Method for generating a soya protein texturate

Abstract

The invention relates to a method for producing an anisotropic plant-based soya texturate, the texturate comprising a water proportion of less than 50 wt.% and more than 50 wt.% soya-based ingredients based on the dry mass, wherein a protein proportion comprises more than 30 wt.% based on the dry mass. In the method, a soya protein mixture with more than 50% of the dry mass is provided and from this a basic mixture is generated such that a water proportion of the basic mixture is in the range from 25 wt.% to 55 wt.%. The basic mixture is extruded. Then, a first axial and / or transversal stretch is exerted on the extrudate, in particular in a channel with a changing cross section, to generate a texturate. Finally, the texturate can be rolled or cut.

Description

[0001] METHOD FOR PRODUCING A SOY PROTEIN TEXTURATE

[0002] The present invention relates to a process for producing a texturate with soy protein.

[0003] BACKGROUND

[0004] Plant proteins in the form of isolates or concentrates are now used in a variety of meat substitutes. This is due, on the one hand, to increased demand for vegetarian or vegan diets and, on the other, to consumer desire for sustainable and resource-efficient agriculture. As the world's most widely cultivated oilseed, soybeans are the most common source of plant protein in both animal feed and meat substitutes.

[0005] In the form of textured soy protein, so-called TVP (for texturized vegetable protein), soybeans are an inexpensive meat substitute or meat additive. Traditionally, such soybean-based products are manufactured by dry or wet extrusion. The proteins are first extracted from soybean meal, which remains from solvent extraction, in which soybean oil is separated from the solid seeds using a chemical such as hexane, or from mechanical extraction, in which the oil is pressed out of the seeds under pressure without the use of chemicals. The resulting meal is first dried, after which it still has a fat content of up to 10% by weight, but also a protein content of between 40% and 55% by weight.

[0006] The flour can then either be further processed to further enrich the protein content or it can be processed directly as a concentrate in an extruder.

[0007] During extrusion, the flour is battered with water at high temperatures (T>120°C) to form a plasticized viscoelastic dough. This dough is then pumped through an extruder die by the rotation of the screws inside the extruder. A sudden drop in pressure to atmospheric pressure causes the water, which is still liquid under pressure at these temperatures, to suddenly evaporate - this is known as flash evaporation. This causes the product to expand as it exits the die. A cutting head controls the size and shape of the textured soy protein leaving the extruder, producing small flakes, large pieces, and even strips, cubes, or nuggets that resemble different types of meat.

[0008] While the flakes look like ground meat, the extruded pieces have a meat-like, chewy texture. This property and flexibility has made textured soy protein, or TSP, a popular substitute for or addition to many meat dishes. However, pure textured soy protein has a slight flavor of its own, so extruded consumer products often have colors, flavors, spices, or binding agents added before they are processed or dried and packaged for sale. Accordingly, with appropriate flavorings, textured soy protein can take on flavors such as beef, chicken, bacon, or salmon, giving this product great versatility and covering a wide range of tastes.

[0009] The moisture content of TSP varies between 8% and 10% by weight. During food preparation, TSP also readily absorbs water, particularly approximately two to three times its weight. Given its availability, sustainability, nutritional profile, and relatively neutral flavor profile, TSP offers an excellent solution to the growing demand for sustainable meat alternatives.

[0010] However, TSP also has a significant disadvantage in conventional manufacturing processes. This is the inability to improve or adjust its texture and mouthfeel, which severely limits its application. Currently, TSP tends to have a spongy, porous structure and therefore poor meat-like properties, particularly in terms of appearance, texture, and mouthfeel. Therefore, they are mostly used in mixed burger / meatball-like products, where the properties of the whole piece (appearance, texture, mouthfeel) play a minor role or can be compensated for by using other ingredients.

[0011] To at least partially compensate for this disadvantage, soy protein can be processed using a high-moisture extrusion process. This is used, among other things, to produce products made from soy protein, such as fibrous products, kebabs, chunks, or chicken breast products. The resulting products often provide a satisfactory base, as they have an anisotropic, meat-like structure, texture, and appearance while largely eliminating the need for binding agents. Such products are manufactured using various technologies: the most common variants are the long cooling slot die and the elongated cooling coupling die.In both cases, the protein matrix is ​​extruded at relatively high temperatures (T > 130 °C ) and a high water content of more than 50 wt% in the screw part of the extruder and then forced through a subsequent cooling die where the material is continuously cooled to 100 °C to avoid sudden evaporation of the water, which could destroy the produced fiber structures in the die part or lead to a porous final product .

[0012] Although this method can be applied to various plant-based raw materials to produce fibrous, protein-based products that are acceptably similar to meat products in appearance and, to some extent, in taste, they lack either the long fiber structures or the desired tenderness, both of which are necessary to successfully replicate meat properties. Nevertheless, there are products produced using this technology that can adequately replicate chicken or doner / gyro-like products. These products do not require long fibrous structures and are quite elastic in terms of bite and firmness.However, when it comes to adjusting juiciness, firmness and fiber length, conventional technologies do not offer the flexibility to achieve this in a targeted manner to authentically mimic different meat products such as beef or pork, which require more tender firmness and longer fiber structures.

[0013] Extrusion at high moisture content (>50% water content) requires a high protein content of the dry matter to achieve the concentration in the base mix required for high gel strength. Therefore, wet extrusion can only be used for base mixes with a protein content of more than 55%, as the creation of a very strong gel structure is a prerequisite for this process. However, this decreases drastically with decreasing protein content and increasing content of polysaccharides, fiber, starch or oil. Such high protein concentrations are usually produced by wet extraction followed by spray drying, which is a very energy-intensive process with a high carbon footprint. This also leads to an increase in the price of raw materials, making the final product less competitive compared to meat products.

[0014] There is therefore a need to make further changes to conventional technologies in order to achieve improvements in the products.

[0015] SUMMARY OF THE INVENTION

[0016] This need is met by the subject matter of the independent patent claims. Further developments and embodiments of the proposed principle are specified in the subclaims.

[0017] Definition textured plant product A food product developed primarily from plant ingredients and exhibiting textural anisotropy.

[0018] Definition of protein mixture

[0019] For the purposes of this application, the term "protein mixture" includes a plant protein mixture. Such a plant protein mixture is usually obtained from a single plant species in the manufacturing process, although contamination from other plants may occur to a small extent.

[0020] Unless otherwise stated, a "plant protein" comprises a plant protein mixture from the respective plant, otherwise it is referred to as a "single plant protein". In addition to the actual plant proteins, the mixture can also contain other components such as starch, sugar, fiber, minerals, fats and oils. Individual amino acids can also be part of the protein mixture. The respective amounts are defined in more detail below in the terms concentrate and isolate. However, the term plant protein mixture is always used when the composition of the mixture differs from the original distribution of the respective plant species.

[0021] Similarly, a "soy protein" or a soy-based plant protein is a protein mixture which is essentially obtained from soy, soy components or proteins of the soy plant and has been processed accordingly.

[0022] A protein mixture can be obtained from the plant species itself, but can also be the result of a side stream. There are also various side streams, press cakes, and residues that can be used as a protein source and thus represent protein mixtures within the meaning of this definition. These include, but are not limited to, residues from sugar production, the production of alcoholic beverages such as beer and wine, residues and side streams from oil production such as soybean oil, coconut oil, and rapeseed oil, or plant-based milk production such as oat milk, pea milk, or field bean milk.Other examples include okara (soy pulp), almond pulp, oat pulp, coconut pulp / meat, sunflower cake, rapeseed cake, linseed meal, hemp cake, cashew residues, peanut cake, corn gluten meal, whey protein, casein micelles, potato fruit water, chickpea pulp, lentil residues, spent brewer's yeast and spent malt (brewer's grains).

[0023] Definition of pulse protein: A pulse protein is a protein mixture obtained from pulses. These include, in particular, broad beans, but also peas, lentils, mung beans, chickpeas, white beans, peanuts, and soy. Here, too, a protein mixture can be obtained either directly from the respective pulse or as a sidestream product.

[0024] Definition of other protein mixtures

[0025] In addition to protein mixtures from pulses, other protein mixtures can also be produced from other raw materials and processes. These include, but are not limited to:

[0026] Textured soy protein, tempeh, hydrolyzed wheat protein, mycoprotein (fungal mycelium, for example from Fusarium venenatum), rice protein, potato protein, corn protein (zein protein), hemp protein, algae protein (e.g. from spirulina or chlorella), rapeseed protein, sunflower protein, cottonseed protein, pumpkin seed protein, quinoa protein, amaranth protein, millet protein, spelt protein, oat protein, barley protein, lemna protein, cassava protein, coconut protein, macadamia protein, cashew protein, chia protein, flaxseed protein, sacha inchi protein, watermelon seed protein, pistachio protein and yeast protein.

[0027] Definition of concentrate and isolate

[0028] The terms plant protein isolate and plant protein concentrate each describe plant protein mixtures whose protein components are present in varying concentrations. The other components of an isolate or concentrate include, for example, fats, sugars including starch and cellulose, which remain in the mixture when the concentrate or isolate is processed. The individual other components are reduced compared to the original concentration, but residues are still present in the isolate or concentrate in varying concentrations due to the various processing options. There is also a small amount of residual moisture in the isolate or concentrate.

[0029] A plant protein isolate, for example, is a mixture of a plant protein in which the concentration of the protein in the mixture is in the range above 85 percent by weight, for example in the range from 87 to 97% by weight. In a protein concentrate, the weight proportion of the protein is usually in the range below 80% by weight or even below 70% by weight, for example in the range from 35% by weight to 75% by weight or even up to approx. 80% by weight. There is also a transition area which, depending on the protein mixture, ranges from 75% by weight to 85% by weight and in which, depending on the manufacturer, protein variant or other parameters, is sometimes referred to as concentrate or isolate.

[0030] Depending on the processing and manufacturing process, a concentrate or isolate can be obtained from a plant species. Thus, the manufacturing process significantly influences not only the concentration of the plant protein mixture, but also, if necessary, the composition of the remaining components and the residual moisture content.

[0031] In addition, there are also low-concentration protein pastes made from the various fruits mentioned above, which arise as side-stream products from existing product processes or are intermediate products and can thus be processed directly in a more resource-efficient manner.

[0032] Definition of other ingredients

[0033] In some aspects, additional functionality in protein composition, taste, textural composition, visual or haptic properties can be achieved through various additional ingredients. It should be noted here, firstly, that the above-mentioned protein mixtures from the various carrier plants are mixed, both in terms of the different crops and in terms of concentration. One example would be the addition of wheat or rice protein to a protein mixture from soy.

[0034] Other ingredients such as salt, spices, but also additional starch, sugar, syrup, sugary fruit juices, fats or oils may also be present. These can be added either as part of the raw mixture at the beginning or during processing. It has been surprisingly found that sugar, oils and salts, or ingredients containing salt or oil (e.g. grape juice concentrate or soy sauce) can not only adjust the taste but can also lead to textural changes. These additional ingredients can be present in free form, but can also be bound in corresponding raw materials in a highly concentrated form, e.g. sugar in syrup.

