Fluid injection method for altering the functional properties of proteins in direct expansion extrusion molding.

Abstract

In certain embodiments, the present invention provides a method for producing an extruded food product, comprising the steps of: (a) introducing a fluid component containing a liquid component and a protein component to form a slurry into an extruder to form a hydrated dough; (b) subjecting the hydrated dough to controlled heat, shear, and pressure conditions within the extruder to form a modified dough; and (c) extruding the modified dough to form an extruded food product. In certain embodiments, the present invention provides a method for producing a food product, comprising the steps of: (a) injecting a fluid component containing a liquid component and a protein component to form a slurry into an extruder; (b) subjecting the fluid component to controlled heat, shear, and pressure conditions to form a modified dough; and (c) extruding the modified dough to form an extruded food product. In certain embodiments, extruded foods and extruded food products produced by these methods are also provided.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims priority to U.S. Provisional Application No. 63 / 457,024, filed on April 4, 2023. The entire content of the application mentioned above is hereby incorporated by reference into this specification.

Background Art

[0002] Background Direct expansion extrusion (extrusion) is a process that uses heat and pressure to create expanded snacks. Breakfast cereals, chips, snack curls, etc. are often made using this technology.

[0003] Conventionally, extrusion is performed by first adding powder into a chamber, where it is hydrated into dough and then conveyed through the chamber using one or two screws. Next, the dough is subjected to strong heat and pressure and extruded from the outlet end, where the dough expands and puffs into its own shape. Refer to Figure 1. Chemically, this extrusion process can be complex because how the dough interacts with heat and pressure can change dramatically when the properties of the dough (viscosity, moisture, thermal stability, etc.) change. For this reason, some types of ingredients, such as proteins, are extremely difficult to use in an extruder.

[0004] Proteins tend to be difficult to use in an extruder for many reasons. Many proteins form gels when heated, which can clog the equipment. Also, in many cases, it is difficult to mix proteins and liquids in the chamber to form a uniform dough. Furthermore, proteins tend to become a dry, hard shell when heated and dried, which prevents the product from being a desirable snack. Phase separation, off - odor, and browning are also common problems with heating protein doughs in the extrusion process, which can have a negative impact on these products.

[0005] Therefore, an improved fluid injection method is needed to modify the functional properties of proteins in direct expansion extrusion molding. [Overview of the Initiative]

[0006] overview In certain embodiments, the present invention provides a method for producing an extruded food product, comprising the steps of: (a) introducing a fluid component containing a liquid component and a protein component to form a slurry into an extruder to form a hydrated dough; (b) subjecting the hydrated dough to controlled heat, shear, and pressure conditions within the extruder to form a modified dough; and (c) extruding the modified dough to form an extruded food product.

[0007] In certain embodiments, the present invention provides a method for producing food ingredients, comprising the steps of (a) injecting a fluid component comprising a liquid component and a protein component to form a slurry into an extruder; (b) subjecting the fluid component to controlled heat, shear, and pressure conditions to form a modified dough; and (c) extruding the modified dough to form an extruded food ingredient.

[0008] In certain embodiments, the present invention provides an extruded food product manufactured by (a) introducing a fluid component containing a liquid component and a protein component to form a slurry into an extruder to form a hydrated dough; (b) subjecting the hydrated dough to controlled heat, shear, and pressure conditions within the extruder to form a modified dough; and (c) extruding the modified dough to form an extruded food product.

[0009] In certain embodiments, the present invention provides an extruded food product manufactured by (a) injecting a fluid component comprising a liquid component and a protein component to form a slurry into an extruder; (b) subjecting the fluid component to controlled heat, shear, and pressure conditions to form a modified dough; and (c) extruding the modified dough to form an extruded food product. [Brief explanation of the drawing]

[0010] [Figure 1] A simplified schematic diagram of a conventional extrusion molding process. [Figure 2] An illustrative process flowchart of the novel fluid injection method of the present invention. [Modes for carrying out the invention]

[0011] Detailed explanation The inventors have developed a novel method for modifying proteins to overcome many of the inherent obstacles in extruding proteins. Unlike previous extrusion methods that use powdered protein components, this newly developed method uses fluid protein components.

[0012] The use of fluid proteins is beneficial from both a functional and economic standpoint. From a functional standpoint, drying proteins alters their functional properties; therefore, using proteins as fluids preserves these beneficial functional properties. From an economic standpoint, drying is expensive, labor-intensive, and requires transportation; therefore, using proteins as fluids will reduce costs.

