Egg substitute food and method for producing the same

Abstract

To provide a method for producing an egg substitute food.SOLUTION: Mixing protein microbial biomass powder with water to obtain a wet mixture, hydrating the wet mixture at room temperature, mixing the wet mixture at high speed, hydrating the mixed wet mixture at 6 degrees Celsius, and mixing the hydrated wet mixture with oil at high speed; A method comprising emulsifying a combined wet mixture, homogenizing the emulsified combined wet mixture, heating the homogenized wet mixture at 85 °C to 90 °C, and adding sodium chloride (NaCl) and citric acid to the heated wet mixture and mixing to a pH of 3.5 to 4.0.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to substitutes for animal-derived meat products, and more particularly to egg substitute foods. [Background technology]

[0002] In recent years, an increasing number of health-conscious consumers are seeking nutritious, healthy, and sustainable foods that minimize adverse effects on physical health. Traditionally, the human diet has consisted of meat (beef, poultry, pork, fish, etc.) and plants (legumes, rice, etc.) to provide the necessary protein, carbohydrates, fat, vitamins, and minerals in appropriate proportions. Furthermore, the biggest challenge to meat availability is population growth, as increasing meat production has environmental impacts. This has resulted in the ability to clone natural products in this century, one of which is the successful reproduction of traditional foods using plant-based products, which then appeals to a wider range of consumers who do not consume meat and its products, including vegetarians, vegans, and some non-vegetarians who are trying to reduce their meat consumption. The global food industry is therefore being called upon to adapt to relatively sustainable and healthier alternatives to animal-derived meat products (e.g., eggs).

[0003] Eggs, in particular, are versatile, nearly ubiquitous, and highly nutritious. However, eggs have many drawbacks. For example, the fat and cholesterol they contain can harm heart health and contribute to prostate cancer. Furthermore, excessive consumption of egg white protein can lead to kidney disease and kidney stones. Typical substitutes for eggs are egg-like plant-based products produced from plants such as soybeans, corn, and peanuts. Furthermore, these egg-like plant-based products may be high in fiber, low in saturated fat, and contain antioxidants. However, these egg-like plant-based structures are not well known because they are very difficult to replicate. Furthermore, egg-like plant-based products have a typical bean off-flavor, making them difficult to flavor to mimic egg-like taste. Also, egg-like plant-based products contain iron, vitamin D, and vitamin B 12 They are poor in other nutrients, such as choline and antioxidants like lutein and zeaxanthin, which play important roles in bone health, cognition, energy, pregnancy, and eye health.

[0004] Currently, the development of meat substitutes and related products is progressing by utilizing microbial cells such as yeast and algae. In this regard, techniques such as cell culture followed by homogenization have been used to produce egg-like plant-based products. However, egg-like plant-based products lack egg-like texture and other characteristics and are not suitable for consumption by mammals such as humans and animals, mainly due to poor digestibility. Normally, when such egg-like plant-based products are ingested, the epithelial cells of the intestine produce a mucus layer that acts as a physical barrier to prevent endotoxins from passing into the bloodstream. However, in cases of endotoxemia and leaky gut syndrome, endotoxins can enter the bloodstream through the breakdown of mucous membranes, causing health risks ranging from allergic to fatal toxic reactions.

[0005] Therefore, in view of the foregoing discussion, there is a need to overcome the shortcomings associated with conventional techniques for producing egg-like plant-based products with egg-like texture and improved digestibility. Summary of the Invention [Problem to be solved by the invention]

[0006] The present disclosure aims to provide a method for producing an egg replacer food product. The present disclosure also aims to provide a composition of the egg replacer food product. It is an object of the present disclosure to provide a solution that at least partially overcomes the problems encountered in the prior art. [Means for solving the problem]

[0007] In one aspect, the present disclosure provides a method of making an egg replacer food product, the method comprising: - mixing the protein microbial biomass powder with water to obtain a wet mixture; - hydrating the wet mixture at room temperature; - mixing the wet mixture at high speed; - hydrating the mixed wet mixture at 6 degrees Celsius; - mixing the hydrated wet mixture with oil at high speed to emulsify the mixed wet mixture; - homogenizing the emulsified mixed wet mixture; - heating the homogenized wet mixture at 85°C to 90°C; and - adding sodium chloride (NaCl) and citric acid to the heated wet mixture and mixing to adjust the pH to 3.5 to 4.0.