[0035] Another possibility is the addition of functional ingredients, such as flavors, or additional special protein or amino acid sources to adjust certain properties or improve human bioavailability. Generally, the additional mixtures and the substances mentioned above are referred to as additional ingredients or additional components.

[0036] Definition of basic mixture

[0037] A base mix is ​​a combination of a protein mixture, whether as a single protein mixture or mixtures of multiple plant species, as an isolate, concentrate, paste, sidestream product, or a combination thereof, and water. Optionally, additional protein mixtures or other ingredients and components can be added to create the base mix.

[0038] The water content of the base mix is ​​adjusted to the desired level for extrusion as needed. This results from the fact that the protein mixture also added has a different water content depending on the processing stage. For very moist mixes, such as paste or okara, little or no water may need to be added. In some cases, it is even conceivable that dry ingredients may need to be added to reduce the overall water content of the dough.

[0039] The dough is then further processed in the extruder. Alternatively, the individual components can also be fed into the extruder during extrusion. The proportions in the base mix are generally given in % by weight, apart from water, based on the respective proportion of dry matter. A base mix with 40% by weight protein based on dry matter and a moisture content of 50% can be obtained using various concentrates or isolates with corresponding amounts of water. There may also be sidestream products with this type of distribution. Accordingly, the proportion of the individual ingredients in the base mix usually varies depending on the different distribution of the components in the ingredients. In particular, less water usually needs to be added because the protein mix or other ingredients also contain moisture.

[0040] In principle, this also applies to other added components such as salts, sugars or fats, since these are also present in the protein mixture in varying quantities.

[0041] Definition of extrudate

[0042] In the following, the dough mass processed in an extruder by kneading or other mechanical processing at the extruder outlet, especially at the end of the screw section, is referred to as the extrudate or viscoelastic mass. The associated process is called extrusion.

[0043] Definition of texturing

[0044] A process by which an extrudate achieves anisotropy in its texture. An extrudate with anisotropy is therefore also referred to as a texturate. Depending on the implementation, texturing can occur in the extruder, but usually only afterward through associated means and measures.

[0045] Definition of anisotropy

[0046] A condition in which the product exhibits different mechanical properties depending on the measurement direction. This is quantified by an anisotropy index, which is measured by hydrating the product to a water content between 65% and 75% and then cutting it in two orthogonal directions. Samples with the same geometric dimensions are used in each case.

[0047] For example, one direction should be along a fiber, the other perpendicular to it, to determine the maximum anisotropy value in the sample. The anisotropy index, in this application, is the ratio of the force required to cut the samples in the direction orthogonal to the fibers to the force required in the direction parallel to them. An anisotropic product has an anisotropy index that is not equal to one, but greater than one.

[0048] The anisotropy index can be determined in various ways, including using a texture analyzer, e.g. TA. XTPLUSC CONNECT TEXTURE ANALYZER from Winopal, using a fixed cutting blade (e.g. LIGHT KNIFE BLADE A / LKB from Winopal). Here, the product is hydrated in water at 80°C until the value specified above is reached. The anisotropy index of chicken or turkey is in the range of 1.2 to 2, while that of beef or pork is more variable and depends on the type of meat. Generally speaking, these two types of meat have somewhat higher anisotropy indices.

[0049] Definition of fiber

[0050] Fibers within the meaning of this application are elastic, cohesive layers that are aligned along a main direction, referred to as the fiber direction. Fibers within the meaning of this application exhibit strong anisotropy, which means that they can be detached or separated from the rest of the product if the fibers are pulled in a direction other than their fiber direction (e.g. from the transverse direction when they are aligned lengthwise, or vice versa). The fibers are therefore relatively loose or detachable if they are pulled in a direction orthogonal to the fiber direction, and elastic and cohesive if they are pulled along the fiber direction. Individual fibers can be detached from the product simply by pulling with the hand.

[0051] Fiber length is the maximum length of the layer that detaches from the product without tearing, while maintaining its strong anisotropy and elasticity in the fiber direction. The average fiber length is usually smaller and follows a normal distribution. Unless otherwise stated, the fiber length generally refers to the average fiber length.

[0052] Definition of strength

[0053] "Strength" in the context of this disclosure refers to the quantitative measure of a sample's resistance to mechanical deformation. Strength is specifically characterized by the maximum force required to induce a given deformation. The sample whose strength is to be measured has a moisture content in the range of 65-75%. This specified moisture range is adjusted by deliberately hydrating the product before the measurement is taken.

[0054] The force itself can be determined using a texture analyzer, e.g., the TA XTPLUSC CONNECT TEXTURE ANALYSER. The needle probe P / 2 of the texture analyzer is used for the measurement.

[0055] It has been shown that hydration in particular leads to different strength values ​​, making comparability between different samples or products more difficult .

[0056] Definition pieces

[0057] Cohesive parts of the textured vegetable product with a thickness of more than 2 mm and dimensions (length and width) of more than 10 mm.

[0058] Definition of thermomechanical treatment

[0059] A process during extrusion in which the dough is exposed to a specific temperature range while being mechanically processed. Mechanical processing may include kneading, rolling, rolling, crushing, and other forms in which a force or torque is applied to the dough.

[0060] Definition of axial and transverse stretching: The deformation of a material along its longitudinal (axial or longitudinal) and / or transverse (lateral) axis, typically occurring in a channel located after the screw section of the extruder. The material is pulled apart along the respective axis. If the stretching occurs after the extruder exit, the extrudate is stretched accordingly.

[0061] Definition of material temperature

[0062] The temperature reached by the protein mixture during thermomechanical treatment in extrusion.

[0063] Definition of online and offline cutting

[0064] Cutting methods that are applied either immediately as the product exits the extruder ( online ) or after a delay after extrusion ( offline ).

[0065] With currently used moisture extrusion, it has been determined that only protein-based matrices with very specific properties can be textured sufficiently to resemble meat products using the high-moisture extrusion (HME) process. It has been shown that suitable protein sources exhibit very high gel strength and viscosity after treatment in the screw section of the extruder, as this directly and significantly influences the shear stresses in the die section (low viscosity, low deformation stresses, no fiber formation).

[0066] Therefore, this technology cannot currently be successfully applied to soy flour, which exhibits very low viscosity and gel strength under typical high-moisture extrusion conditions. To overcome this limitation, the food industry has begun working with soy protein concentrates or isolates with protein contents exceeding 60%, which are subject to highly energy-intensive extraction and drying steps, increasing costs and significantly reducing the sustainability of soy-based texturates. Compared to TSP, high-moisture products also have a very limited room temperature shelf life of up to 4 weeks, whereas TSP can be stored at room temperature for up to two years.

[0067] The inventor has now developed a process that successfully processes soybean flour with a significantly lower protein content than in isolates, while allowing both strength and anisotropy to be adjusted over a wide range. This process achieves a strong molecular interaction between protein chains and polysaccharides, which is a prerequisite for fiber formation and thus for adjusting strength and anisotropy.

[0068] To this end, thermomechanical means, particularly kneading, shearing, and heating, are applied to a mass containing soy flour, soy protein, and a limited amount of moisture in the mixture between 25% and 55% by weight prior to extrusion, resulting in a highly viscoelastic multiphase gel formed from the protein component, water, and the polysaccharide component. The temperature range used for this purpose is slightly above 110°C, although lower temperatures may also be used.

[0069] During thermomechanical treatment in the screw area of ​​the extruder, phase separation occurs due to the thermodynamic incompatibility of the various protein fractions and polysaccharides. The extrudate produced in this way is then subjected to stretching, longitudinally or transversely, or both, and / or shearing. In the die area, the separated phases are deformed in the flow direction. This can lead to local gel fractures and thus to the formation of "fibers." The structure consequently forms fibers that are aligned primarily along the stretching direction, with the thickness and quantity being adjustable for a specific recipe through the geometric parameters. This results in anisotropy and a certain strength. Both parameters can be adjusted, at least in part, independently of each other.

[0070] The above-mentioned deformation forces, exerted on the soy protein mixture primarily in the elements downstream of the extruder, create and reinforce the anisotropic structure of the dispersed phase. This is supported by any uneven moisture distribution, which leads to areas of different consistencies, e.g., due to evaporation and simultaneous condensation, which lead to more pronounced fibers and / or greater anisotropy.

[0071] The inventor has also discovered that tensile stresses occurring during deformation during processing of soy proteins are more effective at generating anisotropy than shear forces. Appropriate control of the occurrence and strength enables the creation of fibrous structures in soy proteins, which are not sufficiently textured in conventional systems due to insufficient deformation of the matrix.

[0072] In particular, it is proposed to exploit strong longitudinal and / or transverse tensile stresses downstream of the extruder screw section to produce fibrous structures in protein-based systems at both medium (<50%) and low (<30%) moisture content. This involves forcing the soy protein extrudate downstream of the screw section through a channel, e.g., in the form of an expansion die, which exerts longitudinal and / or transverse expansion, or a combination of both, on the mass. The texturate can then be rolled.

[0073] The proposed principle allows the strength and anisotropy of the soy protein extrudate to be adjusted, unlike conventional methods, thus overcoming the previous disadvantages of dry extrusion without the need for wet extrusion. Accordingly, fiber lengths of more than 1 cm, and in particular even more than 3 cm, up to several tens of cm on average, can be produced.

[0074] Together with the further processing described below, a basis is created for texturizing that can be tailored to the requirements of the end product, be it fish, chicken, or an alternative made from beef or pork. In some aspects, the inventor proposes a process for producing an anisotropic vegetable texturate, wherein the texturate has a water content of less than 40% by weight and more than 50% by weight based on dry matter of soy-based ingredients. The texturate has a protein content of more than 30% by weight based on dry matter. The process comprises the steps of providing at least one soy-protein mixture having at least 50% by weight based on dry matter.

[0075] A base mixture is then created from the provided protein mix and water, resulting in a water content of between 25% and 55% by weight. This dough is then formed, which is subsequently extruded using thermomechanical treatment, reaching a material temperature in the range of 110 to 160°C during extrusion. Due to the lower water content, this is a dry extrusion or semi-moist extrusion, as opposed to conventional high-moisture extrusion.

[0076] The extrudate is then subjected to a first axial and / or transverse stretch, particularly in a channel with a varying cross-section, to create an anisotropic texture. The texture is then rolled. Based on the measurement specifications given above, the anisotropy index is greater than 1.

[0077] The textured material is then cut to produce pieces with thicknesses greater than 2 mm and lengths and widths greater than 10 mm. This final step can be performed before or after the rolling step, as suggested.

[0078] The process thus creates a texturate that, in some aspects, has a protein content of between 35% and 60% by weight based on the dry matter. Due to the applied stretching, the texturate exhibits anisotropy that can be further enhanced and / or specifically adjusted through further measures. Likewise, fibers are present whose length can be adjusted over a wider range, allowing a variety of different meat products to be imitated. These include, among others, turkey, chicken, pork, duck, and even beef.

[0079] In some aspects, the anisotropy of the texturate is intended to be increased after or even before cutting. For this purpose, a second axial and / or transverse stretch is exerted on the already stretched texturate, in particular by rolling, pressing or rolling the texturate. Likewise, in some aspects, anisotropy in the texturate can be increased and also frozen by rolling, pressing, shearing or rolling or some other mechanical treatment of the texturate. “Frozen” is understood to mean that the texturate hardly relaxes at all or not at all after this process, so that the anisotropy is no longer significantly reduced. A small relaxation shortly after the process is harmless, but the additional step should make the increased anisotropy irreversible.

