Plant-based food product and method for producing the same

Abstract

A method to produce a food product, the method comprising the step of: a) providing a plurality of textured proteins product and a non-textured protein product; b) combining the plurality of textured protein products and the non-textured protein product; c) shaping a resulting combination to form a shaped product; and d) binding the shaped product to form a food product; wherein the non-textured protein product comprises 10 to 20 wt% of plant protein, an inoculum of at least one filamentous fungus and a crosslinking enzyme.

Description

[0001] Plant-based food product and method for producing the same

[0002] TECHNICAL FIELD

[0003] The present application relates to a product and a method of manufacturing a plant-based food product.

[0004] BACKGROUNG

[0005] Over the past few decades, a significant amount of research has been directed towards meeting the challenge of providing sufficient food for the ever-growing human population. However, traditional protein sources such as animal meat have proven to be highly energy inefficient and have a substantial negative impact on the environment due to greenhouse gas emissions and excessive water usage. Additionally, ethical concerns surrounding animal protein production and consumption have also become a growing issue for many people. As a result, there has been a shift towards developing non-animal protein-based food products that can replace traditional meat products and help meet the protein requirements of the expanding population. To appeal to consumers who are accustomed to consuming meat, non-animal protein-based food products must replicate the texture and mouthfeel of animal meat products. Consumers are seeking plant-based products with high protein levels to replace meat, often preferring options resembling minced meat or small meaty chunks. However, most plant-based meat alternatives are currently produced using high moisture extrusion or dry extrusion methods, resulting in small, chunky pieces that do not mimic the whole cuts of animal-based meat, such as tenderloin or filets, which have more complex structures than for example chicken pieces.

[0006] However, one major drawback of these techniques is that they lack the complexity of real meat, resulting in plant-based foods that have the same texture on all the chunky pieces. When comparing textured products to animal meat, the structures are too homogeneous and are lacking the complex structure of meat where muscle pieces are surrounded by collagen / fascia tissue or fat tissue. Large pieces of textured products are often considered too dry and too rubber-like, especially when cold.

[0007] Current offerings primarily consist of a plurality of extruded products, lacking products such as whole cuts. One challenge in creating whole cuts lies in binding these extrudates together, this can be done by a crosslinking enzyme. Yet, the taste of the protein used often remains prominent, dissatisfying consumers. To address this, some manufacturers resort to adding colorants and additives, which consumers generally reject. Additionally, products crosslinked by enzymes may exhibit undesirable holes between pieces, or smooth surfaces making them less "natural".

[0008] An alternative method involves aerobic fungal fermentation, which enhances the nutritional profile and alters the taste of the product. However, this technique isn't viable for large products mimicking whole cuts like loin or tenderloin. In such cases, the aerobic fermentation process is hindered: the product's core doesn't ferment adequately due to limited oxygen and high temperatures. Consequently, the filamentous fungi essential for binding multiple pieces together is mostly absent or quiescent, resulting in inconsistent texture and low tensile strength at the product's center.

[0009] In view of the above, there is a need for a meat substitute that can have an appealing look and texture with good nutritional values to please a broad range of consumers, meat eaters as well as vegans. To change the habits of meat eaters, the plant-based product could look like already well-known meat food similar to whole cut, such as chicken breast, bavette, beef tenderloin, or similar to ground meat or even to meat-derived products such as sausage.

[0010] The present invention intends to overcome, at least in part, the deficiencies of the prior art. In particular, an object of the present invention is to create structured protein products that better resemble whole cuts in look and structure.

[0011] SUMMARY

[0012] The present invention achieves these objectives by proposing a method for producing a plant-based food product wherein a plurality of textured protein products presenting an organoleptic sensation similar to muscle tissue are combined with a non-textured protein product presenting an organoleptic sensation similar to intra-muscle tissue.

[0013] Thereby, an overall texture of the food product may combine the structure and stiffness of the textured protein products with the elasticity, juiciness and tenderness of the nontextured protein product provided between the textured protein products.

[0014] More specifically, the invention relates to a method to prepare a food product, the method comprising steps of: a) providing a plurality of textured proteins product and a non-textured protein product; b) combining the plurality of textured protein products and the non-textured protein product; c) shaping a resulting combination to form a shaped product; and d) binding the shaped product to form the food product; wherein the non-textured protein product comprises 10 to 20 wt% of plant protein, an inoculum of at least one filamentous fungus and a crosslinking enzyme.

[0015] This invention allow to produce a large size food product, wherein the shaped product can have the shape of a sausage with a length being the longest direction of the plant based food and a diameter orthogonal to the length, the diameter can be at least 3 cm and preferably at least 7 cm, the length can be at least 3 cm and preferably at least 7 cm.

[0016] Organoleptic sensation can be adjusted by changing the quantity of non-textured protein product provided and keeping it between 5 wt% and 40 wt% of the weight of the plurality of textured proteins products, preferably between 10 wt% and 20 wt% of the weight of the plurality of textured proteins products.

[0017] The binding is done by the non-textured protein product comprising the filamentous fungus and the crosslinking enzyme. The filamentous fungus used can be selected from the group consisting of ascomycetes, basidiomycetes, deuteromycetes, oomycetes, and / or zygomycetes, in particular edible species belonging to the genus Agaricus, Hericium, Geotrichum, Rhizopus, Aspergillus, Penicillium, Ganoderma, Sporidiobolus, or Pleurotus, Laetiporus, Lentinula, Grifola, Flammulina, Morchella, Hypholoma, Macrolepiota and Cantharellus. More specifically, the species Geotrichum candidum, Rhizopus oligosporus, Rhizopus delemar, Rhizopus oryzae, Rhizopus arrhizus, Aspergillus oryzae, Aspergillus luchuensis, Aspergillus sojae, Penicillium nalgiovense, Penicillium camemberti, Penicillium rogueforti, Ganoderma lucidum, Pleurotus ostreatus, Pleurotus eryngii, or a combination thereof and the concentration of the filamentous fungus, in terms of spores per kg [CFU / kg] of the non-textured protein product, ranges from 1 x 104to 1 x 1013, preferably 1 x 105to 1 x IO10, and more preferably 1 x 107to 1 x 108and the crosslinking enzyme can be selected from the group consisting of transglutaminase, sortases, lysyl oxidases and amine oxidases, tyrosinases or laccases or peroxidases forming E-(y-glutamyl)lysine bridges, an LPXTG motif bridge, a Schiff-Base or aldol condensation products or o-quinone or dityrosyl-type crosslinks, respectively.

[0018] Pressure can be applied to contact the textured protein products with the non-textured protein product. Pressure can be applied during step b), step c) and / or step d) resulting in a shape product containing less than 20% by volume of gas bodies, preferably less than 10% by volume of gas bodies and preferably less than 5% by volume of gas bodies when taking a cross section parallel or perpendicular to the longest direction of said shaped product.

[0019] The filamentous fungus and the crosslinking enzyme can be that the temperature of growth of the fungi and the temperature of activation of the crosslinking enzyme can be the same.