[0008] In another aspect, the present disclosure provides an egg replacer food product, the food product comprising: - 76% to 78% water, - 9% to 10% protein microbial biomass powder; - 0.7% to 1.1% sodium chloride (NaCl); - 9% to 10% oil and food containing.

[0009] Embodiments of the present disclosure substantially eliminate or at least partially address the aforementioned problems in the prior art and enable an efficient method of producing egg replacer food products that contain all vitamins, minerals and antioxidants and have a more egg-like texture without the bean off-flavor.

[0010] Additional aspects, advantages, features and objects of the present disclosure may become apparent from the drawings and detailed description of illustrative embodiments, taken in conjunction with the appended claims.

[0011] It will be appreciated that features of the present disclosure are capable of being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.

[0012] (Drawing summary) The foregoing summary, as well as the following detailed description of exemplary embodiments, will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the disclosure, there are shown in the drawings exemplary configurations of the disclosure. However, the disclosure is not limited to the particular methods and instrumentalities disclosed herein. Moreover, those skilled in the art will appreciate that the drawings are not to scale. Wherever possible, like elements will be designated by like numerals.

[0013] In the accompanying drawings, underlined numbers are used to represent the item the underlined number is located above or adjacent to. Non-underlined numbers refer to items identified by a line connecting the non-underlined number to the item. When a number is not underlined and has an associated arrow, the non-underlined number is used to identify the general item to which the arrow is pointing.

[0014] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following figures: [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 shows a flow chart illustrating steps in a method for producing an egg replacer food product according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0016] The following detailed description sets forth embodiments of the present disclosure and how they can be made. While several ways of making the present disclosure are disclosed, those skilled in the art will recognize that other embodiments are possible for making or carrying out the present disclosure.

[0017] In one aspect, embodiments of the present disclosure provide a method of making an egg replacer food product, the method comprising: - mixing the protein microbial biomass powder with water to obtain a wet mixture; - hydrating the wet mixture at room temperature; - mixing the wet mixture at high speed; - hydrating the mixed wet mixture at 6 degrees Celsius; - mixing the hydrated wet mixture with oil at high speed to emulsify the mixed wet mixture; - homogenizing the emulsified mixed wet mixture; - heating the homogenized wet mixture to 85 to 90 degrees Celsius; and - adding sodium chloride (NaCl) and citric acid to the heated wet mixture and mixing to adjust the pH to 3.5 to 4.0.

[0018] In another aspect, embodiments of the present disclosure provide an egg replacer food product, the food product comprising: - 76% to 78% water, - 9% to 10% protein microbial biomass powder; - 0.7% to 1.1% sodium chloride (NaCl); - 9% to 10% oil and food containing.

[0019] The present disclosure provides a method for producing the egg replacer food product and the egg replacer food product, which includes utilizing a proteinaceous microbial biomass powder derived from a microbial biomass and mixing it with a liquid, salt, and spices to produce the egg replacer food product. Advantageously, this method is efficient and less labor intensive. Furthermore, the egg replacer food produced using said method is an animal-free, vegan and plant-based egg substitute made with turmeric and mung bean protein to create an egg-like texture and flavor, making it suitable for vegetarian and vegan consumers. Additionally, advantageously, meat analog ingredients are easily digestible by humans and animals and provide high quality protein, iron, and vitamins such as B12. For simplicity, hereinafter the term "egg replacer" will be used interchangeably with the term "finished product."

[0020] As used herein throughout this disclosure, the term "protein microbial biomass powder" refers to a dietary supplement extracted from bacterial, yeast, fungal, and algal microorganisms, e.g., in dehydrated form. As used herein, the term "biomass" refers to a measure of the amount of living components (i.e., bacteria) in a sample. Generally, protein microbial biomass powders provide a concentrated protein source that contains no or negligible amounts of carbohydrates, fats, or other compounds. Alternatively, protein microbial biomass powders may contain protein and be enriched with compounds such as vitamins and minerals such as calcium and iron. It can be appreciated that protein is essential for muscle building and recovery. Therefore, protein consumption must be monitored to provide the required amount of protein in the diet while avoiding excessive protein intake over the long term, which can affect the kidneys, liver, bone and calcium balance in the body.