[0080] In some aspects, the rolling step reduces the firmness of the texturate compared to the firmness of the texturate before rolling, in some aspects by 30% to 60%. This further adapts the product to existing meat products in terms of mouthfeel. Likewise, the rolling, rolling, or other mechanical measures mentioned above can increase the average fiber length of the texturate by more than 10 mm, in particular more than 20 mm, and in particular more than 30 mm. In particular, the average fiber length can also increase to more than 100 mm.

[0081] The above-mentioned second axial and / or transverse stretching and / or the strengthening of an anisotropy of the texturate comprises, in some aspects, a section-wise or continuous compression of the texturate during the advance. In some aspects, rolling of the texturate can take place by at least two opposing rollers. It is also possible to carry out rolling with at least one roller which is arranged opposite a roller belt. In a further embodiment, rolling of the texturate takes place by two oppositely arranged belt rollers, each of which comprises a roller belt tensioned and driven by at least two rollers. In some further aspects, the texturate is rolled by a belt roller which comprises a roller belt tensioned and driven by at least two rollers and a row of at least one roller roller opposite the roller belt.In some aspects, rolling is performed with rollers of different sizes. Likewise, it is possible to create the second stretching by rolling the textured material with rollers of different rotational speeds. In some aspects, compression is performed with two oppositely arranged rows of rollers each having a different speed.

[0082] In some aspects, the first and / or second axial and / or transverse stretching deforms and / or locally fractures a dispersed phase of the extrudate and / or the texturate.

[0083] Some aspects deal with the surface of the channel during the initial expansion process. It is expedient to design the surface of the channel so that, at least in some sections, it exhibits lower sliding friction than the surface of the extruder. This reduces sliding friction and reduces slippage, which can lead to undesirable gel fracture. This can include, among other things, a different surface coating, particularly one made of Teflon and ceramic.

[0084] In some aspects, the texturate is dried, for example by air drying. Drying is carried out until the texturate has a moisture content of less than 20% by weight or in particular less than 10% by weight. Slicing can take place before or after, preferably beforehand. Drying significantly increases the shelf life of the finished product. Alternatively, the texturate can also be hydrated to a moisture content between 40% and 110% by weight or in particular between 50% and 70% by weight or in particular between 55% and 75% by weight. This can be done using water or steam. This makes the texturate even better suited to different types of meat.

[0085] Another option is to further treat the pure or hydrated texturate to increase its similarity to existing meat products or to create new product groups. To do this, the texturate can be fried or deep-fried, for example. It can also be marinated, heated in a marinade, or boiled and simultaneously pasteurized or coated with an emulsion. This increases its shelf life, and the texturate can be sold directly to the end consumer. Smoking, for example, to produce jerky-like products is possible. Combinations of the above-mentioned measures are also conceivable.

[0086] In some aspects of the process, a base mix is ​​produced by adjusting the moisture content of the base mix so that the protein content, in particular of soy protein, in the base mix is ​​more than 30% by weight and less than 90% by weight, in particular between 40% by weight and 60% by weight. Accordingly, the process can be used to produce various texturates with different soy protein concentrations, while the texturates still exhibit anisotropy and pronounced fiber formation. Of course, depending on the components added, protein concentrations of up to 85% by weight, based on the dry matter, are also possible.

[0087] A further aspect relates to the provision of at least one protein mixture. The mixture can be provided with different protein proportions as an isolate, concentrate or also as a side stream. For example, the soy protein proportion is between 40% and 95% by weight or in particular between 55% and 85% by weight or in particular between 50% and 70% by weight or in particular more than 60% by weight, in each case based on the dry mass of the protein mixture. Other values ​​are also possible. It should be noted, however, that mixtures with a low protein proportion, lower than in some concentrates, can also be used and that the texturates with the properties mentioned can therefore be produced in the proposed manner.

[0088] The protein mixtures can be combined with one another, e.g., various mixtures of the types listed in the definitions. In addition, other components such as starch, polysaccharides, dietary fiber, fibers, fats, oils, and flavorings can be added. However, it is also possible for these ingredients to already be part of the mixtures or to be part of added sidestream products. Overall, the proposed process significantly reduces the costs of producing texturates through appropriate selection of ingredients.

[0089] In some aspects, an anisotropy index of the texturate measured at a moisture content between 65% and 75% is higher than 1.25 and in particular higher than 1.4 and is in particular between 1.38 and 1.70 and in particular between 1.5 and 2.5. In particular, it can be between 1.4 and 1.7, which corresponds to an index of turkey or chicken meat. A firmness of the texturate measured at a moisture content between 65% and 75% is between 100g and 600g. In some aspects, the fiber length is more than 15mm and is in particular in the range between 15mm and 25mm and in particular between 25mm and 45mm.

[0090] Some aspects deal with the provided soy protein mixture. This can comprise a combination of a soy protein mixture and at least one of a legume protein mixture, in particular a pea protein mixture, a field bean protein mixture, and a sidestream product, wherein the proportion of the soy protein in the dry matter of the provided protein mixture is between 51% by weight and 95% by weight, or in particular between 60% by weight and 90% by weight, or in particular between 51% by weight and 70% by weight, or in particular between 51% by weight and 60% by weight, or in particular between 60% by weight and 75% by weight.A proportion of the other protein in the dry matter of the protein mixture provided is less than 49% and is in particular between 10% by weight and 40% by weight or in particular between 15% by weight and 40% by weight or in particular between 20% by weight and 35% by weight or in particular between 10% by weight and 25% by weight.

[0091] It is also possible to add further different protein mixtures to create the base mixture. In some aspects, the provided protein mixture further comprises an oat milk side stream or a brewer's grain, the proportion of which in the dry matter is between 5% by weight and 40% by weight, or in particular between 10% by weight and 35% by weight, or in particular between 15% by weight and 25% by weight, or in particular between 10% by weight and 20% by weight.

[0092] The soy protein mixture may have been produced from a dry extraction process. In some aspects, it may have a polysaccharide content between 10% and 25% by weight. It is also possible for the soy protein mixture to have a residual moisture content between 2% and 20% by weight.

[0093] In some aspects, for the thermomechanical treating step, a step of kneading the supplied protein mixture and water at an increasing temperature up to a maximum temperature is carried out, optionally wherein the maximum temperature is in the range of 110 ° C to 160 ° C and in particular between 120 ° C and 145 ° C and in particular between 125 ° C and 140 ° C.

[0094] Some further aspects concern the step of axial and / or transverse stretching. This allows the flow velocity of the extrudate to be increased. Likewise, this step can produce a transverse stretch, in which the width of a channel inlet increases toward the channel outlet and, at the same time, the height of a channel inlet decreases toward the channel outlet, with the reduction in height optionally being greater than the increase in width.

[0095] Alternatively or additionally, it is possible for the extrudate to be stretched more along a first direction perpendicular to the direction of advance than along the direction of advance and a second direction perpendicular to the direction of advance and to the first direction. Also alternatively, in some aspects, a flow velocity is increased in a first direction transverse to the direction of advance, while it remains the same or decreases in another second direction. In some aspects, a longitudinal tensile stress is exerted on the extrudate. Finally, in some aspects, a transverse stretch can also be created in which a width of an inlet of the channel increases towards the outlet of the channel, wherein optionally a maximum width of the nozzle corresponds to 0.25 times to 4 times a length of the channel. Combinations thereof and deviations are possible in order to create the desired effect of an anisotropic texture.

[0096] The inventor further proposes an anisotropic texturate containing soy protein. This comprises a first soy protein mixture with a proportion between 50% and 100% by weight, or in particular between 50% and 70% by weight, based on the dry matter, and a second protein mixture with a proportion between 5% and 49% by weight, or in particular between 5% and 40% by weight, or in particular between 10% and 30% by weight, based on the dry matter. The texturate also has a moisture content in the range of less than 40% by weight, or in particular less than 35% by weight.

[0097] According to the proposed principle, the texturate has a soy protein content of between 35% and 85% by weight, or in particular between 40% and 60% by weight, based on dry matter, and possesses a fibrous structure with a preferred direction and a fiber length of more than 10 mm, and in particular more than 15 mm. Due to the fibrous structure, the texturate exhibits anisotropy.

[0098] In some aspects, an anisotropy index of the texturate measured at a moisture content between 65% and 75% is more than 1.25 and in particular more than 1.4 and in particular between 1.38 and 1.7 or in particular between 1.5 and 2.5. The anisotropy index of the texturate is thus in a range similar to that of meat. In some aspects, there is a maximum deviation of 10% from an anisotropy index of chicken meat, in particular chicken breast, turkey meat, in particular turkey breast, and pork schnitzel, so that these types of meat are therefore very well imitated.

[0099] The strength, measured at a moisture content between 65% and 75%, is between 100g and 600g and in particular between 250g and 450g.

[0100] In some aspects, the texturate is formed with a sidestream product, with a dry matter content of between 25% and 80% by weight, or more particularly between 30% and 75% by weight, or more particularly between 40% and 70% by weight. The sidestream product may be a sidestream product from plant-based milk production or beer production.

[0101] In some further aspects, the texturate comprises a third protein mixture, which is formed in particular by a non-legume protein or a sidestream product. In this respect, the texturate can thus comprise a wheat protein mixture, another legume protein mixture (except soy), and a sidestream product. Examples are listed above. Depending on the recipe, the proportion is between 5% and 40% by weight, or in particular between 5% and 35% by weight, or in particular between 10% and 35% by weight, or in particular between 15% and 30% by weight.

[0102] In a further aspect, the moisture content is reduced and is in the range of less than 25% by weight or, in particular, less than 15% by weight. The texturate can also be further processed, e.g., marinated, deep-fried, boiled, smoked, or roasted. It is also possible to coat the texturate with an emulsion or breading, or to roll texturate pieces in it, in order to further approximate the haptic or visual properties, or even the sensory properties such as flavor, to existing meat products.The emulsion or coating may contain flavorings, salt, sugar, natural flavorings, spices, including cayenne pepper, coriander seed powder, cumin powder, ginger powder, paprika powder, turmeric powder, cardamom powder, yeast extract, onion powder, tomato powder, honey powder, mustard, smoke flavoring, acid (citric acid), garlic powder, paprika extract, chili powder, acidity regulator (sodium acetates), parsley, and oregano. These may be mixed with syrup, fats, or oils to form an emulsion that coats the textured product and its pieces.

[0103] A further aspect relates to a processed texturate comprising a protein-containing texturate according to the proposed principle, wherein the processed texturate has a moisture content by hydration of between 40% by weight and 80% by weight or in particular between 45% by weight and 70% by weight or in particular more than 55% by weight.

[0104] BRIEF DESCRIPTION OF THE DRAWINGS

[0105] Further aspects and embodiments according to the proposed principle will become apparent with reference to the various embodiments and examples which will be described in detail in conjunction with the accompanying drawings.