[0020] Alternatively, the binding can be done in a 2 steps process, a first binding step with a first temperature at the core of the shaped product can be set between 4°C and 20°C for a period between 2h and 12h and then a second binding step with a second temperature at the core of the shaped product can be set between 20°C and 35°C for a period of less than 72h and preferably less than 48h.

[0021] A mold can be used to give a specific shape to the shaped product, and said mold can comprise removable parts, said removable parts can pass through the whole shaped product and can be removed before the fungal growth.

[0022] The mold or part of the mold can be removed before the fungal growth.

[0023] After the binding, the crosslinking enzyme and the fungal growth can be deactivated by heating the food product at a temperature of at least 65°C and preferably at least 80°C for at least 10 minutes and preferably at least 30 minutes, the temperature being measured at the center of the shaped product. Textured proteins product can be porous, fibrous, anisotropic, foamed, have a lamellar structure and / or an extrudate and comprise non-animal proteins or are each made from non-animal proteins such as textured vegetable protein.

[0024] The food product describe herein comprise the plurality of textured proteins product and the non-textured protein product, the quantity of non-textured protein product is comprise between 5 wt% and 40 wt% of the total food product, preferably between 10 wt% and 20 wt% of the total food product.

[0025] Said food product can reach at least 3 cm and preferably at least 7 cm, the length can be at least 3 cm and preferably at least 7 cm.

[0026] The food product wherein a cross section parallel or perpendicular to the longest direction of the shaped product can presents less than 20% by volume of gas bodies, preferably less than 10% by volume of gas bodies and preferably less than 5% by volume of gas bodies.

[0027] The current method offers considerable flexibility in terms of shaping and binding process, making it applicable to a diverse range of plant-based products. This versatility allows for the creation of a wide array of plant-based products using the same technique.

[0028] The method presented herein also discloses how a plurality of textured protein products and the non-textured protein product can be mixed together to form a plurality of coated protein products having at its core a textured protein product and at its periphery the non- textured protein product before the shaping and the binding.

[0029] BRIEF DESCRIPTION OF THE FIGURES

[0030] Fig. 1 is a flow diagram illustrating a method for producing a food product according to one embodiment.

[0031] Fig. 2 is a picture of a food product produce according to one embodiment.

[0032] Fig. 3 is a chart presenting the stress as a function of strain for a food product produce according to one embodiment, during a cutting.

[0033] Fig. 4 is a chart presenting the stress as a function of strain for a textured protein product, a food product produced according to one embodiment and a non-textured protein product during compression.

[0034] Fig. 5 is a chart presenting the stress as a function of strain for three different food products produced according to several embodiments, during compression.

[0035] Fig. 6 is a photograph of the shaped product according to one embodiment.

[0036] Fig. 7 is a photograph of the food product according to one embodiment.

[0037] Fig. 8 is a photograph of prior art food product.

[0038] Fig. 9 is a photograph of the food product according to one embodiment.

[0039] Fig. 10 is a photograph of the food product according to one embodiment.

[0040] Fig. 11 is a chart presenting the tensile strength for a prior art food product, and two food products according to one embodiment.

[0041] Fig. 12 is a photograph of the food product according to one embodiment. DETAILED DESCRIPTION

[0042] Fig. 1 presents a method 100 to produce a food product, the method comprising the steps of providing a textured protein product 110, providing a non-textured protein product 115, combining the textured protein product 110 with the non-textured protein product 115, shaping the resulting combination to form a shaped product 120, and binding the shaped product 130 to form the food product.

[0043] The method of the present invention is characterized in that in step 110 at least one textured protein product is provided. The term "provided" in this context means that textured protein product is used or that such textured protein product is prepared. Means and methods for preparing the textured protein product are described further below.

[0044] In one embodiment, the textured protein product may comprise high aspect ratio elements (which may also be referred to as "fibers" herein), forming an "anisotropic fibrous structure". "Anisotropic" refers to the internal structural organization of the fibers within the textured material which is a result of the fabrication process such as wet texturization process, preferably high moisture extrusion cooking or shear cell processing. These processes result in a fibrous internal structure substantially aligned in the direction of a flow field.

[0045] The term "fibrous structure" refers to a structure in which aggregated fibers and / or fiber sheets, in particular consisting of proteins, result in anisotropy characteristics regarding structure and mechanical properties of the fibrous structure. Preferably, the fibrous structure has a high degree of alignment in one direction. The fibrous structure is formed in the wet texturization process as proteins and other components are stretched and / or aligned by application of shear. The fibrous structure is comprised of multiple fiber bundles, aggregated fibers, and / or fiber sheets, sometimes referred to as "fibers". The fibrous structure resulting from wet texturization is known to a person skilled in the art and results in a chewy, animal meat-like texture and appearance.

[0046] In one embodiment, the textured protein products are made by wet texturization through, e.g., high moisture extrusion cooking or shear cell processing. Wet texturization means that a protein-containing formulation is mixed with a water phase, preferably subjected to a temperature of above 100°C under shear, followed by cooling under shear which results in the formation of a fibrous structure. Wet texturization, in particular, refers to texturization at a water content of 40-80 wt%. Remarkably, in wet textured protein products, the fibers are substantially aligned due to the controlled cooling and solidification under flow, which can be of particular importance for the present invention.

[0047] Said wet textured protein products are preferably produced by high moisture extrusion cooking in an extruder, more preferably in a twin-screw extruder, at a moisture content of above 40 wt% and below 80 wt%, even more preferably between 45 wt% and 70 wt%, and at a protein content of above 10 wt%, preferably above 15 wt%, even more preferably above 20 wt%. In particular, the mixture of protein, water and other components is sheared and heated in the extruder to above 100°C, preferably above 120°C and subsequently cooled in a cooling die to below 100°C before exiting the machine to avoid puffing and form a fibrous structure.

[0048] In another embodiment said textured protein product comprise an isotropic internal structure made with the combination of gas bodies and proteins through dry extrusion process resulting in textured protein products such as dry porous textured protein products, TVP or extruded pellets, as utilized for example in WO 2021 / 030412, are processed in a porous structure. As pointed out in WO 2021 / 030412, TVP for example is produced by extruding a molten protein mixture through a die to cause a rather sudden pressure drop at the extruder exit resulting in a less fibrous, more spongy structure. The moisture content in extrusion to form such structures is typically below 35-40 wt% to reach sufficiently high pressure and to provide sufficient coherence of the mixture upon expansion.

[0049] In particular, textured protein product comprises at least 10 wt% protein, preferably at least 15 wt%, most preferably at least 20 wt% protein selected from the group consisting of pea, soy, wheat, sunflower, fava, pumpkin, rice, cereals, pulses, oil seeds, algae, single cells, fungi, proteins derived from fungi, and fermented components or a mixture thereof.

[0050] In another embodiment said textured protein product comprises a combination of wet textured protein product and dry textured protein product.

[0051] In another embodiment said textured protein product comprise an inoculum of at least one filamentous fungus.

[0052] In an alternative method, the textured protein products are produced by fiber spinning or 3D printing.