[0013] This technology provides a method for modifying proteins before introduction into direct expansion extrusion. This is done by hydrating the product and injecting it in a fluid form, rather than supplying it in powder form. Performing fluid injection alters the properties of the expanded product and dramatically changes how the equipment operates. This method is not intuitively understandable and changes the approach to several aspects of processing. This method overcomes obstacles in direct expansion extrusion of proteins. This technology enables novel protein incorporation in extrusion, the use of new proteins in extrusion, and the formation of novel products using proteins.

[0014] In a specific embodiment of this technology, a protein component is hydrated and modified, and then a fluid component containing the protein component (e.g., modified protein, hydrated functional protein) is directly injected into an extruder. This fluid component can be specially modified according to the properties required for the resulting product. This makes it possible to overcome some of the obstacles to protein extrusion and to utilize some proteins that may not be usable by other methods. A schematic diagram of one embodiment of the process flow of the present invention is provided in Figure 2. This newly developed process is not obvious to those with knowledge of the art of extrusion, because many components used in extrusion expand when exposed to water, and the idea of ​​adding water first to form a fluid component somewhat hinders the initial expansion of many directly expanding components.

[0015] Furthermore, this process needs to be strictly controlled; otherwise, excess water will be incorporated into the product. Excess water in the product prevents it from expanding properly. Those skilled in the art would consider that a fluid modified product contains too much water to form a dough, as the water present in the substance binds to hydrating components and is not readily absorbed by components such as starch. However, despite some potential objections, the inventors have found that this technique can be used to inject a portion of a protein in the form of a modified fluid ("fluid component").

[0016] Performing fluid injection dramatically alters the properties of the extrusion process and the resulting expanded product. This process overcomes obstacles in direct expansion extrusion of proteins. This technology enables novel protein incorporation in extrusion, the use of new proteins in extrusion, and the formation of novel products using proteins.

[0017] Many products used in extrusion molding processes benefit from hydrolysis. Hydrolytic enzymes are commonly used to break down protein molecules into smaller units, which have lower viscosity and higher thermal stability. However, to date, many vegan proteins are not sold as hydrolyzed products or have not been hydrolyzed in the form required for extrusion molding. This technology makes it possible to hydrolyze thermally unstable and high-viscosity proteins (i.e., proteins considered unsuitable for extrusion molding) to produce high-quality extruded products.

[0018] Another difficulty encountered in conventional extrusion processes is that some proteins do not hydrate quickly enough for use in extrusion. Traditionally, these proteins had to be hydrated for several hours before they could be incorporated into the extruder as a fluid.

[0019] This method allows the use of proteins that have never been dried (also known as "fresh" proteins). Many milk proteins undergo dramatic changes after drying, such as changes in emulsifying properties, gelling properties, and binding properties. This process allows fresh proteins (i.e., proteins that have never been dried) to be used in extrusion processes.

[0020] Many extruders require the use of a “preconditioner” to partially moisten and heat the powder before it is injected into the extruder. As used herein, “preconditioning” is defined as the process of subjecting the powder to hydration and heating, typically with 1–25% moisture. Preconditioning aids hydration and enables dough formation. However, preconditioning is time- and energy-intensive, may require specialized equipment, and can be costly. This technology makes it possible to reduce or eliminate the need for a preconditioner.

[0021] Some proteins are not pasteurized before packaging. These proteins are not considered "ready-to-eat" (RTE) and must be heat-treated before consumption. Heat treatment is performed during extrusion, but it is difficult to verify for legal purposes. This method allows customers to pasteurize components that do not meet the RTE requirements without using radiation or other invasive sterilization techniques.

[0022] Fluid injection method for proteins In certain embodiments, the present invention provides a method for manufacturing an extruded food product, comprising the following steps: (a) introducing a fluid component comprising a liquid component and a protein component to form a slurry into an extruder to form a hydrated dough, (b) subjecting the hydrated dough to controlled heat, shear, and pressure conditions within the extruder to form a modified dough, and (c) extruding the modified dough to form an extruded food product.

[0023] In certain embodiments, the present invention provides a method for manufacturing a food ingredient, comprising: (a) injecting a fluid component comprising a liquid component and a protein component to form a slurry into an extruder, (b) subjecting the fluid component to controlled heat, shear, and pressure conditions to form a modified dough, and (c) extruding the modified dough to form an extruded food ingredient.

[0024] Liquid component In certain aspects, the liquid component is an aqueous-based or oil-based fluid, but is not limited thereto. In certain aspects, the liquid component is water. The liquid component can also be an emulsion or suspension of an aqueous-based component and an oil-based or hydrocolloid-based component. In certain aspects, the fluid component is pre-conditioned before injection. In certain aspects, a plurality of fluid components are injected into the extruder to form a hydrated dough. In certain aspects, the fluid component is modified before injection into the extruder.