[0021] The method includes mixing a proteinaceous microbial biomass powder with water to obtain a wet mixture. Optionally, the proteinaceous microbial biomass powder comprises the isolated bacterial strain deposited under VTT-E-193585 or a derivative thereof. The isolated bacterial strain or derivative thereof is typically a Gram-negative bacterium (which does not retain the crystal violet stain used in the Gram staining method). It can be appreciated that the isolated bacterial strain or derivative thereof is genetically stable and capable of long-term growth under a wide range of process conditions, from optimal to stressful conditions. Advantageously, the bacterial strain or its derivatives contain iron and vitamin B12. Furthermore, the final product obtained from the strain or its derivatives does not have bean off-flavors and is therefore easier to flavor. Potentially, the final product may contain umami (i.e., savory or "meaty") flavors.

[0022] Optionally, protein microbial biomass powder is produced through upstream and downstream processing. As used herein, the term "downstream processing" refers to the process following the selection of microbial cells, e.g., bacterial cells, that produce high yields of protein. Generally, downstream processing consists of unit operations that facilitate the production of a final product in a way that is useful to the consumer (human or animal). In this regard, downstream processing involves subjecting bacterial cells to physiological, chemical and mechanical conditions to provide a safe end product suitable for consumer use.

[0023] In one embodiment, first, in downstream processing, bacterial cells are cultured by gas fermentation to obtain microbial biomass, where the bioreactor culture is the main unit in which bacterial cells loaded from a stock solution into the bioreactor are cultured under controlled conditions. In particular, raw materials necessary for cell growth, such as carbon dioxide (CO2), hydrogen (H2), oxygen (O2), ammonia (NH3), minerals, etc., are supplied to the bioreactor. Furthermore, cell growth within the bioreactor is continuous, and once the target cell density is reached, bacterial cell microbial biomass is discharged from the bioreactor. Furthermore, the bacterial cells after reaching the target cell density are cultured, and at least one of batch culture and / or continuous culture is selected to obtain the required cell density in the microbial biomass. Second, the microbial biomass is concentrated by separating the liquid (growth medium) and solid phases and removing the liquid phase. At this stage, the microbial biomass is concentrated 10-fold, containing approximately 5% dry matter compared to the initial 0.7% dry matter, due to the removal of the liquid phase. Finally, the microbial biomass is dried to obtain a protein microbial biomass powder. Typically, drum drying is used to obtain the protein microbial biomass powder. In this document, drum drying is used to dry a liquid phase at relatively low temperatures on a rotating, large-volume drum, producing a sheet of drum-dried product.

[0024] Optionally, downstream processing further comprises incubating the microbial biomass with heat treatment at a temperature of from 55°C to 75°C for 15 minutes up to 40 minutes. Incubations can be carried out at temperatures from, for example, 55, 56, 57, 58, 59, 60, 65, or 70°C to 56, 57, 58, 59, 60, 65, 70, or 75°C, for incubation times of from 15, 20, 25, 30, or 35 minutes to 20, 25, 30, 35, or 40 minutes. In particular, incubation at 60, 61, 62 or 65°C up to 61, 62, 65 or 68°C affects the hydrolysis of cell wall structures, leading to partial removal of lipopolysaccharide-containing components (or "endotoxins") during isolation. Advantageously, hydrolysis of the microbial cell wall (or "cell wall") results in a final product with a 10-1000-fold lower endotoxin response. Furthermore, incubation at the above temperature range prevents the growth of undesired microbial cells, kills the bacterial cells, and results in a pure culture of only the desired bacterial cells.