[0053] "Proteinaceous ingredient" refers to protein isolate, concentrate or flour or combinations thereof, which may also contain other macronutrients, such as carbohydrates, fats, dietary fibers, salts, or residual water. Said isolate, concentrate, flour or combination thereof preferably contains a pure protein content of at least 40 wt%, preferably at least 50 wt%, even more preferably at least 60 wt%. The protein isolate, concentrate or flour ("proteinaceous ingredient") could also be referred to as a "protein composition", "protein mix" or "protein powder" in the context of the present invention.

[0054] The textured protein product comprises pea protein as the only protein source. Alternatively, the textured protein comprises pea protein as well as at least one other protein source, preferably from plants. Alternatively, the textured protein product comprises at least pea protein, sunflower protein and oat protein. Alternatively, the textured protein product comprises at least pea protein and yeast protein. Alternatively, the textured protein product comprises at least pea protein and soy protein. Alternatively, the textured protein product comprises soy protein as the only protein source.

[0055] Besides water and proteinaceous ingredient, the formulation of the textured protein product may comprise any other edible components which are added prior to or during the texturization process, such as oil or fat, dietary fibers, flavor components, colorants, or carbohydrates, wherein the other components are preferably from non-slaughtered origin, even more preferably originating from plants, fungi, fermentation processes, lab-grown animal cells, or single cell organisms.

[0056] Optionally, multiple textured protein products can be provided, they can be made from different formulations. For example, one of the textured protein products could be made from one formulation, while another textured protein product could be made from another formulation. It is also possible to provide more than two differently formulated textured protein products.

[0057] The textured protein products may be processed to reach a water content of between 60 and 95 wt%, preferably between 65 and 90 wt% before binding.

[0058] Optionally, part of the textured protein products is processed differently than the other part of the textured protein products.

[0059] Optionally, textured protein products are cooked, sterilized or pasteurized. For example, textured protein products may be sterilized in an autoclave at up to 135°C or be pasteurized at 90 °C for 30 min.

[0060] The textured protein products can have any shape and may be chunk, strand and / or sheets.

[0061] In one embodiment the textured protein products are produced by wet extrusion showing an anisotropic fibrous structure. The textured protein products can be provided with an elongated shape, meaning that one dimension is substantially longer than the other two dimensions ("e.g., a strand") or two dimensions are substantially longer than the third dimension ("e.g., a sheet"). In one embodiment, the longest dimension, or one of the longest dimensions, is preferably substantially aligned to the anisotropic fibrous structure. The alignment of the elongated pieces of the textured protein products in combination with anisotropic fibrous structure is advantageous to create a highly fibrous texture and appearance in the final product.

[0062] The textured protein product can be processed into elongated pieces by means of cutting, pulling, rolling or by soaking in liquid to an extent that the fibrous protein product disintegrates into anisotropic fibrous pieces, but not limited to these methods. In particular, the fibrous structure is substantially aligned to the longest dimension of the elongated piece, which may allow thinner fiber bundles can be peeled off from an elongated piece in the direction of the longest dimension.

[0063] For example, the textured protein product produced by high moisture extrusion cooking may be peeled or cut in the alignment direction of the fibrous structure into strips or sheets representing the textured protein products.

[0064] In one embodiment the textured protein products are produced by dry extrusion showing an isotropic structure. The textured protein products can be provided with an elongated shape, meaning that one dimension is substantially longer than the other two dimensions ("e.g., a strand") or two dimensions are substantially longer than the third dimension ("e.g., a sheet").

[0065] Preferably, the textured protein products are prepared in a way that the longest dimension thereof is at least 2 times longer, most preferably at least 5 times longer than the other two dimensions thereof (i.e., the other two dimensions that are (i) orthogonal to the longest dimension and (ii) orthogonal to each other).

[0066] In step 115 a non-textured protein product is provided. The non-textured protein product can be provided before, during or after the textured product is provided. One of the purpose of the non-textured protein product is to fixed or to glue the textured protein products.

[0067] Preferably, the non-textured protein product comprises an isotropic internal structure, also referred to as "amorph structure". "Isotropic" refers to the internal structure of the non- textured material which is a result of the fabrication process such as mixing, emulsifying, and / or compressing.

[0068] The non-textured protein product can comprise pea protein as the only protein source. Alternatively, the non-textured protein product can comprise pea protein as well as at least one other protein source, preferably from plants. Alternatively, the non-textured protein product can comprises at least pea protein, sunflower protein and oat protein. Alternatively, the non-textured protein product can comprises at least pea protein and yeast protein. Alternatively, the non-textured protein product can comprises at least pea protein and soy protein. Alternatively, the non-textured protein product can comprises soy protein as the only protein.

[0069] Besides water and proteinaceous ingredient, the formulation of the non-textured protein product may comprise any other edible components which are added prior to or during the fabrication process, such as oil or fat, dietary fibers, flavor components, colorants, or carbohydrates, wherein the other components are preferably from non-slaughtered origin, even more preferably originating from plants, fungi, fermentation processes, lab-grown animal cells, or single cell organisms.

[0070] In one embodiment, said non-textured protein product comprises water, 10 to 25 wt% of plant protein, nutrients, an inoculum of at least one filamentous fungus and a crosslinking enzyme. Said crosslinking enzyme is selected from the group consisting of transglutaminase, sortases, lysyl oxidases and amine oxidases, tyrosinases or laccases or peroxidases forming E-(y-glutamyl)lysine bridges, an LPXTG motif bridge, a Schiff-Base or aldol condensation products or o-quinone or dityrosyl-type crosslinks.

[0071] In one embodiment, said non-textured protein product comprises 1 to 20 wt% water, and preferably 10 to 20 wt% of plant protein, an inoculum of at least one filamentous fungus and a crosslinking enzyme. In one embodiment, 0.1% to 8 wt% of hydrocolloids are also added to the non-textured protein product. Said hydrocolloids are preferably selected from the group consisting of agar, modified cellulose, xanthan gum, carrageenan and alginate.

[0072] The inoculum contains an amount of colony forming units of the microbials species that can be spores, active vegetative hyphae, and active parts of fungal tissue, it may include as well dormant hyphae and parts of fungal tissue, e.g., dehydrated or lyophilized hyphae and parts of fungal tissue. The inoculum can take different forms, such as spores, mycelial fragments, or liquid or solid culture suspensions, and may contain both the vegetative and reproductive structures of the filamentous fungus as well as a spawning substrate. Spawning substrate can be grains, vermiculite, sawdust or other appropriate powdered or granulated substrate that ensures a large amount of colony forming units once the inoculum has been mixed with the rest of the non-textured protein product.