[0025] Protein In certain embodiments, regardless of whether the protein is originally fresh or in powder form, the protein is a milk protein concentrate, milk protein isolate, non-fat dry milk solids, whey protein concentrate, whey protein isolate, sweet whey product, micellar casein product, acid casein, casein sodium, casein calcium, other casein salts, whey protein phospholipid concentrate (or ProCream®), milk mineral extract containing protein, modified variants of these components (e.g., hydrolysates), other milk solids and their derivatives, but not limited thereto. Further, the protein can be a legume protein concentrate (such as yellow pea, chickpea, etc.), legume protein isolate (such as yellow pea, chickpea, etc.), legume protein powder, broad bean protein concentrate, other lentil or legume proteins, canola protein concentrate, canola protein isolate, chia protein, flax protein (golden or brown variety), soybean protein concentrate, soybean protein isolate, pumpkin protein, sweet potato protein, potato protein, rice protein, or other plant proteins (regardless of whether they are concentrates, isolates, or powders). The protein can also be bovine protein, collagen protein, egg (albumin) protein or derivative, synthetic protein, algal protein, cell mass protein, or insect protein (such as cricket), regardless of whether it is in the form of a concentrate or an isolate.

[0026] In certain embodiments, the protein solids are fresh. As used herein, the term "fresh" when referring to protein solids means that the protein solids have never been dried.

[0027] In certain embodiments, protein components are thermally unstable. As used herein, the term “unstable” means easily altered or destroyed. As used herein, a “thermally unstable protein” is one that can be altered or destroyed at high temperatures, i.e., its form, structure, and / or function are altered or destroyed at high temperatures. In this context, the opposite of unstable is “stable.” As used herein, proteins are considered unstable at temperatures above 60°C.

[0028] Fluid component In certain embodiments, the fluid components forming the slurry include a liquid component and a protein component.

[0029] In certain embodiments, the fluid component comprises about 1–40% by weight of protein components and about 60–99% water (i.e., liquid components). In certain embodiments, the fluid components each contain 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, 35%, 36%, 37%, 38%, 39%, 40% protein solids, and 9 The water content (i.e., liquid component) is 9.9%, 99.8%, 99.7%, 99.6%, 99.5%, 99.4%, 99.3%, 99.2%, 99.1%, 99%, 98%, 97%, 96%, 95%, 94%, 93%, 92%, 91%, 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 79%, 78%, 77%, 76%, or 75%, 74%, 73%, 72%, 71%, 70%, 69%, 68%, 67%, 66%, 65%, 64%, 63%, 62%, 61%, and 60%. In certain embodiments, the fluid component, in terms of percentage of total protein solids or solids of the final extruded product, comprises about 5–10% protein solids and about 90–95% liquid components. In certain embodiments, the fluid component comprises about 15–25% protein solids and about 85–75% fluid. In certain embodiments, the total solids of plant protein are, but not limited to, 15–20% solids, while the total solids of milk protein are, but not limited to, 10–25% solids.

[0030] In certain embodiments, the protein components are hydrated.

[0031] In certain embodiments, the fluid component is hydrolyzed before injection.

[0032] In certain embodiments, the fluid component is cultured before or after injection.

[0033] In certain embodiments, the fluid component is fermented before or after injection.

[0034] Other ingredients In certain embodiments, one or more additional components are combined with or merged with a fluid component to form a fluid component comprising a liquid component and a protein component.

[0035] In certain embodiments, one or more additional components are introduced or injected into the extrusion chamber as additional components.

[0036] In certain embodiments, one or more additional components are proteins, fibers, starches, powders, oils, sweeteners, vitamins, hydrophilic colloids, colorants, and / or processing aids. Processing aids are defined as components used to assist or improve processing properties. In certain embodiments, processing aids are present at concentrations less than 2%. In certain embodiments, processing aids are present at 0%, 0.1%, 0.2%, 0.3%, 0.4%, 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, 1.3%, 1.4%, 1.5%, 1.6%, 1.7%, 1.8%, 1.9%, or 2.0% w / w.

[0037] In certain embodiments, one or more additional components are cultured before or after injection.

[0038] In certain embodiments, one or more additional components are fermented before being combined with the fluid component, or before or after being injected into the extrusion chamber.

[0039] In certain embodiments, one or more additional components are not pre-conditioned before being combined with or injected with the fluid component.

[0040] In certain embodiments, one or more additional components are pre-conditioned before being combined with the fluid component or before being injected.

