 2 to 8 hours. The press mold 51 forms the stacked pile 42 into any desired shape, for example, a shape that is aesthetically pleasing and / or similar to a desired meat product.

[0073] In some examples, the stack can be cured by applying repeated high pressures of about 8 - 10 Kg / cm for 1 - 10 seconds in each repetition. This curing can be carried out for about 2 - 6 hours, and in some examples, about 4 hours. For example, the stack can intermittently receive a high pressure of about 8 - 10 Kg / cm for 1 - 10 seconds in each repetition, and such curing can completely cure the stack in about 4 hours. Thus, the curing time is significantly shortened. Further, in such examples, by intermittently receiving the high pressure, a "temporary mass" that can be more easily handled for processes including movement, cutting, etc. is generated. Additionally, the mass holds its shape under high pressure and can be cut (sliced) without waiting for the curing to be completed. 2 In some examples, the stack can be cured by applying repeated high pressures of about 8 - 10 Kg / cm for 1 - 10 seconds in each repetition. This curing can be carried out for about 2 - 6 hours, and in some examples, about 4 hours. For example, the stack can intermittently receive a high pressure of about 8 - 10 Kg / cm for 1 - 10 seconds in each repetition, and such curing can completely cure the stack in about 4 hours. Thus, the curing time is significantly shortened. Further, in such examples, by intermittently receiving the high pressure, a "temporary mass" that can be more easily handled for processes including movement, cutting, etc. is generated. Additionally, the mass holds its shape under high pressure and can be cut (sliced) without waiting for the curing to be completed. 2 In some examples, the stack can be cured by applying repeated high pressures of about 8 - 10 Kg / cm for 1 - 10 seconds in each repetition. This curing can be carried out for about 2 - 6 hours, and in some examples, about 4 hours. For example, the stack can intermittently receive a high pressure of about 8 - 10 Kg / cm for 1 - 10 seconds in each repetition, and such curing can completely cure the stack in about 4 hours. Thus, the curing time is significantly shortened. Further, in such examples, by intermittently receiving the high pressure, a "temporary mass" that can be more easily handled for processes including movement, cutting, etc. is generated. Additionally, the mass holds its shape under high pressure and can be cut (sliced) without waiting for the curing to be completed.

[0074] In some embodiments, the low temperature is not necessarily for faster curing, but is required for food preservation. Referring to FIG. 6A, the cured stacked pile 42 of the mat 41 may be trimmed to create a clean edge. As a result, an alternative meat mass 61 is obtained. The meat mass 61 (or lump or stacked pile) may be further divided into homogeneous or geometrically distinct segments 62 for packaging, transportation, and sale (FIG. 6B).

[0075] Referring to FIG. 7, the lump manufacturing apparatus 100 is configured to cut the stack 13 into the mat 41 and stack the mat 41 into a stacked pile 61. First, the slicer 101 receives the stack 13 from, for example, the automatic sole stacking system 31 and slices the stack 13 into the mat 41. In some embodiments, the slicer 101 slices the stack 13 along one or more slicing planes, each of the slicing planes being inclined at the same angle with respect to the layer plane, whereby each mat 41 includes a plurality of elongated sole strands (11A) from a first edible layer having a second edible material therebetween. The lump manufacturing apparatus 100 may be automated under the control of a controller processor 135 (which may be the same or different from the controller processor 35) configured to execute computer instructions stored in a non-transitory memory 136 (which may be the same or different non-transitory memory as the memory 36).

[0076] An operator 102, such as a pneumatic finger, is provided to enable the controller processor 135 to supply the stack 13 to the meat slicer 101 and / or direct the mat 41 from the meat slicer 101 to the conveyor 103, and the conveyor may be composed of one or more conveyors operating together to form a single production line. A debris removal tray 104 may be provided to collect and discard the first few slices of each stack 13 or reuse them for some other product.

[0077] The first applicator 106, for example a duster, is arranged above the conveyor 103 and is configured to apply a plurality of second adhesive layers 44, for example an adhesive powder such as gluten, to the mat 41 running thereunder. In some embodiments, the first applicator 106 is installed on a moving arm or support so as to be able to move to the mat 41 as required. The second applicator 107 may be provided above a different part of the conveyor 103 than the first applicator 106 of the conveyor 103 for dispensing the fat additive 45. The second applicator 107 may be a duster or similar device for dispensing "sensory fat", or an applicator (such as a P.C.P. pump) configured to dispense "visual fat". In some cases, the first applicator 106 and the second applicator 107 can be arranged to be interchangeable with respect to the conveyor 103.