[0106] Figure 1 shows a mixing extruder as it can be used for the proposed process and the extruder arrangement according to the proposed principle;

[0107] Figure 2 shows a first embodiment of an expansion nozzle in cross-sectional view according to the proposed principle;

[0108] Figures 3A and 3B show two further designs of expansion nozzles according to the proposed principle;

[0109] Figures 4A to 4E show possible embodiments of a roller arrangement according to the proposed principle in cross-sectional view; Figure 5 shows an embodiment of the process for texturizing soy protein according to some aspects of the proposed principle;

[0110] Figures 6A to 6D show various textures and products produced by the process according to the proposed principle .

[0111] DETAILED DESCRIPTION

[0112] The following embodiments and examples show various aspects and their combinations according to the proposed principle. The embodiments and examples are not always true to scale. Likewise, various elements can be shown enlarged or reduced in size to emphasize individual aspects. It goes without saying that the individual aspects and features of the embodiments and examples shown in the figures can be combined with one another without thereby impairing the inventive principle. Some aspects have a regular structure or shape. It should be noted that in practice slight deviations from the ideal shape can occur without, however, contradicting the inventive idea.

[0113] Furthermore, the individual figures, features, and aspects are not necessarily shown in the correct size, and the proportions between the individual elements may not always be correct. Some aspects and features are emphasized by being shown enlarged. However, terms such as "top", "above", "below", "below", "larger", "smaller", and the like are correctly represented with reference to the elements in the figures. This makes it possible to infer such relationships between the elements from the illustrations.

[0114] Figure 1 shows part of an extruder assembly according to the proposed principle. The extruder assembly is designed with a mixing extruder 1 with a twin worm gear, in which the supplied mass is kneaded by means of two worm gears and driven forward toward an outlet of the mixing extruder. For this purpose, the mixing extruder 1 comprises a motor with a gear 10, to which the two worm gears are anchored. Connected to this are several sections 11a, 11b, 11c, 11d, and 11e of the mixing extruder.

[0115] The respective sections are mechanically sealed to one another via flanges or other means. In this way, the mixing extruder shown can be either lengthened by adding individual sections or shortened by removing them. The screw sections 12a, 12b, and 12c are designed in a similar manner, so that they too can be lengthened or shortened by adding or removing individual screw elements.

[0116] In particular, the mixing extruder 1 according to the proposed principle comprises two inlet sections 11a with associated screw elements 12b. The inlet sections 11a have an opening for supplying the base mixture or water. In detail, in the illustrated embodiment, the base mixture is introduced via a hopper 14 into a first section 11a of the mixing extruder 1. Subsequently, the water is also added via an inlet 15, so that the two first extruder sections 11a primarily serve for initial mixing to form a dough from the water and the supplied base mixture.

[0117] Connected to the first sections 11a are a plurality of further sections 11b, 11c and 11d, some of which are filled with different screw elements 12a. As can be seen in the illustration in Figure 1, the screw elements serve on the one hand to advance the dough, but also to knead the dough while increasing the pressure and temperature. The screw elements ensure thorough mixing in the initial phase, but then also exert forces on the kneaded dough so that the interaction between the sugar proteins and the saccharides or sugar chains is intensified and leads to the formation of a multi-phase gel. For this purpose, the individual sections are equipped with a plurality of heating elements (not shown here) which can be controlled separately and independently of one another. This means that different temperature profiles and thus different temperatures of the advanced dough can be set in the individual sections 11a to 11e.Furthermore, the individual screw elements in each section are designed differently. Some screw elements serve to knead and shear the mass of the base mixture and the added water to create a dough with a multi-phase gel. At the same time, the kneading and further advancement of the added base mixture in these areas increases the pressure to between 15 and 20 bar.

[0118] With a simultaneous increase in the material temperature or a high temperature, for example in the range of 110 °C to 145 °C and a pressure of several bar, polymerization of the protein mixture with the water and the other components occurs, resulting in a gel-like viscoelastic mass. This is kneaded in different ways by the individual screw elements 12a and each advanced in small pieces to an exit section 1le of the mixing extruder 1. The heating and shearing of highly concentrated biopolymer mixtures increases the thermodynamic incompatibility and leads to phase separation, i.e. an inhomogeneous gel structure, similar to an emulsion, with at least one dispersed phase.

[0119] The outlet section 11e of the mixing extruder 1 has a slightly conical shape on the outlet side with an ejection zone 13 to which an expansion nozzle according to the proposed principle is connected either directly or via an intermediate piece. However, for reasons of clarity this is only indicated and explained in a few exemplary embodiments. The dough mass located in this outlet section is thus pressed under high pressure in the range of several bar, for example up to 100 bar, through the ejection zone into the expansion nozzle and there is subjected to expansion deformation by a uniform forward propulsion. In this non-limiting exemplary embodiment, an expansion nozzle 20 is connected to the mixing extruder 1. The expansion nozzle 20 comprises an expansion body 21 with an inlet region 23 and an outlet region 24. The inlet region 23 has a diameter oran area that is significantly larger than the diameter or the area of ​​the output area 24. The shape of the input area 23 and also of the output area 24 can be shaped differently, as will be explained in more detail in the following figures.

[0120] The inlet region 23 is connected either directly to the discharge zone of the mixing extruder 1 or via a tubular intermediate piece 30 to the discharge zone 13. In the present exemplary embodiment, the expansion nozzle comprises an inner region which is referred to as the expansion section 22 and is characterized by a cross-section which tapers continuously with the same gradient over the length L of the expansion nozzle. In other words, the diameter (or radius) Ri and the respective area in the inlet region 23 are continuously reduced over the length of the expansion nozzle down to the cross-section R2 and the respective area of ​​the outlet section 24. In the cross-sectional view of the nozzle 20 shown here, the tapered part thus forms a parallelogram with the two parallel sides corresponding to the inlet section 23 and the outlet section 24.Viewed three-dimensionally, it is a truncated cone, whereby the respective base and end surfaces can be either circular, as shown, or round-ended with a conical inlet.

[0121] The length L of the expansion nozzle is at least three to four times the diameter Ri in the inlet area. Due to the tapered cross-section here, the flow velocity of the dough is continuously increased at a constant mass flow rate as it advances through the expansion nozzle 20. In the exemplary embodiment, the flow velocity also increases evenly due to the uniformly decreasing cross-section.

[0122] To achieve a constant mass flow, this means that the flow velocity depends on the radius of the inlet and outlet areas, or rather on their respective areas. For example, if the inlet area has an area three times larger than the area of ​​the outlet area, the flow velocity in the outlet area must also be increased by a factor of three to ensure the same mass flow.

[0123] Due to the increasing flow velocity, the advanced dough mass is stretched parallel to the direction of advance. As a result, elongated fiber structures form at the continued high pressure of over 7 bar and the high temperature in the expansion nozzle in the range of over 100 °C. As the viscoelastic mass is propelled through the nozzle, shear and tensile stresses are generated which lead to deformation and / or fracture of the dispersed phase, creating more strongly oriented / pronounced and less pronounced regions of the dispersed phase. The extrudate with soy protein thus becomes anisotropic.

[0124] The uniform taper, which can be controlled in particular by adjusting the length of the expansion nozzle as well as the inlet and outlet cross sections, prevents wall slippage and shear stress, which leads to tearing of the propelled mass.

[0125] In another aspect, the coating of the inside of the expansion nozzle can also be coated with a special low-friction material. In addition to stainless steel, which is used in food production, among other applications, a plastic such as Teflon can also be considered. This material is particularly low-friction, so that the dough mass experiences greatly reduced or almost non-existent shear stress at the edge. This creates long fibers in the dough mass along the direction of advance.

[0126] Depending on the proteins used and the base mixture for the extrudate, different expansion stresses are necessary to avoid gel fracture of the material or, depending on the respective size, to deliberately induce it. It may also be useful to allow the extruded extrudate to "rest" for a while after expansion so that the fibers can align. Accordingly, the expansion nozzles can also be designed differently, with multiple sections, and generally also have other shapes.

[0127] At the outlet 24 of the expansion die 20, the extrudate leaves the die and enters the atmosphere, resulting in a further pressure drop and a simultaneous temperature reduction. The water content of the texturized material after exiting the die is less than 40% by weight, or in particular less than 30% by weight, so the extrudate is referred to as a dry or semi-moist extrudate.

[0128] The sudden loss of pressure and possibly also the falling temperature (the expansion nozzle would then be heated or at least at a temperature close to or above 100 °C) can, depending on the mixture fed in, i.e. depending on the soy protein mixture used and other protein components of different origins, lead to slight pore formation due to so-called "flash evaporation" of the evaporating residual water in the extrudate. At a temperature in the nozzle of below 100 °C this evaporation does not occur. Accordingly, the temperature in the nozzle can be reduced during propulsion in order to specifically control this process and thus achieve the desired mouthfeel of the texturate. Alternatively, a nozzle with a constant cross-section can be connected downstream of the expansion nozzle in which the mass cools down. In this case, the use of a nozzle material with good heat conduction is advisable.

[0129] The extrudate thus produced is then fed via a short conveyor belt to a roller arrangement 3. The roller arrangement 3 creates or reinforces an anisotropy of the extrudate already formed in the ejection nozzle, so that a desired structure is established at the outlet of the roller arrangement 3. Possible embodiments of this roller arrangement are described in the following figures.

[0130] The rolling process, for example in the form of rolling or pressing, is designed such that shear and expansion forces are exerted on the textured material in a different, particularly orthogonal, direction compared to the direction of advance. Depending on the design of the die 20, the forces exerted on the extrudate in the roller arrangement can also be orthogonal to the expansion stresses in the expansion die.

[0131] To put it simply, in this exemplary embodiment the texturate is processed in the roller arrangement 3 in such a way that it is now stretched in a different direction. The intensity can be adjusted by the gap height and speed in order to achieve different structures. In some aspects this can be achieved, for example, by increasing the shear forces orthogonal to the transport direction. For this purpose, for example, the texturate is cut into larger strips which are then rotated by 90° and passed through the rollers (not shown here, however). The forces exerted in this way result in the texturate forming fibrous, elongated structures due to the existing pore formation, which are easy to bite or chew.

[0132] The rolling step exerts strong deformation stresses on the deformed extrudate with its multiphase gel, leading to significant further development of the dispersed phase, the already fractured areas, or the expanded (or expanded and condensed) regions. This leads to further development of anisotropic structure formation in the gel. Depending on the conditions chosen before and during rolling (number of rolls, height, speed, etc.), the texture, appearance, and mouthfeel of the soy protein product can be customized.

[0133] This is followed by further processing. For example, cutting into pieces of predetermined shape and size is optionally provided in the machine 5. After cutting, the resulting product 4 comprises, for example, strip-shaped pieces of equal length. The cut strips have a length which in some aspects essentially corresponds to the length of the fibers of the texturate. Optionally, further air drying is carried out by a suitable air dryer 6 so that the total proportion of water in the soy protein texturate 4 is further reduced. At the end of the process, the total proportion of water in the texturate is less than 25% by weight, but in particular also less than 15% by weight. The now air-dried soy protein texturate can now be packaged and further processed.