[0025] Optionally, the downstream processing further comprises homogenizing the bacterial cells of the microbial biomass prior to the drying step. As used herein, the term "homogenization" refers to any means of physically disrupting bacterial cell walls. As used herein, homogenization can be performed using high-pressure homogenization (HPH), a physical or mechanical process in which a sample stream is forced through a high-pressure homogenizer to homogenize bacterial cells and / or reduce the particle size of any components. Typically, homogenization is performed at 900 bar.

[0026] Generally, homogenization at least partially breaks down the cell walls of bacterial cells. Furthermore, homogenization makes the final product more meat-like. Beneficially, the breakdown of cell walls facilitates digestion. Furthermore, proteins can be obtained by high-pressure homogenization or, in some cases, grinding. Furthermore, homogenization is carried out at pressures ranging from 800, 900, 1000, 1200, or 1500 bar to 900, 1000, 1200, 1500, or 2000 bar. Here, the final product is improved by reducing endotoxin levels. Additionally, milling disrupts bacterial cells and releases proteins.

[0027] Optionally, the feed for cultivation by gas fermentation comprises at least one selected from CO2, methane (CH4), H2, O2, NH3 or at least one mineral, wherein minerals including ammonium, phosphate, potassium, sodium, vanadium, iron, sulfate, magnesium, calcium, molybdenum, manganese, boron, zinc, cobalt, selenium, iodine, copper and / or nickel are added.

[0028] In one embodiment, the pH of the microbial biomass is adjusted from 7.4, 7.5, or 7.6 to 7.5, 7.6, or 8.0 after separating the liquid phase. It can be appreciated that an appropriate pH is an essential element for a growth medium that promotes bacterial growth. Here, the pH is adjusted before or after homogenization. If the pH of the protein microbial biomass powder is less than 7.0, the extrusion will not have a meat-like texture.

[0029] The method involves hydrating the wet mixture at room temperature, where the protein microbial biomass powder is placed in a container with water and immersed in the water, and the protein microbial biomass powder absorbs water, where a hydration time ranging from at least 90 or 100 minutes to 100 or 110 minutes is required.

[0030] This method involves high-speed mixing of the wet mixture, where the protein microbial biomass powder is very dry and therefore requires high-speed mixing, preferably in the range of 1,000 to 28,000 revolutions per minute (rpm), for 1 minute before homogenization. High-speed mixing can be performed, for example, at 1,000, 1,100, 1,500, 2,000, 5,000, 10,000, or 20,000 revolutions per minute, up to 1,500, 2,000, 5,000, 10,000, 20,000, or 28,000 revolutions per minute. Furthermore, high speed mixing is required to obtain a uniform dispersion, particularly in industrial scale high speed or shear mixers such as Silverson, IKA Ultra Turrax, etc.

[0031] The method includes hydrating the mixed wet mixture at 6° C., where the mixed wet mixture is hydrated until fully hydrated. Optionally, the mixed wet mixture is allowed to stand overnight, for at least 16 hours, for the protein microbial biomass powder to absorb water.

[0032] The method includes mixing the hydrated wet mixture with oil at high speed and emulsifying the mixed wet mixture, wherein the oil is any neutral tasting oil. Further, the oil is selected to be at least one of rapeseed oil, sunflower oil, or soybean oil because of its neutral taste. Advantageously, the addition of oil creates an emulsion that allows for the formation of the final product, and no further emulsifiers need to be added since the protein microbial biomass powder already contains them. Additionally, the oil enhances the gelling effect that occurs during the final heating. Typically, high speed mixing may be performed using an IKA Ultra Turrax homogenizer at 20,000 revolutions per minute (rpm) for 2 minutes. Finally, in the final cooking step, the emulsion is heated to form a structure called an "emulsion gel." Oil is used to mimic the nutritional value of real eggs, especially since real eggs contain 10% fat. Furthermore, oil can make the final product smoother and improve its mouthfeel.