[0073] The number of colony forming units in the inoculum and its composition can vary depending on the desired outcome and the characteristics of the microbial species being used. In one embodiment the inoculum is made of spores. The concentration of the filamentous fungi, in terms of spores per kg [CFU / kg] of the non-textured protein product, ranges from 1 x 104to 1 x 1013, preferably 1 x 105to 1 x IO10, and more preferably 1 x 107to 1 x 109. Said fungi are preferably selected from the group consisting of ascomycetes, basidiomycetes, deuteromycetes, oomycetes, and / or zygomycetes, in particular edible species belonging to the genera Rhizopus, Aspergillus, Penicillium, Fusarium, Actinomucor, Amylomyces, Mucor, Monascus, Neurospora, Endomyces, Ganoderma, Sporidiobolus, Agaricus, Hericium, Geotrichum, or Pleurotus. More specifically, the species Geotrichum candidum, Rhizopus microsporus var. oligosporus (short: R. oligosporus), R. delemar, R. arrhizus, R. oryzae, Aspergillus oryzae, A. luchuensis, A. sojae, Penicillium nalgiovense, P. camemberti, P. rogueforti, Neurospora intermedia, Ganoderma lucidum, Pleurotus ostreatus, Pleurotus eryngii, Lentinula edodes or a combination thereof.

[0074] In one embodiment at least two filamentous fungi are co-inoculated and / or co-incubated. The two filamentous fungi can be from the genus Rhizopus and particularly Rhizopus oligosporus and Penicillium and particularly Penicillium nalgiovense.

[0075] In one embodiment at least two filamentous fungi are co-inoculated and / or co-incubated. The two filamentous fungi can be from the genus Rhizopus and particularly Rhizopus oligosporus and Aspergillus and particularly Aspergillus oryzae.

[0076] Optionally, multiple kinds of non-textured protein product are provided, they can be made from different formulations. For example, one kind of non-textured protein product could be made from one formulation, while another kind of non-textured protein product could be made from another formulation. It is also possible to provide more than two differently formulated non-textured protein product.

[0077] Optionally, part of the non-textured protein product is processed differently than the other part of the non-textured protein product. The non-textured protein product can be prepared by various methods, for example by preparing a dough. "Dough" refers to a semi-solid system comprising proteinaceous ingredients, water, and other optional ingredients such as yeast, salt, sugar, enzymes and fats. The ingredients are mixed together to form a malleable, deformable, and viscoelastic mass.

[0078] The dough is composed of several ingredients, including but not limited to proteinaceous ingredient and an aqueous solution. The quantity of proteinaceous ingredient can be comprised in between 5 to 30 wt%, preferably between 7 to 25 wt%, preferably between 10 to 25 wt%, preferably proteinaceous ingredient comprising pea protein. The dough is obtained by mixing the proteinaceous ingredient and the aqueous solution. The proteinaceous ingredient used can be in any suitable form, preferably in a powder form and may be in different aggregate states. The mixing can be conducted with any proper device, some non-limitative examples can be a paddle mixer, helical ribbon stirrer, blade stirrer, vane stirrer, bowl chopper, rotating drum mixer, dough kneader, colloid mill, cutter, Stephan mixer, elk-conche, static mixer, impinging jets, rotor stator mixer, stirred tank, Rushton turbine mixer, impeller mixer, crossbeam mixer, anchor mixer and / or propeller mixer.

[0079] Additional ingredients such as hydrocolloids, inoculum, or crosslinking enzymes may be added during, before, or after the creation of the dough. Furthermore, temperature, pH, and duration of the mixing can be adjusted during, before, or after the mixing to achieve the desired mechanical properties, specifically in terms of viscosity and granulometry. These adjustments allow for the optimization of the non-textured protein product's characteristics.

[0080] In one embodiment, the mixing is performed between 0°C and 50 °C, more preferably 5°C and 35 °C, more preferably 10°C and 30 °C to not modify the configuration of the proteins.

[0081] In another embodiment, the dough is heated at more than 30°C preferably more than 50°C and more preferably more than 80°C increase the thermal agitation and modify the configuration of the proteins or of the hydrocolloid particles if any.

[0082] In some embodiments, the pH can be decreased below 5 or in the contrary increase above 9. This results in a change in the configuration of the protein or of the hydrocolloid if any, reduce aggregate size and gives a viable environment for the inoculum if any.

[0083] Optionally, the dough can be cooked, sterilized or pasteurized. For example, the non- textured protein products may be sterilized in an autoclave at up to 135°C or the textured protein product can be pasteurized at 90 °C for 30 min, the inoculum and the crosslinking enzyme being added after the pasteurization and / or sterilization.

[0084] The non-textured protein products may be semi-solids like a dough or a gel, or in a liquid form.

[0085] "Gel" refers to a semi-solid system consisting of a network of molecules or solid particles, preferably proteins or colloids, dispersed throughout a liquid phase, preferably water. The solid particles are crosslinked by chemical or physical interactions to form a three- dimensional network that entraps a liquid phase.

[0086] The preparation of textured protein product and the non-textured protein product can be done either simultaneously or successively. In case of they are produced successively the non-textured protein product and the textured protein products can be produce in any order i.e., first the non-textured protein product and then the textured protein products or first the textured protein products and then the non-textured protein product. If too much time elapses between the fabrication of the non-textured protein product and its blending with the textured protein products, the non-textured protein product may begin to gel or solidify, which can impair its effectiveness in binding the textured protein products together. Therefore, it is important to minimize the time gap between the fabrication of the non-textured protein product and the shaping (describe more in details below) of the products to ensure optimal non-textured protein product performance.

[0087] Textured protein product and non-textured protein product are combined 120 to create a combined product.

[0088] In one embodiment, the textured protein products and the non-textured protein product are blended together, the combined product is a plurality of textured protein products coated by the non-textured protein product.

[0089] In another embodiment, when the non-textured protein product is solid, the textured protein product and the non-textured protein product can be assembled together randomly or not.

[0090] In one embodiment, at least 1, preferably 5 and more preferably 10 textured protein products or more may be combined with the non-textured protein product. The total combined product may comprise between 1 wt% and 99 wt% of non-textured protein product.

[0091] In step 130, the combined products are then arranged manually or mechanically with a dedicated machine such as a robot and / or a filing machine creating the shaped product.

[0092] In one embodiment, the combined products are then arranged in a specific manner i.e., with a specific scheme and / or aligned along a preferential direction. In another embodiment, the combined products are then arranged in a random manner i.e., the combined products are not aligned along a preferential direction. In one embodiment the combined products are preferably chunk and are filed into a casing with a filing machine.

[0093] In one embodiment the combined products are preferably elongated pieces and preferably strands and / or sheets. The elongated pieces are deposited in a shape. In one embodiment the elongated pieces are not substantially aligned along the same direction, they can be dropped randomly on the shape. In another embodiment the elongated pieces are substantially aligned along the same direction, preferably along the longest length of the elongated pieces. The elongated pieces can be aligned in the same direction, they can also be stacked and positioned side by side and / or in front of each other. In a further embodiment elongated pieces having the form of a sheet can be deposited on the shape prior to the strands to form a more complex structure. In a further embodiment, at least one sheet partially or totally encircles the strands, the sheet is wound around the preferred direction formed by the great length of the strands to form another complex structure. In these embodiments, the quantity non-textured protein product can be comprised between 5 and 40 wt% of the total food product, preferably between 10 and 20 wt%.