[0134] In an alternative embodiment, the extruder assembly also includes a deep fryer or atomizer, in which the air-dried texturate can be deep-fried or dusted. This dusting with a powder or coating with an emulsion layer in the device 7 can take place both during air drying and afterward. It is also possible to roll the texturate pieces in a powder or emulsion in a roller drum and coat them in this way.

[0135] In the extruder arrangement shown in Figure 1, the individual components 3, 5, 6, and 7 can also be combined or interchanged with one another to create a specific consistency, appearance, and shape for the desired end product. For example, it is possible to add additional colorants during the drying step to effect a color change in the texture. Furthermore, smoke flavors or similar can also be added.

[0136] Figure 2 shows an embodiment of an expansion nozzle 20 in which expansion sections and rest sections alternate with one another. In the exemplary embodiment, the inlet region 23 and also the outlet region 24 of the expansion nozzle are not circular, but rectangular. However, other inlet cross-sectional shapes and outlet cross-sectional shapes are also possible in this context; moreover, the shape of the inlet cross-section can also be selected to be different from the shape of the outlet cross-section, so that the shape of the expansion sections or also the rest sections changes accordingly. This change is designed in such a way that the application of force, be it shear forces or expansion forces, occurs as evenly and continuously as possible, i.e. there are no large or sudden jumps that could lead to the mass breaking off.

[0137] The inlet section 25d of the expansion nozzle 20 in Figure 2 is followed by a conically tapered and narrowing first expansion section 25b. In this case, the outlet diameter R3 is approximately one third as large as the inlet diameter Ri. The first expansion section 25b is designed with a continuous taper in the direction of the outlet region 24 and has a length Li that is greater than the first rest section 25d in the inlet region of the expansion nozzle and also a second rest region 25c adjoining the outlet of the first expansion section. This second rest region 25c is short, being only one fifth to one quarter of the length of the expansion section 25b and then merges into a second, shorter expansion section 25b. On the outlet side, this expansion is in turn connected to a further rest section 25e, which simultaneously forms the outlet region 24.

[0138] Figures 3A and 3B address further aspects, namely that the inlet cross-section does not decrease uniformly (albeit in sections), but rather the inlet reduces in one preferred direction, while in the other direction it actually increases relative to the outlet. This forms an outlet, which, for example, forms a slot, whereby the width-to-height ratio and the shape of the side surfaces can vary.

[0139] Figure 3A shows a design with a round inlet cross-section. This or an oval inlet cross-section can often be flanged onto the outlet of an extruder particularly easily. In the design of Figure 3A, the round shape in the inlet area 23 is transformed into a rectangular shape with clear corners in the outlet 24, which is essentially formed by a narrow slot, so that its width B is significantly greater than the height H. In this design, the areas of the inlet and the outlet are the same size, so that only a transverse strain occurs here, but no or only a very small longitudinal strain. Accordingly, the mass is deformed primarily transversely to the direction of advance. In Figure 3B, the areas are again different, so that here not only a transverse strain of the mass but also a longitudinal strain is generated.

[0140] Figure 3B shows a further embodiment of an expansion nozzle, which is constructed similarly to the embodiment in Figure 3A. The key difference, however, is the different geometry. While the nozzle in Figure 3A deforms evenly over its length, the embodiment in Figure 3B has, on the one hand, a differently shaped inlet, namely a rectangle with rounded edges, and, on the other hand, the outlet, which is shaped like a slot. This does not result in a uniform taper in the two expansion sections 25b, but rather a widening of the width B in each case, with a simultaneous reduction in the height H. In this embodiment, there are also two longer rest sections 25d and 25e, as well as one short rest section. Nevertheless, the length of the rest sections in this exemplary embodiment is shorter than the width B of the nozzle at the outlet 24.

[0141] In these two designs, the expansion nozzle exhibits a decreasing H / W ratio across its length. For example, the width can increase by a factor of 3 while the height H decreases by the same factor. However, other factors are also possible in this context, whereby the cross-sectional area of ​​the exit area 24 also decreases compared to the entrance area 23.

[0142] For example, the height of the nozzle at the exit can decrease significantly more than the width increases. As a result, the overall area of ​​the exit becomes smaller than the cross-sectional area at the entrance. Accordingly, in this embodiment, not only a transverse flow velocity and thus an expansion of the extrudate perpendicular to the forward direction, but also a longitudinal expansion occurs.

[0143] From the designs of the expansion nozzle 20 in Figures 2 to 3B it can be seen that, depending on the selected geometry, different expansion stresses can be exerted on the propelled mass and the soy protein extrudate, which lead to an increase in the anisotropy. In the designs shown, there is therefore on the one hand a reduction in the flow area, e.g. in the design of Figure 3, but on the other hand a reduction or change along a first direction (e.g. width of the nozzle) perpendicular to the propulsion direction can also be different along a second direction perpendicular to the propulsion direction (e.g. height H).

[0144] Accordingly, the unequal reduction in the two different spatial directions results in not only a longitudinal strain, i.e. along the length of the expansion nozzle, but also a transverse strain, i.e. along the width B or the height H. The transverse strains are in turn different due to the different height and width.

[0145] In general, the expansion nozzles shown here in Figures 3A and 3B are characterized, among other things, by the fact that they increase in width while their height decreases significantly, even though the total area between the inlet and outlet is barely reduced (although this is just as easily the case with design 3B). As a result, the propulsion speed remains essentially constant or increases slightly, so that transverse tensile stresses or transverse and longitudinal tensile stresses occur, leading to fiber formation in a direction perpendicular to the propulsion.

[0146] In addition, the stretching nozzle can have several shorter or longer stretching sections as well as rest sections in which the dough is not stretched any further or is only stretched slightly. The stretching nozzle can also be equipped with additional heating or cooling elements in order to create different temperatures in the individual sections if necessary. This makes it possible, as required, to keep the temperature at the outlet of the stretching nozzle above the vapor pressure of the water so that the emerging texturate material experiences a sudden drop in pressure at an increased temperature. Any water that is still present therefore leads to an anisotropic distribution, creating areas of varying softness in the product, which lead to the improved mouthfeel.

[0147] The nozzles shown here can be combined as desired with regard to their individual sections, geometries, and wall coatings to control fiber formation and prepare the desired end product. Particular attention should be paid to a viscoelastic mass, which ensures that sliding occurs primarily on the side walls.

[0148] If the texturate has a lower viscosity, which is the case with soy protein mixtures with a higher water content, for example, it is advisable to taper the cross-section over a longer distance and thus subject the extrudate to only low tensile stresses so that the extruded dough does not tear off and lead, for example, to wall slippage or warping. Dies made from dough with a higher viscosity, on the other hand, can be stretched to a greater extent without wall slippage occurring. Accordingly, shorter stretching sections or stretching sections with a greater taper could be provided here so that the flow velocity is increased while the mass flow remains the same. Rest sections between individual stretching sections serve to relax the extruded dough somewhat and thus prevent the dough from tearing off and the production of shorter fibers.

[0149] Using the process steps presented here, the anisotropy, firmness, appearance and mouthfeel of the soy protein texturate can be adjusted over a wide range. This includes the extrusion parameters and their geometry, e.g. using single or twin screw gears and the length of the extruder, as well as the pressure and temperature during extrusion and the extrusion speed. The amount of water in the dough, i.e. the sum of the water quantities in the soy protein mixture and the other mixtures, as well as the amount of water added, plays a role in the recipe itself. This should be below 50% by weight or even below 40% by weight in order to achieve greater viscosity and to support the interaction between the protein chains and between protein chains and sugar molecules or chains. The existing and, if necessary,Only slightly bound water leads to a multi-phase gel during kneading and propulsion, in which areas rich in water and areas poor in water separate. Oils or fats present in the soy protein mixture can support this effect. It has surprisingly been found that the proposed process can also be used to process soy flour mixtures which have a relatively high content of other non-protein components. This also includes meal or dietary fiber, such as residues of the shell, which can amount to up to 20% by weight. However, through interaction in the various phases of the process, these can be used to strengthen the dispersed phases and so promote anisotropy. The following table shows an example of the calorific value of one soy meal.

[0150] To further adjust the texture, the soy flour can also be extruded with other ingredients. These can be other flours, protein concentrates or isolates. Wheat protein in the form of concentrates or isolates has been shown to be particularly suitable for controlling the fiber length and elasticity of the soy protein texturate. The proportion of wheat protein mixture in the form of an isolate can be, for example, 20% by weight. In some common examples, a combination of soy flour and soy protein isolate and a pulse protein mixture is used. This helps to control the firmness and anisotropy, respectively in a range between 100g and 600g and between 1.35 and 1.7. These parameters are in the same range as turkey or chicken meat.

[0151] The water absorption capacity and other instant properties can be adjusted using other flours such as oat flour or oat protein concentrate. Full-fat soy flour can also be added to control the fat content. This can be added to a total of up to 70% of the basic mixture (30% soy flour, 70% other ingredients). Figure 4A shows a possible design of a roller arrangement to explain some aspects of producing a texturate with directional anisotropy. In this case, the roller arrangement comprises two opposing belt rollers 31 and 32. These are arranged opposite one another. In this case, however, the two roller belts 300 of the belt rollers 31, 32 are not aligned parallel, but one belt roller is arranged at an angle to the second belt roller. This results in a wider inlet and a thinner outlet in the cross-sectional view shown.In other words, the distance between the two roller belts 300 decreases in the forward direction, i.e. in the direction towards the outlet of the roller arrangement.

[0152] Each roller belt 300 is driven by a plurality of rotating rollers 310, the rotation direction of the rollers being counterclockwise for the upper roller belt 300 and clockwise for the lower roller belt 31. The speed of the opposing rollers is the same. Consequently, a uniform forward speed of the two roller belts 300 is achieved for the belt rollers 31 and 32, respectively.

[0153] The texturate provided by the mixing extruder and the ejection nozzle 20 is fed to the inlet area of ​​the roller arrangement 30. The texturate is gripped by the two roller belts 300 of the belt rollers and propelled forward due to the existing static friction. The rotation speed of the two roller belts 300 can be somewhat greater than that given by the mass flow of the ejection nozzle 20. The static friction between the viscoelastic mass of the extrudate 40 and the roller belts 300 then results in further tensile stress which, with a simultaneous reduction in the thickness or the distance between the two roller belts 300, creates anisotropy in the forward direction and increases fiber formation in the forward direction. As a result, the dispersed phase of the texturate is further deformed and the individual protein-protein or protein-polysaccharide chains are aligned with one another and along the direction of advance.Due to the pressure built up on the mass, the individual phases are subjected to varying degrees of stress or...

[0154] This leads to a localized application of shear or tensile stress and subsequent layer formation, also known as gel fracture.

[0155] In contrast to the ejection nozzle 20, where static friction and thus the buildup of potential shear stress should be minimal, static friction is deliberately created between the roller belts 300 and the advancing material in the roller arrangement in order to reliably transport the Textura! despite deformation and counterpressure. The rollers are usually made of Teflon or a polymer with very low adhesion. This allows an existing anisotropy to be intensified and / or generated in the form of gel fracture and thus layer formation.