[0033] The method includes homogenizing the emulsified mixed wet mixture, wherein the homogenization is carried out at from 500 bar to 1200 bar. The homogenization can be carried out, for example, at from 500, 600, 700, 800, 900, or 1000 bar to 500, 600, 700, 800, 900, 1000, or 1200 bar. In one example, the emulsified wet mixture may be homogenized in two runs at 500 bar or one run at 800 bar. Additionally, if a batch machine is used, the mixed wet mixture is mixed at least twice and run at at least 800 bar. In particular, if the pressure is lower than 500 bar, the resulting emulsified wet mixture will not have a good structure, whereas for pressures above 500 bar, a high-pressure homogenizer such as an SPX FLOW homogenizer is used.

[0034] The method involves heating the homogenized wet mixture to 85° C. to 90° C. The homogenized wet mixture can be heated, for example, to 85, 86, or 87° C. to 86, 87, or 90° C., where bacteria are removed by pasteurization or sterilization. Further heating results in a stable, homogenous structure. In particular, heating is important for the formation of the final texture. Furthermore, adding salt (NaCl) before heating results in a scrambled egg-like structure upon heating. If the homogenized wet mixture is not heated, the scrambled egg-like structure will not be obtained in the final heating step. Heating the protein unfolds, promoting its precipitation by citric acid, which then lowers the pH, bringing the protein closer to its isoelectric point and making it insoluble in water, causing precipitation.

[0035] The method includes adding sodium chloride (NaCl) and citric acid to the heated wet mixture and mixing to achieve a pH of 3.5 to 4.0, which can be, for example, 3.5, 3.6, 3.7, 3.8, or 3.9 to 3.6, 3.7, 3.8, 3.9, or 4.0. Here, a frying pan may be used to heat the wet mixture, particularly heating is a necessary step, from 85, 86, 87, 88, or 89°C to 86, 87, 88, 89, or 90°C before adding NaCl and citric acid. Furthermore, if the final product is a liquid egg product in a jar and the consumer prepares scrambled eggs at home, heating is performed in a frying pan. If the final product is ready-to-eat scrambled eggs, heating can be performed in an industrial oven, microwave, stove, or other heating system.

[0036] Optionally, the wet mixture having a pH of 3.5 to 4.0 comprises: - 76% to 78% water, - 9% to 10% protein microbial biomass powder; - 0.7% to 1.1% sodium chloride (NaCl); - 9% to 10% oil.

[0037] Optionally, in this regard, the combined wet mixture having a pH of from 3.5, 3.6, 3.7, 3.8, or 3.9 to 3.6, 3.7, 3.8, 3.9, or 4.0 may contain water that is, for example, 76 or 77% to 77 or 78% of the total combined wet mixture. Additionally, the amount of sodium chloride (NaCl) may be, for example, from 0.7, 0.8, 0.9, or 1.0% to 0.8, 0.9, 1.0, or 1.1%. Wet mixes mixed using the above parameters resulted in a better egg-like structure without noticeable off-flavors.

[0038] Furthermore, if salt and citric acid are added after heating, the mixed wet mixture needs to be heated again to obtain a scrambled egg-like structure. However, if salt and citric acid are added before heating, no further heating is necessary. It can be seen that citric acid aids precipitation. Furthermore, sodium chloride may also promote precipitation.

[0039] The present disclosure also relates to said egg replacer food product. The various embodiments and variants disclosed above apply mutatis mutandis to the egg replacer food product.

[0040] Optionally, the oil is selected to be at least one of rapeseed oil, sunflower oil, and soybean oil. The use of oils with a neutral taste can improve the flavor and mouthfeel of the egg replacer food.

[0041] Optionally, the proteinaceous microbial biomass powder comprises the isolated bacterial strain deposited under VTT-E-193585 or a derivative thereof.

[0042] Optionally, an egg replacer food product is obtained by the method described above.

[0043] Detailed Description of the Drawings Referring to FIG. 1 , a flowchart 100 illustrating steps of a method for making an egg replacer food product according to one embodiment of the present disclosure is shown. In step 102, protein microbial biomass powder is mixed with water. In step 104, the wet mixture is hydrated at room temperature. In step 106, the wet mixture is mixed at high speed. In step 108, the mixed wet mixture is hydrated at 6° C. In step 110, the hydrated wet mixture is mixed at high speed with oil to emulsify the mixed wet mixture. In step 112, the emulsified wet mixture is homogenized. In step 114, the homogenized wet mixture is heated to 85° C. to 90° C. In step 116, NaCl and citric acid are added to the heated wet mixture, and the wet mixture is mixed to achieve a pH of 3.5 to 4.0.