[0094] The shape product can be of any form or size, such as circular, cylindrical or can mimic the form of sausage or of a whole cut meat product or any other meat product. In one embodiment, the shaped product has the shape of a sausage with a length being the longest direction of the fermented plant-based food and a diameter orthogonal to the length, the diameter is at least 3 cm and preferably at least 7 cm, the length is at least 3 cm and preferably at least 7 cm.

[0095] The shaping can be performed manually or mechanically. During the shaping process, the combined products are subjected to pressure. The pressure should be sufficient to have less than 20 vol.% of gas bodies in the shaped product, preferably less than 10 vol.% gas bodies and more preferably less than 5 vol.% gas bodies. Gas bodies can encompass a variety of gases, including but not limited to air, oxygen, nitrogen, carbon dioxide, or a combination of these gases. These gases can form small bubbles, which may or may not be visible to the naked eye. Other parameters can be adjusted such as the duration of the shaping process or the temperature. Several shaping techniques can be employed, such as casting, filing, compression, forming, blow molding, compression molding, extrusion molding, injection molding, laminating, reaction injection molding, matrix molding, rotational molding, spin casting, transfer molding, thermoforming, vacuum forming, 3D printing, laminating.

[0096] In one embodiment, the combined products are placed in a mold. The mold can have any shape, such as the shape of a sausage, a chicken filet, a steak or any other geometrical shape aiming to mimic whole cut products or not. The mold can also have one or more removable parts such as small cylinders with a diameter between 0.05 cm and 5 cm, preferably between 0.1 cm and 1 cm. Cylinders can pass through the shaped product. The removable part can be removed during and / or after the molding step and preferably before or during the binding step in order to increase the oxygenation inside the shaped product to increase the fungal growth. Alternatively, cylinders can have holes on the periphery and said cylinders can be connected to an aeration device to increase the air flow in the shape product.

[0097] During the shaping, the combined products are subjected to pressure, for example by vacuum molding. The pressure should be sufficient to ensure contact between the combined products. The vacuum applied should be less than 1 bar, preferably below 990 mbar, preferably between 900 mbar and 990 mbar. The products may be contained in a bag during molding. Alternatively, the pressure should be sufficient to have less than 20 vol.% of gas bodies in the shaped product, preferably less than 10 vol.% gas bodies and more preferably less than 5 vol.% gas bodies. Other parameters can be adjusted such as the duration of the molding process, as well as the temperature. In one embodiment, during and / or after shaping, the shaped product can be frozen. Preferably, the conditions required for the solidification, or the gelling of the non-textured protein product are not present, and the process of solidification or gelling is not fully active before freezing. The time between the fabrication of the non-textured protein product and the freezing is kept as low as possible to have the minimum of solidification or gelling that have the time to occur before the freezing. Freezing can be performed at temperatures within the range of 0°C to -80°C, preferentially within the range of -4°C to -30°C, most preferentially within the range of -10° to -20°C. The shaped product may be cooled from room temperature to the target temperature in more than 30 second and in less than 80 hours, preferably between O.lh and 24h and more preferably between 0.4h and 24h. This freezing deactivates the solidification or gelling processes temporarily and can add a texture to the product due to the water crystallization. The freeze product is then thawed to a temperature at which the solidification or gelling processes may be active again.

[0098] The shaped product is then bind 140 by the cross-linking enzyme and / or by the growth of at least one filamentous fungus producing the food product. The non-textured protein product gradually gels and / or solidifies over time, until it reaches its desired texture. To facilitate the solidification of the non-textured protein product, the shaped product is left to rest for a sufficient period of time at a controlled temperature, allowing the non-textured protein product to bind the non-textured protein product and the textured protein product together in one food product. The shaped product can rest either inside or outside of the mold, for example in a vacuum bag.

[0099] The removable part of the mold can be removed before or during the binding step, in order to increase the oxygenation and the heat removable during the binding step 140 to improve the growth of the filamentous fungus.

[0100] In one embodiment the binding 140 is done in one single step, the crosslinking enzyme and the filamentous fungus are active simultaneously. The crosslinking enzyme allows to create covalent bond between proteins in the non-textured protein product and between proteins in the non-textured protein product and at the surface of the textured protein products. At the same time the filamentous fungus grows, long mycelium grows in the non-textured protein product as well as at the surface and / or inside of the protein textured products.

[0101] In this embodiment, the binding is done by allowing the shaped product to rest under controlled temperature and oxygen to incubate the filamentous fungi and activate the crosslinking enzyme. For example, at a temperature between 5°C and 50°C, and preferably between 20°C and 35°C for a period of less than 72h and preferably less than 48h.

[0102] In this embodiment, once the food product reaches the desired solidity and texture, the growth of the filamentous fungi and the crosslinking enzyme can be deactivated using various physical or chemical means such as pressure, temperature, UV radiation, salt, gas, and / or pH adjustment.

[0103] In another embodiment the binding 140 is a two-step process. First the crosslinking enzyme allows to create covalent bond between proteins in the non-textured protein product and between proteins in the non-textured protein product and at the surface of the textured protein products creating a scaffold. Second, the filamentous fungus starts to grow, long mycelium grows in the non-textured protein product as well as at the surface and / or inside of the protein textured products.

[0104] This is possible because the conditions to activate the growth of the filamentous growth and to activate the crosslinking enzyme are different. One condition that can be finely tuned is the temperature.

[0105] The first part of the binding is done by changing the temperature to a temperature sufficient to activate the crosslinking enzyme. Some crosslinking enzymes can be activated at a temperature superior to 50°C, for those crosslinking enzymes, the shaped product is then heated to the temperature of 50°C for at least 30 min at its core. Alternatively, some crosslinking enzymes can be activated at a temperature superior to 4°C, the shaped product may be placed in a fridge as for the core of the shaped product to reach a temperature of 4°C for at least 12 h.

[0106] This first binding can be used to solidify the shaped product in order to remove the mold or part of the mold to increase the oxygenation and the heat removal for the fungal growth.

[0107] The second part of the binding is done by allowing the shaped product to rest under controlled temperature and oxygen to incubate the filamentous fungi. For example, at a temperature between 5°C and 50°C, and preferably between 20°C and 35°C for a period of less than 72h and preferably less than 48h.

[0108] Alternatively, the filamentous fungus growth can be activated first then the crosslinking enzyme second.

[0109] In one embodiment, once the food product reaches the desired solidity and texture, the filamentous fungus and the enzyme responsible for the crosslinking can be deactivated at the same time or not, using various physical or chemical means such as pressure, temperature, UV radiation, salt, gas, and / or pH adjustment. Preferably, the filamentous fungus and the crosslinking enzyme are deactivated by heating the food product above the filamentous fungus growth condition and enzyme's stability temperature.

[0110] Once the food product is formed, according to any of the methods described above, the food product comprises at least 40 wt% water, more preferably at least 60%. Preferably, the food product comprises less or equal to 95 wt% of water, more preferably less or equal to 85 wt% or less or equal to 80 wt%, even more preferably less or equal to 75% wt%.