[0078] The mat stacker 108 is configured to receive and stack the mat 41 from the conveyor 103. The mat stacker 108 may also continuously weigh each stack of mats 41, and when the stacked pile 61 reaches the target weight or dimension, the mat stacker stops stacking the mat 41 and sends the pile of mats 41 forward on the conveyor 103 or a different conveyor. In some embodiments, the mats 41 are substantially parallel to each other. Alternatively, the mats 41 are substantially 0° to 10° with respect to each other, substantially 0° to 20° with respect to each other, substantially 0° to 30° with respect to each other, or substantially 0° to 45° with respect to each other. Arranging the mats 41 at different angles makes it possible to arrange the cross-section of the stacked pile 61 product to meet the customer's requirements. In the present embodiment of FIG. 7, the conveyor 103 includes a stopper 109 that prevents the stack of mats 41 from leaving the mat stacker 108. However, the stack of mats 41 may be prevented from leaving the mat stacker 108 by other means, such as one of a plurality of conveyors constituting the conveyor 103.

[0079] The buffer conveyor 110 extends from the end of the mat stacker 108, i.e., the conveyor 103, and enables an operator to collect the stacked piles 61 and transfer them to the press mold 51 as required. For example, a conveyor cleaning box 111 composed of a scraper and / or a rotary brush may be provided at a convenient position along the conveyor 103 to clean excess waste from the conveyor 103. In some embodiments, a control box 112 is provided to house a controller processor 135, a memory 136, and any other electronic devices, pneumatic systems, drivers, etc. as required. A display screen 113 may be provided to display the state of the lump manufacturing apparatus 100, its various components, and other parameters necessary for the control and operation of the system, such as the speed of the conveyor 103, the weight of the currently stacked pile 61, and the amount of binder in the first applicator 106.

[0080] Referring to FIGS. 8A-8D, in some embodiments, the cured meat lump 61 is further divided into smaller segments by cutting or tearing the cured meat lump 61 at various acute angles with respect to the plane of the second adhesive layer 44 parallel to the longitudinal axis of the fibers constituting the sole 11 to create smaller segments 71 as shown in FIGS. 8A and 8B. The smaller segments 71 may be separated and stacked with a plurality of third adhesive layers 74 (FIG. 8C) to form an alternative meat lump 75. The alternative meat lump 75 may be placed in a press mold according to the structure resulting in the desired final result. FIG. 8D shows an arbitrarily selected method. The mold 15 is placed aside, for example, typically under a pressure of 0.5 Kg / cm 2 for the curing of the second adhesive layer 44 at a temperature of 0°C to 8°C, preferably about 4°C. As a result, an alternative meat lump 75 with sub-divisions mimicking smaller and less symmetrical "muscle" groups is obtained. The alternative meat lump 75 may be packaged, transported, and sold as is, or may be subjected to further processing, for example, cut into segments 62 as described above.

[0081] Referring to FIGS. 9A - 9C, a second exemplary finishing process is shown which utilizes the mat 41 of FIG. 4 and is manufactured as described above with reference to FIGS. 1 - 3. A binding material 84, such as an edible adhesive, is applied to a portion proximate to one end of each mat 41, for example about 1 / 3, except for the upper mat 41, to form a rectangle of adhesive that can be parallel to the longitudinal axis of the fibers from the sole 11. The mats 41 are stacked so as to overlap like roof panels to form an essentially elongated stepped mat 81, and the binding material 84 is between the overlapping portions of the adjacent stacked mats 41.

[0082] Next, a coating 85 of a binding material, such as an edible adhesive like gluten, is applied to the upper part of the elongated stepped mat 81 to cover the remaining portion of the mat 41 that remains exposed, for example about 2 / 3. Next, if desired, a fat additive 45 may be added to the long mat 81. Next, the elongated stepped mat 81 is tightly wound (FIG. 10A) to form a cylindrical meat roll 91 as shown in FIGS. 10B and 10C, in which the fibers extend from one end to the other end and the binding materials 84 and 85 are around and between them. The meat roll 91 may be cured in a press mold, for example, typically under a pressure of 0.5 Kg / cm 2 at a temperature of 0°C - 8°C, preferably about 4°C.

[0083] Referring to FIGS. 11A and 11B, some meat rolls 91 may be covered with an additional binding material 124, such as an adhesive powder like gluten, to form a mass roll 121. The mass roll 121 may be placed in a press mold for proper final shaping. The mass roll 121 may be cured in a press mold, for example, typically under a pressure of 0.5 Kg / cm 2 at a temperature of about 0°C - 8°C, preferably about 4°C. The resulting mass roll 121 is an alternative meat having a finer subdivision into smaller "muscle" groups.