[0156] In a further embodiment, the two belt rollers can also be arranged at an angle to the outlet plane so that they both converge towards each other. This results in a gap between the two belt rollers 31 and 32 that decreases in the forward direction. Furthermore, some roller rollers 311 are provided with a tempering device so that the advanced mass can be subjected to additional heating or cooling in successive steps. This allows a further degree of freedom, allowing the temperature of the textured material to be adjusted during advancement through the rollers.

[0157] The aforementioned roller arrangements can also be arranged vertically so that the propulsion of the viscoelastic mass is assisted by gravity. In some aspects, the individual rollers 310 and 311 are also designed with an additional toothed ring that engages with the corresponding roller belts 300. This enables an intimate connection and prevents slipping on the individual roller rollers when pressure is exerted on the mass 40. By using several rollers 310, 311 per roller belt 300, i.e. more than two, continuous pressure can also be exerted on the propelled mass along the entire propulsion section. This is particularly useful when the propulsion section is somewhat longer overall or the roller belt itself is designed to be elastic.Through the design and arrangement of the individual rollers and the roller belts relative to each other, a defined pressure can be exerted on the viscoelastic mass in order to achieve the desired gel fracture and thus the desired anisotropy.

[0158] A further embodiment of a roller arrangement is shown in Figure 4B, in which different belt rollers 31, 32 and 32' are used. The lower planar belt roller 31 comprises a roller belt 300' which is provided with a surface structuring which is impressed onto the surface of the extrudate as the mass is propelled over the roller arrangement. The two upper belt rollers 32, 32' in this embodiment comprise a plurality of rollers 313 with a smaller diameter than the rollers 310 of the belt roller 31. In addition, one of the two belt rollers 32, 32' is arranged parallel to the belt roller 31, so that the distance between them does not change or changes only insignificantly during propulsion. This does cause propulsion, but without further significant deformation, so that this section can also be referred to as the rest section.The second belt roller 32' is again inclined relative to the lower belt roller 31, so that a wider inlet zone and a narrower outlet zone are formed, the distance between which corresponds to the distance between the belt roller 32 and the belt roller 31. The two roller belts of the belt rollers 32 and 32' can also be additionally structured.

[0159] In some aspects, it is conceivable in this context to provide individual rollers with different diameters in order to thereby reduce the thickness of the extruded mass. The two belt rollers 32 and 32' can also be configured with rollers of different sizes, for example, to achieve a reduction in the area between the roller belts and to exert pressure on the extrudate during propulsion.

[0160] The roller arrangements presented here, with surface structuring on at least one roller belt, allow for the imposition of additional anisotropy on an inherently isotropic extrudate. Likewise, any existing anisotropy can be enhanced. Accordingly, they can also be used to texture protein mixtures whose extrudate exhibits little or only minimal structure when propelled through a corresponding nozzle.

[0161] Figure 4C shows a further aspect of a roller arrangement as can be used to generate and enhance the anisotropy. In Figure 4C, a plate element 150 is provided which is stationary and at the same time arranged at an angle relative to a belt roller 31, so that a gap present in the advancing direction becomes increasingly smaller. The angle between the roller belt 300 and the plate can be adjusted in some aspects. The extrudate mass is driven by the belt roller 31 with a roller belt 300 in the direction of the outlet, so that a very thin, but wide-pressed texturate is pressed out there as a strip. The plate element 350 is designed with heating or cooling elements so that the temperature of the texturate can be adjusted. In addition, the surface of the plate 350 can comprise different materials in order to adjust static friction and / or sliding friction between the extrudate and the plate 350.In this embodiment, the plate 350 achieves a uniform and continuous linear reduction of the extrudate in the direction of the exit.

[0162] In a slightly different embodiment, the individual plate 350 is replaced by a plurality of plate elements 355 which are adjustable in height and arranged one behind the other. The two plate elements following the first plate element each have a bevelled or curved surface facing the inlet, which is followed by a surface running parallel to the roller belt. Accordingly, a transition from a first distance to a second distance through these curved regions is essentially continuous and uniform, i.e. takes place without any major breakage. In this exemplary embodiment too, the distance between the belt roller with its roller belt and the undersides of the plate elements which are each adjustable in height is reduced, as a result of which the extrudate is subjected to transverse and longitudinal tension and the desired texturing is thus produced.The adjustable plate elements make it possible to exert different transverse and longitudinal tensions on the extrudate, allowing adjustments to be made when the recipe changes and achieving the desired texturing. The plate shapes shown here can also be designed differently, for example, with different gradients, and not, as shown here, with a curved entry area where a surface parallel to the roller belt is positioned.

[0163] Figures 4D and 4E show two further designs of a belt roller. In the design of Figure 4D, a roller belt 300 is provided, on which the texturate lies and is moved forward by the roller. A plurality of rollers 310 (three are shown here, but there can be more or fewer) are arranged above the roller belt 300, depending on the design at the same or at decreasing distances. Their reaction speed is adapted to the speed of the belt. This exerts a deformation on the texturate being passed through. Figure 4E shows a modification. Here too, the texturate is driven forward by a roller belt. The deformation takes place, however, by roller rollers 310 which are arranged opposite one another in pairs and have a defined distance from one another. A further belt is arranged between two pairs. Here, too, the rotational speeds of the roller rollers and those of the belts are adapted.

[0164] Figure 5 shows by way of example the steps of a method for producing a so-aprotein textured product according to the proposed principle, as it can be produced by way of example with the extruder arrangement shown in Figure 1 and the downstream elements.

[0165] Figure 5 shows a first embodiment of the proposed method. In step S1, a soy protein mixture is prepared. This comprises a soy protein isolate and a protein isolate from pea protein. The protein content in the respective isolates is approximately 85% by weight based on the dry matter, with a residual moisture content in the range of approximately 5% by weight and other components. In this embodiment, plant fibers are barely present in the isolates. The two isolates are mixed in a ratio of 80% soy protein mixture to 20% pea protein mixture. This mixture corresponds approximately to 60% of the base mixture, resulting in a dry matter content of 0.95*0.6 = 57% in the base mixture. The pure protein content in the base mixture is 0.85*0.6 = 51%.

[0166] In step S2, water is added to the base mix, namely 35% based on the total mass of the base mix. This results in a total moisture content of 0.6*0.05+0.35 = 38%. The base mix thus contains 38% moisture by weight and 51% pure protein by weight. The remaining portion of approximately 11% by weight is divided among the other components of the protein isolate, i.e., sugar, salts, and oils. In addition, some flavorings, starch, and oils are added, amounting to approximately 5% dry matter by weight based on the mass of the base mix.

[0167] The resulting dough is then kneaded in an extruder under pressure and elevated temperature in step S3. The dough is kneaded in sections and then extruded slightly. In the initial sections, the temperature is rapidly increased from room temperature to over 100°C, and then maintained at around 135°C for the remaining kneading and extrusion steps.

[0168] In the discharge zone of the mixing extruder, the mass is transferred directly into an expansion die. The expansion die comprises a short inlet section with a substantially constant cross-section, an elongated expansion section, and an outlet section.

[0169] In this embodiment, in step S4 the extrudate is subjected to longitudinal stretching at a temperature of approximately 125°C, the stress of which results from a continuous reduction of the inlet cross-section to the outlet cross-section. The area of ​​the inlet cross-section is 8 times larger than the outlet cross-section. The stretching takes place over a distance which is 5 to 6 times larger than the diameter of the inlet cross-section. Therefore, due to the constant mass flow, the flow velocity over this distance also changes by a factor of 8, as a result of which the dough is stretched primarily lengthwise. In the middle section of the stretching nozzle, the static friction is reduced by a suitable coating, so that the resulting texture does not get stuck and no major shear forces occur that could lead to wall slippage or breakage of the dough.

[0170] The axial and longitudinal stretching structures the extrudate, forming longitudinal fibers with an average length between 10 mm and 20 mm. This also leads to anisotropy, as the fibers have a preferred direction. The temperature does not change significantly during the stretching process, i.e., at the end of the stretching die, the texturized material has a temperature of approximately 125 °C. At the die outlet, the trapped water recondenses, resulting in rapid cooling. At the same time, the fibrous structure created is not destroyed.

[0171] In step S5, the textured material, which is still warm and still releasing moisture, is rolled using a roller that generates tensile stress in the direction of advance, so that the existing anisotropy is reinforced and the fiber length increases even further. At the same time, the strength of the textured material is reduced by the pressing and rolling process because, in addition to the tensile stress, a shear stress is also generated orthogonal to the direction of advance or transport of the textured material. The temperature during this process is approximately 55 °C to 70 °C. The rolled product is then cut into smaller pieces in step S6, resulting in textured material pieces 5 cm to 10 cm long with a fibrous structure extending over the entire length of the piece.

[0172] In step S7, the pieces produced in this way are immersed in a herb, salt, and spice mixture to form a thin emulsion layer resembling marinated chicken or turkey. This mixture can contain appropriate flavorings. It also increases shelf life and flavor. The remaining moisture can be used to adhere this mixture. Alternatively, the textured pieces can be sprayed beforehand, for example, with an oil-water mixture, a sugar- or starch-containing liquid, a marinade, or similar, to improve adhesion.

[0173] In another example, a soy protein mix is ​​provided. In this example, it comprises a protein concentrate made from soy. The proportion of soy protein in the concentrate is 50%. Likewise, a wheat protein mix is ​​provided as a concentrate, in which the proportion of wheat protein in the wheat protein concentrate is approximately 70% by weight. The soy protein concentrate contains a residual moisture content of approximately 10% by weight, sugar in the range of 20% by weight, and other ingredients also amounting to 20% by weight. In the wheat protein concentrate, the residual moisture content is approximately 10% by weight, sugar in the range of 10% by weight, and other ingredients also amounting to 10% by weight.

[0174] Alternatively, instead of the wheat protein concentrate used above, another protein isolate with a similar or even higher protein content can be used.

[0175] The two concentrates are mixed with a ratio of 60% soy protein blend and 40% wheat protein blend, each based on the dry matter in the base mix. This portion of the base mix thus has a residual moisture content of 10%*60%+10%*40% = 10%. The soy protein content in the dry matter is 50%*60% = 30%, and the wheat protein content is 70%*40% = 28%.

[0176] Additionally, 10% by weight of vegetable oil, salt, and sugar are added to the mixture. Flavorings and spices are also added. This reduces the protein components by 10% by weight of the total dry matter, i.e., approximately 52% by weight, while the moisture content remains at 10%.

[0177] In step S2, water is added to the mixture in sufficient quantity to give the resulting dough a total moisture content of approximately 30% by weight. The dough is then kneaded into a dough in step S3 under pressure and at an increased temperature. The dough is kneaded in sections and then slightly advanced. In the first sections, the temperature is rapidly increased from room temperature to over 100 °C and then kept in a range of 130 °C to 140 °C for the remaining kneading and advance steps. The pressure here is over 20 bar. The advance rate is adjusted so that the mass transforms into a viscoelastic matrix, with a dispersed phase developing.

[0178] In the discharge zone of the mixing extruder, the mass is transferred directly into an expansion die. The expansion die comprises a short inlet section, in which the cross-section remains essentially constant, an elongated expansion section, and an outlet section.