[0111] The food product comprises a minimum of two distinct phases. The first phase comprises a non-textured protein product, capable of elastically deforming and providing a moisture sensation upon chewing, reminiscent of intra-muscle tissue. The second phase, on the other hand, comprises a textured protein product, which is firm and provides a mouthfeel similar to meat muscle. It is even possible to introduce various types of textured protein products to enhance the complexity of the food product, resulting in more than two phases.

[0112] In the first phase, the non-textured protein product can exhibit elastic deformation until it reaches the yield point, where it undergoes fracturing. On the other hand, the second phase can require more energy to deform and has a distinct fracturing point from the first phase. By combining these two phases, the food product can achieve a more intricate structure, closely mimicking the physical properties of meat products.

[0113] The food product produced by one, or a combination, of the methods presented herein is designed to provide a satisfying and juicy experience for consumers, similar to that of a traditional meat product, for example by releasing juices when bitten or cut, further enhancing the overall juiciness experience.

[0114] Ideally, the food product includes a heat-sensitive component that has not been exposed to temperatures beyond a critical point during the manufacturing process. This precaution is taken to prevent degradation of the heat-sensitive component. However, it is expected that the heat-sensitive component will naturally degrade when the food product is cooked by the consumer. This degradation is intentional, as it contributes to the development of color, smell, and taste similar to cooked meat, such as when meat products are prepared in a pan.

[0115] Once the food product is formed, according to any of the methods described above, further processing may be performed to improve taste, preservation and / or transportation. In particular, the food product may be marinated, spiced, smoked, cured, dehydrated, pressed, infused with water and / or oil, steamed, boiled, cut, rolled, pulled, flavored, colored, preserved, frozen, cooked, fried, rehydrated, or post-processed in any other way as typically done with animal meat products.

[0116] The food product can undergo further processing. In one embodiment, the food product is fermented using microorganisms. Fermentation can be performed using a variety of microorganisms. Suitable microorganisms may be selected from the group of Zygomycota and Ascomycota, preferably from a genus selected from the group of Aspergillus, Rhizopus, Penicillium and Fusarium, Geotrichum. In another embodiment, the fermentation is performed using basidiomycetes, preferably from a genus selected from the group consisting of Pleurotus, Hericium, Laetiporus, Lentinula, Ganoderma, Grifola, Agaricus, Flammulina, Morchella, Hypholoma, Macrolepiota and Cantharellus.

[0117] In some embodiments, the food product is exposed to an acid, base or salt, either in solution or in solid form, to further stiffen, soften, color or change the taste of the food product.

[0118] The food product may further comprise spices, salts, acids, flavors, colorants, carbohydrates, lipids, herbs, dietary fibers or other food components to tailor texture, taste, appearance, nutritional content or color.

[0119] The food product can also be used to make other products.

[0120] Examples:

[0121] Food product 1:

[0122] The textured protein product is product by high moisture extrusion cooking, the water content is 70 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 5 wt%. The non-textured protein product is produced by mixing water 79 wt% with proteinaceous ingredient 18 wt% and other ingredients such as spices or processing aid 1 wt% and a crosslinking enzyme 2 wt%. spores of Rhizopus delemar are added in a quantity equal to 1 wt% of the total weight of the textured protein product provided and the non-textured protein product without spores. All the ingredients are mixed together at a speed of 120 rpm for 2 min.

[0123] Food product 1 contain 70 wt% of textured protein product produced by HMEC and 30 wt% of non-textured protein product. Textured protein product and non-textured protein product were added to the mold in alternate fashion, 8 layers of textured protein product and 7 layers of non-textured protein product. The mold with the textured and non-textured protein product are then transferred into a vacuum bag to perform vacuum molding at 980 mbar. The shaped product is left at 30°C for 30h for binding and fermenting. After binding the crosslinking enzyme and the fungal growth are deactivated by heating the food product 1 at 70°C for at least 30 minutes. The temperature being measured at the center of the food product 1.

[0124] When the food product 1 reach room temperature, it is cut into cubes with the following dimensions: 20 x 20 x 20 mm. The cubes are cut at the centre of the food product 1. A cube cut from food product 1 created with this method is presented in Fig.2.

[0125] Cutting analysis:

[0126] The cube from food product 1 is placed under the cutting probe and the cut is made with the blade being orthogonal to the plane made by the layers of textured and non-textured protein product.

[0127] The food product 1 is cut with a straight Warner-Bratzler shear blade with a speed of 1 mm / s to 110% strain to ensure entire cutting of the food product. The strain and the force required to move the shear blade through the food product are recorded upon hitting a preload force of 0.1 N.

[0128] Fig. 3. shows the force required for the shear blade to cut through the food product 1. The curve shows two different recurring patterns. Pattern (a) shows a mainly linear increase in force, pattern (b) shows a steep decrease in force. Pattern (a) occurs when the blade is building up force to shear through the textured protein product layer, whereas pattern (b) occurs as soon as the force reaches a threshold value to cut the textured protein product and the blade consequently reaches a layer of less firm non-textured protein product. This demonstrates the mechanical properties of food product 1, designed to emulate the sensory experience of a consumer while chewing such food product. It showcases the complexity of the bite, replicating the various phases existing in meat.

[0129] Food product 2:

[0130] The textured protein product is product by high moisture extrusion cooking, the water content is 70 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 5 wt%. The non-textured protein product is produced by mixing water 79 wt% with proteinaceous ingredient 18 wt% and other ingredients such as spices or processing aid 1 wt% and a crosslinking enzyme 2 wt%. spores of Rhizopus delemar are added in a quantity equal to 1 wt% of the total weight of the textured protein product provided and the non-textured protein product without spores. All the ingredients are mixed together at a speed of 120 rpm for 2 min.

[0131] A plurality of elongated pieces of textured protein product 80 wt% are mixed with the non- textured protein product 20 wt%. The non-textured protein coating the textured protein product. The mixture is then randomly deposited onto a mold. The mold with the textured and non-textured products are transferred into a vacuum bag to perform vacuum molding at 980 mbar. The shaped product is left at 4°C for 18h for binding. After binding the crosslinking enzyme is deactivated by heating the food product at 70°C for at least 30 minutes. The temperature being measured at the center of the food product 2.

[0132] Food product 3:

[0133] The textured protein product is a textured vegetable protein (TVP) product by dry extrusion, the water content is 64 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 11 wt%.

[0134] The non-textured protein product is produced by mixing water 79 wt% with proteinaceous ingredient 18 wt% and other ingredients such as spices or processing aid 1 wt% and a crosslinking enzyme 2 wt%. spores of Rhizopus delemar are added in a quantity equal to 1 wt% of the total weight of the textured protein product provided and the non-textured protein product without spores. All the ingredients are mixed together at a speed of 120 rpm for 2 min.

[0135] A plurality of TVP products 5 wt% are mixed with the non-textured protein product 95 wt%. The non-textured protein coating the textured protein product. The mixture is then randomly deposited onto a mold. The mold with the mixture is then transferred into a vacuum bag and vacuum molding to 980 mbar is done. The shaped product is then frozen at -20°C for 3h, then heated at 50°C for 4 hours for binding. After binding the crosslinking enzyme is deactivated by heating the food product at 70°C for at least 30 minutes. The temperature is being measured at the center of the food product 3.