[0084] There can be various ways of making rolls. Wrapping around a "classical mass", wrapping around a "clustered mass", wrapping around a "roll - grouped mass", and any other combination of the above.

Claims

Claim 1 A method for manufacturing an edible product, the method comprising: (a) obtaining a plurality of first edible layers composed of a first edible material, each of the first edible layers having one or more soles defined by being more elastic with respect to shear in a direction transverse to the longitudinal axis than in a direction along the longitudinal axis, and each of the first edible layers defining a plane containing the longitudinal axis; (b) obtaining a second edible material having adhesive properties; (c) distributing a portion of the second edible material to form a first adhesive layer on one of the plurality of first edible layers; (d) forming a first stack of the first edible layers with the first adhesive layer between each two first edible layers while the longitudinal axes of most of the first edible layers are substantially parallel to each other; (e) slicing the first stack into a plurality of mats along one or more slicing planes, each of the slicing planes being parallel to the longitudinal axis and angled with respect to the plane of the first edible layer intersected by the slicing plane, whereby each mat includes a plurality of elongated sole strands of the first edible material having the second edible material therebetween; A method comprising the above steps. Claim 2 (f) obtaining a third edible material having adhesive properties; (g) distributing a portion of the third edible material to form a second adhesive layer on one of the plurality of mats; (h) forming a second stack of the mat and the second adhesive layer, maintaining the mats substantially overlapping each other and maintaining the orientation of the elongated sole strands along the longitudinal axis; The method according to claim 1, further comprising the above steps. Claim 3 (i) dividing the second stack into smaller segments at various acute angles with respect to the plane parallel to the longitudinal axis to produce smaller segments; (j) stacking the smaller segments with either the second edible material or the third edible material sandwiched therebetween to form a meat substitute block; The method according to claim 2, further comprising the above steps. Claim 4 The method according to claim 3, further comprising (k) shaping the meat substitute block in a press mold. Claim 5 The third edible material includes the second edible material, and the method according to any one of claims 2 to 4.

6. Step (h) is to stack the plurality of mats in an overlapping manner to produce an elongated stepped mat, and the third edible material is at least between the overlapping portions of the adjacent overlapping mats, and applying a binding material to the upper surface of the elongated stepped mat, and lifting up the elongated stepped mat to produce a cylindrical meat roll, and the method according to any one of claims 2 to 5 is performed by.

7. Step (h) is to arrange the plurality of mats in a continuous manner to produce an elongated mat, and optionally, the third edible material is at least above and / or between the boundary portions of the adjacent mats, and applying a binding material to the upper surface of the elongated mat, and lifting up the elongated mat to produce a cylindrical meat roll, and the method according to any one of claims 2 to 5 is performed by.

8. The sole strands in the mat extend from one end to the other end, and the binding material is around and between the sole strands, and the method according to claim 6 or 7.

9. The method according to any one of claims 6 to 8, further comprising curing each cylindrical meat roll.

10. The method according to any one of claims 6 to 9, further comprising covering the plurality of cylindrical meat rolls with an additional binding material and joining the plurality of cylindrical meat rolls to form a block roll while maintaining the elongated sole strands of the plurality of cylindrical meat rolls substantially parallel to each other.

11. The adhesion characteristics of the second adhesive layer are inherent in the respective materials, or are generated by the respective materials after further processing and / or after a period of time after the distribution of the respective materials, and the method according to any one of claims 2 to 10.

12. The mats are substantially parallel to each other, and the method according to any one of claims 2 to 11.

13. The mats are substantially at 0° to 10° with respect to each other, and the method according to any one of claims 2 to 11.

14. The mats are substantially at 0° to 20° with respect to each other, and the method according to any one of claims 2 to 11.

15. The method according to any one of claims 2 to 11, wherein the mats are substantially 0° to 30° relative to each other.

16. The method according to any one of claims 2 to 11, wherein the mats are substantially 0° to 45° relative to each other.

17. The method according to any one of claims 1 to 16, wherein the one or more slice surfaces are two or more slice surfaces that are substantially equidistant from each other.

18. The method according to any one of claims 1 to 17, further comprising providing a fat additive between at least two soles and / or mats.

19. The method according to any one of claims 1 to 18, further comprising marinating the sole to add at least one of moisture, fat, color, flavor, and organic or inorganic nutrients between step (a) and step (b).