[0179] In this embodiment, in step S4 the mass is subjected to longitudinal stretching at a temperature of approximately 125°C to 140°C, the stress in which results from a continuous reduction of the inlet cross-section to the outlet cross-section. The area of ​​the inlet cross-section is 8 times larger than the outlet cross-section. The stretching takes place over a distance which is 3 to 4 times larger than the diameter of the inlet cross-section. Therefore, due to the constant mass flow, the flow velocity over this distance also changes by a factor of 8, as a result of which the dough is stretched primarily lengthwise. In the middle section of the stretching nozzle, the static friction is reduced by a suitable coating, so that the propelled mass does not get stuck and no major shear forces occur that could lead to wall slippage or breakage of the dough.

[0180] The temperature does not change significantly during the expansion deformation, i.e., at the end of the expansion die, the texturate has a temperature of approximately 125 °C. At the outlet, water evaporates rapidly due to the accelerated pressure drop. This results in a somewhat more porous structure of the texturate without destroying the long-fiber structure produced by the expansion stress.

[0181] In step S5, the textured material, which is still warm and still releasing moisture, is rolled using a roller that generates a shear stress orthogonal to the direction of advance or transport of the textured material. The roller comprises a number of rollers whose spacing decreases along the direction of advance so that pressure is exerted perpendicular to the direction of advance, leading to forces in the plane perpendicular to the direction of advance. The temperature during this process is approximately 45°C to 60°C. The rolled product is then cut into smaller pieces to produce textured material pieces 5 cm to 10 cm long, with a fibrous structure extending over the entire length of the piece.

[0182] In a first example, the soy protein pieces produced in this way are simply dried after cutting and rolling to reduce the water content and achieve longer storage stability. They are then packaged for further processing. Drying continues until the total water content in the final product has dropped below 20% by weight.

[0183] In an alternative example, the produced soy protein pieces are placed in a herb, salt, and spice mixture to form a thin emulsion layer similar to smoked and dried meat. This mixture can contain appropriate flavorings. It also increases shelf life and flavor. The remaining moisture can be used to adhere this mixture. Alternatively, it is also possible to spray the texture pieces beforehand, for example, with an oil-water mixture, a sugar- or starch-containing liquid, a marinade, or something similar, to improve adhesion.

[0184] Furthermore, the soy protein pieces can also be pasteurized and hydrated.

[0185] In a further alternative example not shown in Figure 5, a protein mixture of soy flour and a rapeseed protein mixture is produced by mixing them in proportions of 80 to 95% by weight to 20 to 5% by weight. The soy concentrate contains, in addition to a protein content of 45% by weight, starch and sugar at 25% by weight, residual moisture of 10% by weight, and fibers, oils and other components amounting to 20% by weight. The rapeseed protein is an isolate with a protein content of 85% by weight, 3% by weight is residual moisture, 2% by weight starch, and the rest minerals, fibers, oils and fats.

[0186] The mixture specified above results in protein contents of around 57% by weight, sugar and starch in the range of 18% by weight, a residual moisture content of 8% by weight, and 17% by weight remaining components. This mass can then be mixed with water, for example, to produce the basic mixture, with 20 parts water being added to 80% by weight of this mixture. This results in a total proportion of 47.5% by weight of pure protein and 26.4% by weight of water in the basic mixture. The remainder is made up of 14% by weight starch and sugar as well as the other components. This basic mixture can be further processed using the proposed method.

[0187] For this purpose, the base mixture is first kneaded in an extruder and then the mass is fed to an expansion die. This die has an oval inlet cross-section which becomes increasingly wider and narrower along the length of the die. The total cross-sectional area decreases slightly along the length of the die, so that the flow velocity increases slightly. The increase in width leads to tensile stresses, primarily in a direction perpendicular to the forward motion. The dispersed phase produced in the extruder is strengthened by the transverse tensile stress and leads to anisotropy of the soy protein extrudate.

[0188] The temperature is reduced across the nozzle to just under 100 °C so that flash evaporation does not occur on exit. However, because of the high gel strength, no significant expansion occurs but rather condensation. The result at the exit of the expansion nozzle is a wide strand whose fiber direction is perpendicular to the exit direction. The strand is cut into pieces perpendicular to the direction of advance and then fed to a roller device. This is designed so that a belt roller drives the pieces in a forward direction which is essentially parallel to the fiber structure created by the expansion nozzle. The belt roller firstly reinforces the existing anisotropy in the fiber direction and secondly breaks up the structure slightly by tensile stress in the direction perpendicular to this. After hydration with water, a fibrous structure is created which resembles a chip.

[0189] The finished pieces are then dusted with breadcrumbs. A thin layer is sprayed on, ensuring the breadcrumbs adhere well. The finished pieces can then be frozen, for example, or at least refrigerated for a longer shelf life.

[0190] In another embodiment, a soy protein isolate with a protein content of 85% by weight is used as the base mix. This is added to the base mix at 70% by weight. Further ingredients include oils, fats, flavorings, and spices at approximately 12.5% ​​by weight, and a dark cereal flour at approximately 16.5% by weight. Water is then added to this base mix so that the total moisture content in the resulting dough is approximately 31.5% by weight.

[0191] The extruder operates at a lower temperature of approximately 110 °C. The extruder geometry is designed so that the resulting shear and kneading forces produce an extrudate as a highly viscoelastic multiphase gel. The low water content in this, as well as in the previous, embodiment is more similar to a dry extrusion than a semi-moist extrusion. The produced mass has a high viscosity due to the water content of less than 35% by weight.

[0192] In addition to the examples of the process shown here, there are of course various other recipes with soy protein that lead to various products with high anisotropy and strength in the above-mentioned ranges, provided that appropriate stretching and subsequent rolling are carried out as suggested.

[0193] Example group 1

[0194] In a first example, a protein mix based on soy protein is used. This is a pure soy protein mix with no added proteins from other fruits. However, other substances can be added, such as sugar, oils, fibers, flavors, and others. The soy protein mix can be in the form of an isolate, concentrate, or even a pulp or sidestream product. The latter may be advantageous because the residual moisture content is already at a level where little or no water needs to be added. Conversely, energy-intensive drying can be dispensed with.

[0195] Additional flavorings are added to adjust the taste. The mixtures are blended with water to produce a dough with a total moisture content between 35% and 50% by weight.

[0196] The material temperature in the extruder during extrusion is between 130°C and 145°C, but higher material temperatures of up to 160°C are also possible. After the screw section of the extruder, the extrudate is directly subjected to axial and transverse tensile stress. This occurs through an expansion die whose square cross-section tapers along its length and features an elongated slit at the outlet. The exit temperature is approximately 100°C at the exit of the expansion die, but can also be higher.

[0197] The finished textured material already possesses a pronounced anisotropy in the longitudinal direction due to the axial stretching. It has been determined that an average fiber length in the textured material can be adjusted within a certain range by adjusting or changing the propulsion speed. Overall, fiber lengths from over 20 mm up to a length of approximately 100 mm are achievable.

[0198] Example group 2

[0199] In a second example group, a protein mixture based on soy protein is combined with a pea protein mixture and a broad bean protein mixture. In this embodiment, the proportions of the pea protein mixture and the broad bean protein mixture are roughly the same, although different proportions can of course occur as long as the proportion of the soy protein mixture is above 50% by weight. Here, too, the respective mixtures comprise concentrates or isolates, with proportions of carbohydrates, starch and various sugars in the range from 2% to 20% by weight, as well as salt in the range from 3% by weight and oils and fats between 3% and 10% by weight, in each case based on the dry matter. No other flavorings were added. Because of the slightly modified protein mixtures, the total amount of water added also changes.However, the total moisture content of the dough is in the range between 25% and 45% by weight.

[0200] The resulting dough is kneaded and extruded in an extruder at increasing temperatures up to a material temperature of between 120 ° C and 150 ° C. At the extruder outlet, a dilatation die is arranged, the inlet cross-section of which tapers along its length to a slot perpendicular to the forward direction. The temperature at the outlet of the dilatation die is over 100 ° C.

[0201] The texturate emerging at the outlet cools down quickly due to evaporation and recondensation. As water and moisture evaporate, the water content of the texturate also decreases further, so that when cooled it is less than 40% by weight. The texturate is cut while warm into oblong pieces which are around 5 cm wide and 15 cm to 20 cm long. These pieces are then rolled again while warm at around 50 °C to 60 °C so that the elongated fiber structure and thus the existing anisotropy are specifically adjusted. This also reduces the strength somewhat, so that the resulting weight is in the range between 100g and 600g and in particular between 200g and 500g. The average fiber length is between 8 cm and 15 cm and is therefore somewhat shorter than the length of the individual pieces.

[0202] Due to the additional rolling, the anisotropy index is slightly below 2, i.e., the force applied to cut the pieces across the grain is significantly greater than the force along the grain. It is thus similar to chicken pieces. Example group 3

[0203] A third example group uses a protein blend based on soy protein, which has been combined with a wheat protein blend and a pea protein blend. The amount of soy protein blend is over 50% by weight, and in this example, 65% by weight. The protein content is approximately 75% by weight, each based on dry matter. A wheat protein concentrate and a pea protein concentrate each account for 15% of pure protein, each with a 65% content of pure protein based on dry matter. Flavorings and fats are also added, amounting to 5% by weight.

[0204] This results in a protein content of the dry matter of 65% * 75% + 15% * 65% + 15% * 65% = 68.25%. The sugar content is approximately 15% by weight (from the concentrates), the rest being fiber, salts, added flavorings, oils, and fats. Depending on the moisture content, water is now added so that the total moisture content is approximately 30% to 35% by weight based on the total mass. Further processing takes place in the extruder at a temperature of approximately 130°C. The finished extrudate is stretched longitudinally in a channel, during which the temperature and pressure are slowly reduced. At the channel outlet, the now anisotropic texturate has a temperature of approximately 100°C.

[0205] It is then rolled to reduce strength and increase anisotropy, or to further align the fibers. After cooling, the textured material is rehydrated in a water bath to a water content of approximately 65%. This not only causes the textured material to swell, but also changes its strength to approximately 150g to 300g.

[0206] Example group 4

[0207] In a fourth example group, a protein mixture based on soy protein is used, which is mixed with a sidestream product. In this embodiment, the sidestream is also watery, meaning its water content is in the range of 65% to 75% by weight. This means that no additional water needs to be added to prepare the dough and the base mix. Instead, "dry" soy protein is added until the water or moisture content is in the desired range in the example group, between 35% and 47%.

[0208] The direct use of sidestream products reduces process costs because they do not require energy-intensive dewatering. Transportation costs can also be reduced accordingly. In this case, sugar and other ingredients are already included, so they no longer need to be added.

[0209] The dry content of the oat milk side stream is between 10% by weight! and 45% by weight, in this example between approximately 25% by weight! and 35% by weight!, with the pure protein content in turn being between 30% and 70%.

[0210] The dough is extruded in an extruder at material temperatures between 110 °C and 160 °C, and in particular between 130 °C and 150 °C. The extrudate is then pressed through a die, although due to a slightly modified die geometry and the boundary conditions, only a slight anisotropy occurs. For this reason, a belt roller with several rollers is arranged downstream of the die outlet. The vertical distance between the roller belt and the individual rollers decreases slightly over the lateral transport section, so that the extrudate is slightly pressed with each pass and stretched due to the continuous transport.