[0136] Compression analysis:

[0137] The food products 1, food products 2 and food products 3 are successively placed under the middle of the compression stamp to ensure uniform compression. The food products are compressed orthogonally to the plane made by the layers of textured protein product and the non-textured protein product of the food product 1 and food product 2. The food product 3 not presenting a preferential direction is compressed orthogonally to a face of the food product 3.

[0138] The food product is compressed with a 60 mm compression stamp with a speed of 0.033 mm / s (equals 10% strain / min) to 10% strain. The strain and the force required to compress the food product are recorded upon hitting a pre-load force of 0.1 N. Fig. 4 and Fig. 5 show the stress a as a function of strain E where: stress o = F / A, with F = Force (N) and A = surface area (m2) strain E = AL / L, with L = food product thickness (m) and AL = compressed distance (m)

[0139] In Figure 4, a comparison of stress applied to different samples to achieve deformation is presented. Three samples are analyzed: a textured protein product (high moisture extrudate), the non-textured protein product and the food product 1.

[0140] The non-textured protein product exhibits quasi-linear behavior with an elastic response. Throughout the deformation process, this sample remains elastic, soft, and consistent.

[0141] In contrast, the textured protein product shows a distinct evolution. As deformation increases, the stress required also increases. No linear relationship is observed in this case. The textured protein sample is initially firm and becomes progressively firmer with increasing deformation until it eventually breaks.

[0142] The food product 1 combines characteristics from both protein products. During the deformation process, the food product 1 displays a stress required to deform the food product that lies between the other two samples. Unlike the non-textured protein product, it does not follow a purely linear and elastic response with a constant Young's modulus. Instead, its behavior shows some deviation from linearity similar to the textured protein product.

[0143] In Figure 5, three different food products are presented, each with varying compositions and ratio of textured and non-textured protein product.

[0144] The curve for food product 3 demonstrates a quasi-linear behavior, differing from the other two products. It is the softer of the 3 food products presented.

[0145] Food product 2 demonstrates a quasi-quadratic increase in the stress required to achieve deformation.

[0146] The curve of food product 1 exhibits intriguing findings. At low strain, the stress required to deform food product 1 is comparable to the stress needed for food product 3. However, at higher strain levels, food product 1 demands progressively more stress for deformation, resembling the behavior of food product 2. This suggests that merely changing the arrangement between textured and non-textured protein product can lead to significant changes in the mechanical properties of the food product.

[0147] The proportion of textured protein product and non-textured protein product, along with the properties of the textured protein product itself, play crucial roles in shaping the mechanical responses.

[0148] Food product 4:

[0149] The textured protein product is product by high moisture extrusion cooking, the water content is 70 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 5 wt%. The textured protein product is then cut into small pieces between 0.5 and 1 cm.

[0150] The non-textured protein product is produced by mixing water 82wt% with proteinaceous ingredientl5 wt% and cornstarch 3 wt%. All the ingredients are mixed together at a speed of 120 rpm for 2 min to form a dough. Then a cross-linking enzyme 3 wt% of the total amount of the non-textured protein product is added to the dough and then mixed. Then spores of Rhizopus delemar in a quantity equal to 0.5 wt% of the total mass of the dough and Aspergillus Oryzae in a quantity equal to 0.5 wt% of the total mass of the dough are added and mixed to the dough.

[0151] The textured protein product and the non-textured protein product are then combined and mixed for 1 minute. The product is then stored at a temperature of 5°C for 4h. The result presented Fig.6 is then incubated at 30°C for 48h. The combination between the crosslinking enzyme and the growth of the fungi binds the different pieces together. The result is presented Fig. 7.

[0152] Food product 5:

[0153] The textured protein product is a textured vegetable protein (TVP) product by dry extrusion, the water content is 64 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 11 wt%.

[0154] A plurality of TVP products is shaped into a mold in an alternate fashion and inoculated with 1 wt % of the total weight of the textured protein product of spore of Rhizopus delemar. The shaped product is left at 30°C for 30h for binding and fermenting. After binding the fungal growth is deactivated by heating the food product 5 at 70°C for at least 30 minutes. The temperature being measured at the center of the food product 5. The food product 5 can be seen in Fig. 8.

[0155] Food product 6:

[0156] The textured protein product is a textured vegetable protein (TVP) product by dry extrusion, the water content is 64 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 11 wt%.

[0157] The non-textured protein product is produced by mixing water 79 wt% with proteinaceous ingredient 18 wt% and other ingredients such as spices or processing aid 1 wt% and a crosslinking enzyme 2 wt%. spores of Rhizopus delemar are added in a quantity equal to 1 wt% of the total weight of the textured protein product provided and the non-textured protein product without spores. All the ingredients are mixed together at a speed of 120 rpm for 2 min.

[0158] A plurality of TVP products 50 wt% are mixed with the non-textured protein product 50 wt% and layered into a mold in an alternate fashion. The non-textured protein product is coating the textured protein product. The mold with the shaped product is then transferred into a vacuum bag and vacuum molding to 980 mbar is performed. The shaped product is left at 30°C for 30h for binding and fermenting. After binding the crosslinking enzyme and the fungal growth are deactivated by heating the food product 6 at 70°C for at least 30 minutes. The temperature being measured at the center of the food product 6. Food product 6 can be seen on Fig. 9.

[0159] Food product 7:

[0160] The textured protein product is a textured vegetable protein (TVP) product by dry extrusion, the water content is 64 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 11 wt%.

[0161] The non-textured protein product is produced by mixing water 79 wt% with proteinaceous ingredient 18 wt% and other ingredients such as spices or processing aid 1 wt% and a crosslinking enzyme 2 wt%. spores of Rhizopus delemar are added in a quantity equal to 1 wt% of the total weight of the textured protein product provided and the non-textured protein product without spores. All the ingredients are mixed together at a speed of 120 rpm for 2 min.

[0162] A plurality of TVP products 50 wt% are mixed with the non-textured protein product 50 wt% and layered into a mold in an alternate fashion. The non-textured protein product is coating the textured protein product. The mold with the shaped product is not vacuum molded. The shaped product is left at 30°C for 30h for binding and fermenting. After binding the crosslinking enzyme and the fungal growth are deactivated by heating the food product 7 at 70°C for at least 30 minutes. The temperature being measured at the center of the food product 7. The food product 7 can be seen in Fig. 10.

[0163] Foods product 5, 6 and 7 are then analyzed through a tensile test. First the food products are cut into bars of 150 mm long, 30 mm thick and 30 mm wide. 3 bars were cut and tested per food product.

[0164] The tensile strength of the food products 5, 6 and 7 was measured using the texture analyzer: ZwickiLine Texture Analyser (Zwick Roell, Ulm, Germany). The bars were analyzed with the tensile test, measuring the maximum tensile strength (Fmax) of the mycelium in Megapascal (MPa). The texture analyzer measured the value of Fmax by dividing the maximum tensile force by the cross-sectional area of the prototype. For the analysis, the bars were fixed into the tensiles of the texture analyzer with a grip separation of 40 mm and at initial separation of the tensiles of 50 mm. The pre-load was 0.2 Newton (N) and the speed of the extension was 0.5 mm / s.