[0044] Steps 102, 104, 106, 108, 110, 112, 114, and 116 are merely exemplary, and other alternatives may be provided, such as one or more steps being added, one or more steps being deleted, or a different sequence in which one or more steps are provided, without departing from the scope of the claims.

[0045] Modifications can be made to the embodiments of the present disclosure described above without departing from the scope of the disclosure, which is defined by the claims. The terms "including," "comprising," "incorporating," "have," "is," and the like, used to describe and claim the present disclosure, are intended to be construed in a non-exclusive manner, i.e., allowing for the presence of items, components, or elements not expressly recited. References to the singular should also be construed to relate to the plural.

Claims

1. 1. A method for producing an egg replacer food product, the method comprising: - mixing the protein microbial biomass powder with water to obtain a wet mixture; - hydrating said wet mixture at room temperature; - mixing said wet mixture at high speed; - hydrating the mixed wet mixture at 6°C; - mixing the hydrated wet mixture with oil at high speed to emulsify the mixed wet mixture; - homogenizing the emulsified mixed wet mixture; - heating the homogenized wet mixture at 85 to 90 degrees Celsius; and - adding sodium chloride (NaCl) and citric acid to the heated wet mixture and mixing to achieve a pH of 3.5 to 4.

0.

2. 10. The method of claim 1, further comprising heating the mixed wet mixture to a pH of 3.5 to 4.

0.

3. The total weight of the wet mixture having a pH of 3.5 to 4.0 includes: - 76% to 78% water, - 9% to 10% of said protein microbial biomass powder; - sodium chloride (NaCl) from 0.7% to 1.1%; 3. The method of claim 1 or 2, comprising: 9% to 10% oil.

4. The method according to any one of claims 1 to 3, wherein the oil is selected to be at least one of rapeseed oil, sunflower oil, soybean oil.

5. 5. The method according to any one of claims 1 to 4, wherein the homogenization is carried out at from 500 to 1200 bar.

6. 6. The method of any one of claims 1 to 5, wherein the proteinaceous microbial biomass powder comprises the isolated bacterial strain deposited under number VTT-E-193585 or a derivative thereof.

7. The protein microbial biomass powder is produced through upstream and downstream processing, the downstream processing comprising: - cultivating bacterial cells by gas fermentation to obtain microbial biomass; - concentrating the microbial biomass by separating the liquid and solid phases of the microbial biomass and removing the liquid phase; - drying the microbial biomass to obtain the proteinaceous microbial biomass powder.

8. 8. The method of claim 7, wherein the downstream processing further comprises incubating the microbial biomass with heat treatment at a temperature of from 55°C to 75°C for 15 to 40 minutes.

9. 9. The method of claim 7 or 8, wherein the downstream processing further comprises homogenizing the bacterial cells of the microbial biomass prior to the drying step.

10. 10. The method of claim 9, wherein the homogenization is carried out at a pressure of from 800 bar to 2000 bar in at least one run.

11. The feed for the culture by gas fermentation is CO ２ , C.H. ４ , H ２ , O ２ , N.H. ３ The method according to any one of claims 7 to 10, comprising at least one mineral selected from the group consisting of:

12. 12. The method of any one of claims 7 to 11, further comprising adjusting the pH of the microbial biomass to 7.4 to 8.0 after separating the liquid phase.

13. - 76% to 78% water, - 9% to 10% protein microbial biomass powder, - sodium chloride (NaCl) from 0.7% to 1.1%; - Egg replacer containing 9% to 10% oil.

14. 14. The egg replacer food product of claim 13, wherein the oil is selected to be at least one of rapeseed oil, sunflower oil, soybean oil.

15. 15. The egg replacer food of claim 13 or 14, wherein the proteinaceous microbial biomass powder comprises the isolated bacterial strain deposited as VTT-E-193585 or a derivative thereof.

16. An egg substitute food obtained by the method according to any one of claims 1 to 12.

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