20. The method according to any one of claims 1 to 19, wherein the sole has a thickness of 0.4 mm to 15 mm.

21. The method according to any one of claims 1 to 20, further comprising a curing step after each step of forming the stack.

22. Each hardening step includes hardening the stack under a pressure of about 0.5 Kg / cm ２ for 0.5 to 12 hours, the method according to claim 21.

23. The method according to any one of claims 1 to 22, wherein the method is performed at a temperature of 0°C to 8°C.

24. The method according to any one of claims 1 to 23, wherein the adhesion characteristics of the first adhesive layer are inherent to the material or are generated by the material after further processing and / or after a period of time after dispensing of the material.

25. The method according to any one of claims 1 to 24, wherein the first edible layers are substantially parallel to each other.

26. The method according to any one of claims 1 to 24, wherein the first edible layers are substantially 0° to 10° relative to each other.

27. The method according to any one of claims 1 to 24, wherein the first edible layers are substantially 0° to 20° relative to each other.

28. The method according to any one of claims 1 to 24, wherein the first edible layers are substantially 0° to 30° relative to each other.

29. The method according to any one of claims 1 to 24, wherein the first edible layers are substantially 0° to 45° relative to each other.

30. The method according to any one of claims 1 to 29, wherein the first edible material and / or the second edible material is simple edible.

31. The method according to any one of claims 1 to 29, wherein the first edible material and / or the second edible material becomes edible by a preparation process.

32. An apparatus for forming an alternative meat product that is more elastic with respect to shear in a direction transverse to the longitudinal axis than in a direction along the longitudinal axis, the apparatus comprising: a controller processor; a non-transitory memory configured to store computer instructions executed by the controller processor; a first conveyor for receiving and conveying the sole of a first edible material that extends along the longitudinal axis of the sole and is more elastic with respect to shear in a direction transverse to the longitudinal axis than in a direction along the longitudinal axis; a second conveyor for receiving and conveying a stack of soles; a sensor configured to determine the orientation of each sole, generate sole characteristic information related to the orientation of the sole, and transmit the sole characteristic information to the controller processor; a robot arm configured to pick up the sole from the first conveyor and position a plurality of the soles in a first edible layer that substantially overlaps with each other on the second conveyor based on the sole characteristic information, wherein each of the first edible layers defines a layer plane including the longitudinal axis; a binder applicator for applying a first adhesive layer on each first edible layer. The apparatus, wherein the controller processor controls the robot arm and the binder applicator to form a first stack formed of a desired number of the first edible layers and the first adhesive layers.

33. The apparatus according to claim 32, further comprising a mold attached to the second conveyor configured to receive the first edible layer, the mold being formed with an open top, the binder applicator being movable relative to the second conveyor and configured to pass back and forth over the mold to apply a binder layer on each first edible layer.

34. The apparatus according to claim 32, further comprising a mold mounted on the second conveyor configured to receive the sole layer, wherein the second conveyor is configured to reciprocate the mold under the binder applicator for applying the first adhesive layer on each first edible layer.

35. The apparatus according to any one of claims 32 to 34, further comprising a cutting unit configured to supply a required number of half soles or partial soles, wherein the robot arm is configured to pick up from the cutting unit and place in the mold as required to complete each sole layer.

36. The apparatus further comprises a mass manufacturing device configured to cut the first stack into mats and stack the mats on a second stack, the mass manufacturing device comprising: a slicer configured to receive the stack from the second conveyor and slice the stack into mats; an operator configured to supply the first stack to a meat slicer and / or direct the mat out of the meat slicer; a third conveyor configured to receive and transfer the mat from the slicer; a first applicator disposed above the third conveyor and configured to apply a second adhesive layer to each of the mats traveling thereunder; a mat stacker configured to receive and stack the mat from the third conveyor 103, the mat stacker being configured to continuously weigh the second stack of mats and release the second stack when the second stack reaches a target weight, the apparatus according to any one of claims 32 to 35.

37. The apparatus according to claim 36, further comprising a second applicator provided on the third conveyor and configured to distribute a fat additive.

38. The apparatus according to claim 37, further comprising a waste removal tray configured to collect at least a first slice of each first stack and discard it or reuse it for some other product.

39. a press mold configured to shape the second stack into a desired shape; a buffer conveyor extending from the mat stacker for transferring the second stack to the press mold; The apparatus according to any one of claims 36 to 38, further comprising

40. The apparatus according to any one of claims 36 to 39, further comprising a conveyor cleaning box configured to clean excess waste from the third conveyor.

41. An alternative meat product manufactured by the method according to any one of claims 1 to 31.

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