[0165] The results are presented in Fig. 11, the food product 5 without the non-textured protein product presents a low tensile strength, as expected this food product 5 without the non- textured protein product is badly fermented at the core because of poor oxygenation and heat removal. On the contrary the food product 6 with the non-textured protein product presents a good tensile strength, the outer periphery of the food product is fermented and mycelium from the filamentous fungi are visible with naked eyes, although at the core of the food product 6 mycelium are not visible. Food product 7 has the higher tensile test, indeed the non-textured protein product comprising the transglutaminase enzyme as well as the filamentous fungi allow to strongly bind the textured protein product on the periphery but also in the core of the food product 7.

[0166] Food product 8:

[0167] The textured protein product is a textured vegetable protein (TVP) product by dry extrusion, the water content is 64 wt%, the proteinaceous ingredient content is 25 wt% the textured protein product also contains other ingredients such as fibers and oil representing 11 wt%.

[0168] The non-textured protein product is produced by mixing water 79 wt% with proteinaceous ingredient 18 wt% and other ingredients such as spices or processing aid 1 wt% and a crosslinking enzyme 2 wt%. spores of Rhizopus delemar are added in a quantity equal to 1 wt% of the total weight of the textured protein product provided and the non-textured protein product without spores. All the ingredients are mixed together at a speed of 120 rpm for 2 min.

[0169] A plurality of chunk of TVP products 80 wt% are mixed with the non-textured protein product 20 wt% and randomly filed in a casing that serve as a mold. The non-textured protein product is coating the textured protein product. The shaped product is left at 30°C for 30h for binding and fermenting. After binding the crosslinking enzyme and the fungal growth are deactivated by heating the food product 7 at 70°C for at least 30 minutes. The temperature being measured at the center of the food product 8. The food product is then fermented with Penicillium nalgiovense. The food product 8 can be seen in Fig. 12.

[0170] The examples presented herein illustrate the possibility of achieving food products with diverse and complex structures, capable of mimicking the different phases present in meat. By carefully adjusting the ratio of textured protein product to the non-textured protein product and manipulating the properties of the textured protein product, it becomes feasible to tailor the food product to meet specific textural preferences and mimic the characteristics of meat.

Claims

Claims1. A method to produce a food product, the method comprising the step of: a) providing a plurality of textured proteins product and a non-textured protein product; b) combining the plurality of textured protein products and the non-textured protein product; c) shaping a resulting combination to form a shaped product; and d) binding the shaped product to form a food product; wherein the non-textured protein product comprises 10 to 20 wt% of plant protein, an inoculum of at least one filamentous fungus and a crosslinking enzyme.

2. The method according to claim 1, wherein the shaped product has the shape of a sausage with a length being the longest direction of the shaped product and a diameter orthogonal to the length, the diameter is at least 3 cm and preferably at least 7 cm, the length is at least 3 cm and preferably at least 7 cm.

3. The method according to claim 1 or 2, wherein the quantity of non-textured protein product provided is between 5 wt% and 40 wt% of the weight of the plurality of textured proteins products, preferably between 10 wt% and 20 wt% of the weight of the plurality of textured proteins products.

4. The method according to any of the preceding claims, wherein the filamentous fungus is selected from the group consisting of ascomycetes, basidiomycetes, deuteromycetes, oomycetes, and / or zygomycetes, in particular edible species belonging to the genus Agaricus, Hericium, Geotrichum, Rhizopus, Aspergillus, Penicillium, Ganoderma, Sporidiobolus, or Pleurotus, Laetiporus, Lentinula, Grifola, Flammulina, Morchella, Hypholoma, Macrolepiota and Cantharellus. More specifically, the species Geotrichum candidum, Rhizopus oligosporus, Rhizopus delemar, Rhizopus oryzae, Rhizopus arrhizus, Aspergillus oryzae, Aspergillus luchuensis, Aspergillus sojae, Penicillium nalgiovense, Penicillium camemberti, Penicillium rogueforti, Ganoderma lucidum, Pleurotus ostreatus, Pleurotus eryngii, or a combination thereof and the concentration of the filamentous fungus, in terms of spores per kg [CFU / kg] of the non-textured protein product, ranges from 1 x 104to 1 x 1013, preferably 1 x 105to 1 x 1010, and more preferably 1 x 107to 1 x 108and the crosslinking enzyme is selected from the group consisting of transglutaminase, sortases, lysyl oxidases and amine oxidases, tyrosinases or laccases or peroxidases forming E-(y-glutamyl)lysine bridges, an LPXTG motif bridge, a Schiff-Base or aldol condensation products or o-quinone or dityrosyl-type crosslinks, respectively.

5. The method according to any of the preceding claims, wherein pressure is applied during step b), step c) and / or step d) resulting in a shape product containing less than 20% by volume of gas bodies, preferably less than 10% by volume of gas bodies and preferably less than 5% by volume of gas bodies when taking a cross section parallel or perpendicular to the longest direction of said shaped product.

6. The method according to any of the preceding claims, wherein the binding is done by having the shaped product at a temperature sufficient to activate the crosslinking enzyme then by proliferation and growth of the filamentous fungi.

7. The method according to claim 6, wherein the binding is a 2 steps process, a first binding step with a first temperature at the core of the shaped product is set between 4°C and 20°C for a period between 2h and 12h and then a second binding step with a second temperature at the core of the shaped product is set between 20°C and 35°C for a period of less than 72h and preferably less than 48h.

8. The method according to claim 6 or 7, wherein the shaped product is maintained in a mold after step b).

9. The method according to any one of claims 7 to 8, wherein the mold can comprise removable parts, said removable parts pass through the whole shaped product and are removed before the second binding step.

10. The method according to any one of claims 7 to 9, wherein the mold is removed before the second binding step.

11. The method according to any of the preceding claims, wherein the crosslinking enzyme and the fungal growth are deactivated by heating the food product at a temperature of at least 65°C and preferably at least 80°C for at least 10 minutes and preferably at least 30 minutes, the temperature being measured at the center of the shaped product.

12. The method according to any of the preceding claims, wherein the plurality of textured proteins product is each porous, fibrous, anisotropic, foamed, have a lamellar structure and / or an extrudate and comprise non-animal proteins or are each made from nonanimal proteins such as textured vegetable protein.

13. A food product produce by any of the preceding claims, comprising the plurality of textured proteins product and the non-textured protein product, the quantity of nontextured protein product is comprised between 5 wt% and 40 wt% of the total food product, preferably between 10 wt% and 20 wt% of the total food product.

14. The food product according to claim 13, wherein the food product is at least 3 cm and preferably at least 7 cm, the length is at least 3 cm and preferably at least 7 cm.

15. The food product according to any of claim 13 to 14, wherein a cross section parallel or perpendicular to the longest direction of the food product presents less than 20% by volume of gas bodies, preferably less than 10% by volume of gas bodies and preferably less than 5% by volume of gas bodies.

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