[0041] In certain embodiments, the fluid component and one or more additional components are combined before being combined with the fluid component or before being injected into the extruder.

[0042] In certain embodiments, the fluid component and one or more additional components are injected separately into the extruder and combined within the extruder.

[0043] Other examples of ingredients include proteins with unique functional properties (e.g., whey, casein salts, gluten, soy, etc.), fibers with unique properties (methylcellulose, lentil fiber, soluble tapioca fiber, corn fiber, etc.), starches with unique properties (rice starch, lentil starch, tapioca starch, etc.), flours with unique properties (corn flour, wheat flour, fine-grained flour, etc.), oils with unique properties (canola oil, vegetable oil, MCT oil, etc.), and processing aids (acidulants, calcium carbonate, preservatives, phosphates, enzymes, desiccants, alkalizing agents, etc.).

[0044] Hydrated fabric In certain embodiments, a hydrated dough is produced containing approximately 40-90% protein and approximately 10-60% liquid components. In certain embodiments, the hydrated dough contains approximately 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, or 90% protein.

[0045] Extrusion molding conditions Conditions such as heat, pressure, and mechanical shear vary depending on the application, protein source, and other components. These conditions will be known to those skilled in the art. For example, protein-reinforced dough is heated to 120°C and extruded under a screw profile with some mechanical resistance at a die pressure of 400 psi. The conditions will vary dramatically depending on the product characteristics and the raw materials used, but these will be known to those skilled in the art.

[0046] Extruded foods and extruded ingredients This technology enables higher levels of protein inclusion than is possible by other methods in many applications. In certain embodiments, the present invention is an extruded food or extruded food ingredient produced by the method described herein. In certain embodiments, the extruded food contains 40-90% protein. In certain embodiments, the extruded food contains 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%, 49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%, 77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, or 90% protein.

[0047] In certain embodiments, the extruded food contains 5 to 95 grams of protein per 100 grams of product. In certain embodiments, the extruded food contains 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 4 Contains 9, 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, or 95 grams of protein.

[0048] The present invention is illustrated below by the following non-limiting embodiments. [Examples]

[0049] Example 1 The following is an example comparing the differences between a conventional high-protein extrusion molding method without fluid injection (see Figure 1) and the novel fluid injection method of the present invention (see Figure 2). There is no difference in the composition of the chips (Table 1). The only difference in this example is that the chips are produced using two different processing methods. As shown in Table 2, the two processing methods resulted in chips with completely different properties.

[0050] (Table 1) Composition of chips TIFF2026519918000001.tif54165

[0051] (Table 2) Changes in processing conditions TIFF2026519918000002.tif28165* Fluid injection without other treatments applied. Shows changes in water absorption and other properties.

[0052] Example 2 In one example, a pea protein concentrate was hydrated to a solid content of 25%, and the material was hydrolyzed over 3 hours to a degree of hydrolysis (DH) of 18%. The material was then injected into an extruder and mixed with a blend of pea protein, starch, and calcium carbonate. When extruded under similar processing conditions, the product was dramatically more watery and noodle-like (indicating that the water that needed to be removed from the product could still be removed). However, removing the water in response to increased water retention resulted in a significantly more cohesive, easier-to-form, more expandable, and softer extruded product. The product could also be reduced to a much lower moisture level, resulting in a dramatically softer and less glassy product. This hydrolysis slurry was also dried and added directly to a hopper; the product expanded slightly more than the control, but was far inferior to the fluid injection treatment in terms of softness, dryness, or expansion.

[0053] Example 3 In another embodiment, milk protein isolate (MPI) was solubilized over 24 hours to a 20% solids content. This MPI was then injected into an extruder to produce protein chips containing MPI, rice starch, and calcium carbonate. The final blend targeted a 40% protein content. The untreated chips were unexpanded, dense, and had a glassy texture. However, complete solubilization of casein in MPI resulted in a product that expanded much better than the control and had a much softer texture. This product also possessed a microcellular structure that facilitated drying.

[0054] Example 4 In another embodiment, pea protein concentrate was hydrated, and the total pH was increased using an alkalizing agent (NaOH) in fluid form. This was then used to create a high-protein application (55% protein) by combining it with pea protein concentrate, tapioca starch, and calcium carbonate. In this application, the change in pH allowed for better solubility of the powder product and further promotion of gelatinization of the overall mixture. The ability to create a dough that solidifies easily and has smooth edges makes it promising for use in more complex shapes.

[0055] The above-described specification and examples fully disclose and enable the implementation of the present invention, but are not intended to limit the scope of the invention, which is defined by the claims appended herein.

[0056] All publications, patents, and patent applications are incorporated herein by reference. While the above specification describes the present invention in relation to its particular embodiments, and many details are provided for illustrative purposes, it will be apparent to those skilled in the art that there is room for additional embodiments of the present invention and that some of the details described herein may be considerably modified without departing from the basic principles of the invention.

[0057] In the context describing this invention, the terms “a,” “an,” and “the,” as well as the use of similar referents, should be interpreted as encompassing both singular and plural forms unless otherwise indicated herein or unless clearly inconsistent with the context. The terms “comprising,” “having,” “including,” and “containing” should be interpreted as unrestricted terms (i.e., “including, but not limited to”) unless otherwise noted herein. The descriptions of value ranges herein are merely intended to serve as abbreviated methods for individually referring to each individual value falling within that range, unless otherwise indicated herein, and each individual value is incorporated herein as if it were individually stated herein. All methods described herein can be performed in any preferred order unless otherwise indicated herein or unless clearly inconsistent with the context. The use of any examples or exemplary language provided herein (e.g., “such as”) is intended solely to clarify the invention and does not limit the scope of the invention unless otherwise claimed. Nothing in this specification should be construed as indicating that any element not claimed is essential for the practice of the invention.

[0058] Embodiments of the present invention are described herein, including the best modes known to the inventors for carrying out the invention. Variations of these embodiments may become apparent to those skilled in the art by reading the foregoing description. The inventors anticipate that those skilled in the art will use such variations as appropriate, and they intend that the invention may be carried out in ways other than those specifically described herein. Accordingly, the invention includes all modifications and equivalents of the subject matter described in the claims appended herein, to the extent permitted by applicable law. Furthermore, in all possible variations thereof, any combination of the above elements is incorporated into the invention unless otherwise shown herein, or unless otherwise clearly inconsistent with the context.

Claims

1. A method for manufacturing extruded food products, comprising the following steps: (a) A step of introducing a fluid component containing a liquid component and a protein component to form a slurry into an extrusion molding machine in order to form a hydrated dough. (b) A step of subjecting the hydrated dough to controlled heat, shear, and pressure conditions in an extruder in order to form a modified dough. (c) A step of extruding the modified dough in order to form an extruded food product. The method, including the method described above.

2. A method for manufacturing food ingredients, (a) A step of injecting a fluid component containing liquid and protein components that form a slurry into an extrusion molding machine. (b) A step of subjecting the fluid component to controlled thermal, shear, and pressure conditions in order to form a modified fabric. (c) A step of extruding the modified dough in order to form an extruded food ingredient. The method, including the method described above.

3. The method according to claim 1 or 2, wherein the fluid component comprises one or more protein components.

4. The method according to any one of claims 1 to 3, wherein the fluid component further comprises fibers, starch, powder, oil, processing aids, sweeteners, and / or colorants.

5. The method according to any one of claims 1 to 4, wherein the fluid component is fermented before or after injection.

6. The method according to any one of claims 1 to 5, wherein the fluid component is pre-conditioned before injection.

7. The method according to any one of claims 1 to 6, wherein the fluid component is modified before being injected into the extrusion molding machine.

8. The method according to any one of claims 1 to 7, wherein step (a) further comprises introducing a fluid into an extrusion chamber.

9. The method according to claim 8, wherein the fluid is an aqueous-based fluid, an oil-based fluid, or an emulsion or suspension of an aqueous-based component and an oil-based or hydrophilic colloid-based component.

10. The method according to claim 9, wherein the fluid is water.

11. The method according to any one of claims 1 to 10, wherein step (a) further comprises introducing an additional component into an extrusion chamber.

12. The method according to claim 6d, wherein the additional components are fiber, starch, powder, oil, processing aids, sweeteners, and / or colorants.

13. The method according to any one of claims 1 to 12, wherein the protein component is fresh.

14. The method according to any one of claims 1 to 12, wherein the protein component is hydrated.

15. The method according to any one of claims 1 to 14, wherein the fluid component comprises about 0.1% to 40% by weight of protein components and about 60% to 99.9% of liquid components.

16. The method according to any one of claims 1 to 15, wherein the liquid component is an aqueous fluid, an oil, a hydrophilic colloid, an emulsion or suspension of an aqueous fluid and an oil, or an emulsion or suspension of an aqueous fluid and a hydrophilic colloid.

17. The method according to any one of claims 1 to 16, wherein the modified dough contains 35 to 80% protein components.

18. An extruded food product manufactured by the method described in any one of claims 1 to 17.

19. The extruded food according to claim 18, comprising 5 to 95 grams of protein per 100 grams of product.

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