[0211] It has been shown in this group of examples that the shape, number and speed of the rollers can not only enhance texture but also create it in an extrudate. This effect can be observed in all example groups, with the roller devices shown in this application either reinforcing an existing anisotropy or creating stabilization, depending on the extrudate composition. It has also been shown that subsequent rolling reduces the strength of the fibrous, anisotropic texture. This slightly enhances the anisotropy and results in a better mouthfeel that is more similar to turkey or chicken meat.

[0212] Figures 6A to 6D show different textures and products from the above example groups, as well as variations thereof. The individual pieces were manufactured using the process presented here.

[0213] Figure 6A shows a texturate made from hydrated soybean meal (left part of Figure 6A). In the right part of Figure 6B, the texturate has also been deep-fried after hydration. Both figures show the fibrous structure of the product. Soybean meal has a protein content of less than 90% by weight of the dry matter. In addition, the meal contains fiber, sugar, and other components that come from the soybean processing. The length of each texturate piece is a few centimeters.

[0214] Figure 6B shows additional textured pieces made from soy scrap. Unlike the previous pieces, however, the fiber length was altered here through further rolling and adjustment of the extrusion parameters, so that the fibers are longer than the textured pieces, which have a length of 2 to 3 cm. Rolling not only allows the fiber length to be adjusted as shown, but also loosens the product somewhat, which also changes its mouthfeel. In this respect, these textured pieces are very similar to chicken.

[0215] Figure 6C is an example with more than 80% by weight and 20% by weight of rapeseed protein in the dry matter. The mixture was mixed with water up to a content of approximately 35% by weight and then extruded so that a slight anisotropy arises. The texturate was then rolled to produce the elongated fibers. The texturate has not yet dried. Figure 6D, in contrast, shows a texturate with more than 80% by weight and 20% by weight of an oat milk side stream in the dry matter. The extrusion parameters and also the parameters for setting the rolling are the same. In contrast to Figure 6C, the texturate here is slightly more open-pored.

Claims

PATENT CLAIMS 1 . A process for producing an anisotropic vegetable soy texture, the texture comprising a water content of less than 50% by weight and more than 50% by weight of soy-based ingredients based on the dry matter, wherein a protein content comprises more than 30% by weight based on the dry matter, comprising the steps of: Providing at least one soy protein mixture having at least 50% by weight based on dry matter; Creating a base mixture from the provided protein mixture and water, such that the water content of the base mixture is in the range of 25% to 55% by weight; Creating a dough from the base mixture; Extruding the dough by means of thermomechanical treatment, whereby the dough reaches a material temperature in the range of 110 to 160 ° C during extrusion; Exerting a first axial and / or transverse stretching to the extrudate, in particular in a channel with a changing cross-section to produce a texture; Cutting of the textured material with thicknesses greater than 2 mm and length and width greater than 10 mm.

2. A process according to claim 1, wherein the texturate comprises a protein content of between 35 and 60% protein content based on the dry matter, optionally wherein a proportion of soy protein is more than 90% of the total protein content.

3. A method according to claim 1 or 2, further comprising before or after the cutting step: Exerting a second axial and / or transverse stretching to the textured material, in particular by rolling the textured material; and / or Increasing an anisotropy of the textured material by exerting a pressure on the textured material in a direction perpendicular to the forward direction while at the same time substantially unrestricted expansion of the texture in the other direction perpendicular to the forward direction; Increasing an anisotropy in the textured material by rolling the textured material; and / or Pressing and stretching the textured material; and / or Shearing the texture. 4 . Method according to one of the preceding claims, in which the exertion of a second axial and / or transverse stretching and / or the strengthening of an anisotropy of the texturate comprises: a section-by-section or continuous compression of the texturate during the advance; and / or a section-by-section pressing against a wall during simultaneous advance; and / or rolling of the texturate by at least two opposing rollers; and / or rolling with at least one roller which is arranged opposite a roller belt; rolling of the texturate by two oppositely arranged belt rollers, each comprising a roller belt tensioned and driven by at least two rollers; and / or rolling of the texturate by a belt roller which comprises a roller belt tensioned and driven by at least two rollers and a row of at least one roller roller opposite the roller belt;and / or rolling the textured material with rollers of different sizes; and / or rolling the textured material with rollers having different rotational speeds; and / or pressing the textured material together, with two oppositely arranged rows of rollers each having a different speed.

5. A method according to any one of claims 3 or 4, wherein the rolling step is designed to reduce a strength of the texturate compared to the strength of the texturate before rolling, in particular by 30% to 60%; and / or to increase an average fiber length of the texturate by more than 10 mm and in particular more than 20 mm and in particular more than 30 mm. 6 . Method according to one of the preceding claims, wherein a surface of the channel has at least in sections a lower sliding friction than a surface of the extruder, in particular due to a different surface coating, in particular one made of Teflon and ceramic.

7. Method according to one of the preceding claims, wherein the first and / or the second axial and / or transverse stretching deforms and / or locally breaks a dispersed phase of the extrudate and / or the texturate.

8. Method according to one of the preceding claims, further comprising: Drying, in particular air drying, the cut textured material to a moisture content of less than 20% by weight or in particular less than 10% by weight.

9. Method according to one of the preceding claims, further comprising: Hydrating the texturate to a moisture content of between 40% and 110% by weight or in particular between 50% and 70% by weight or in particular between 55% and 75% by weight, in particular in a water bath from 5 ° C to 100 ° C or with steam up to 115 ° C. 10 . Method according to one of the preceding claims, further comprising, in particular after drying or hydrating one of: Frying the texture; Deep frying the texture; Marinating the texture; Cooking or heating in a marinade; Smoking the texture; Coating with an emulsion; or a combination of several of the above.

11. A method according to any one of the preceding claims, wherein the step of providing at least one soy protein mixture comprises: Providing the soy protein mixture with a protein content of between 20% by weight and 95% by weight, or in particular between 25% by weight and 80% by weight, or in particular between 30% by weight and 70% by weight, or in particular less than 60% by weight, each based on the dry mass of the protein mixture; and / or providing a combination of a soy protein mixture in combination with at least one legume protein mixture and a non-legume protein mixture; and / or providing non-protein-containing further ingredients, in particular one or more of starch, polysaccharides, fats, oils, and flavorings.

12. Process according to one of the preceding claims, in which an anisotropy index of the texturate measured at a moisture content between 65% and 75% is more than 1.25 and in particular more than 1.4 and in particular between 1.38 and 1.70 and in particular between 1.5 and 2.

5.

13. A method according to any one of the preceding claims, wherein a strength of the textured material measured at a moisture content of between 65% and 75% is between 100g and 600g.

14. Method according to one of the preceding claims, in which a fiber length is greater than 15 mm and in particular in the range between 15 mm and 25 mm and in particular between 25 mm and 45 mm.

15. Method according to one of the preceding claims, in which the soy protein mixture provided comprises a combination of a soy protein mixture and at least one of a legume protein mixture, in particular a pea protein mixture, a field bean protein mixture and a side stream product, wherein a proportion of the soy protein in the dry matter of the protein mixture provided is between 51% by weight and 95% by weight or in particular between 60% by weight and 90% by weight or in particular between 51% by weight and 70% by weight or in particular between 51% by weight and 60% by weight or in particular between 60% by weight and 75% by weight;a proportion of the other protein in the dry matter of the protein mixture provided is less than 49% and in particular between 10% and 40% by weight or in particular between 15% and 40% by weight or in particular between 20% and 35% by weight or in particular between 10% and 25% by weight; 16. Method according to one of the preceding claims, in which the protein mixture provided further comprises an oat milk side stream or a brewer's spent grain, the proportion in the dry matter being between 5% by weight and 40% by weight or in particular between 10% by weight and 35% by weight or in particular between 15% by weight and 25% by weight or in particular between 10% by weight and 20% by weight.

17. A process according to any one of the preceding claims, wherein the soy protein mixture was produced from a dry extraction process; and / or has a polysaccharide content of between 10% and 25% by weight of the soy protein mixture; and / or the soy protein mixture has a residual moisture content of between 2% and 20% by weight of the soy protein mixture.

18. Method according to one of the preceding claims, wherein applying a first axial and / or transverse stretch comprises at least one of the following: Increasing a flow velocity of the extrudate within the channel; Creating a transverse stretch in which a width of an entrance of a channel increases towards the exit of the channel and simultaneously a height of an entrance of the channel decreases towards the exit of the channel, optionally wherein the decrease in height is greater than the increase in width; Stretching the extrudate along a first direction perpendicular to the direction of advance more than along the direction of advance and a second direction perpendicular to the direction of advance and the first direction; Increasing a flow velocity in a first direction transverse to the direction of propulsion while remaining the same or decreasing it in a second direction; Generating a longitudinal tensile stress on the extrudate; and generating a transverse strain in which a width of an inlet of the channel increases towards the outlet of the channel, wherein optionally a maximum width of the nozzle corresponds to 0.25 times to 4 times a length of the channel.

19. Protein-containing texturate, comprising a soy protein mixture with a proportion between 50% by weight and 100% by weight or in particular between 50% by weight and 70% by weight based on the dry matter, a second protein mixture with a proportion between 5% by weight and 49% by weight or in particular between 5% by weight and 40% by weight or in particular between 10% by weight and 30% by weight based on the dry matter; a moisture content in the range less than 50% by weight or in particular less than 35% by weight; wherein a protein content in the texturate, in particular in soy protein content, is in the range between 35% by weight and 85% by weight of the dry matter; wherein the textured material comprises fibers with a preferred direction and a length of more than 10 mm and in particular more than 15 mm.

20. Protein-containing texturate according to claim 19, wherein an anisotropy index of the texturate at a moisture content between 65% and 75% is more than 1.25 and in particular more than 1.4 and in particular between 1.38 and 1.70 and in particular between 1.5 and 2.

5.

21. Protein-containing texturate according to claim 19 or 20, wherein a strength of the texturate measured at a moisture content of between 65% and 75% is between 100g and 600g.

22. Protein-containing texturate according to one of claims 19 to 21, in which the second protein mixture is formed with a non-pulse protein, in particular a wheat protein, with a proportion of the dry matter between 5% by weight and 40% by weight or in particular between 10% by weight and 35% by weight or in particular between 15% by weight and 30% by weight.

23. Protein-containing texturate according to one of claims 19 to 22, in which the second protein mixture is formed with a side stream product, in particular a brewer's spent grain or a product from vegetable milk production, with a proportion of the dry matter between 5% by weight and 49% by weight or in particular between 10% by weight and 35% by weight or in particular between 15% by weight and 30% by weight.

24. Protein-containing texturate according to one of claims 19 to 23, in which the moisture content is in the range of less than 25% by weight or in particular less than 15% by weight.

25. Protein-containing texturate according to any one of claims 19 to 24, wherein the texturate is marinated; and / or cooked or heated in a marinade; and / or fried; or is deep-fried; or is coated with an emulsion; or is breaded; or is smoked.

26. Protein-containing texturate according to one of claims 19 to 25, wherein the anisotropy index of the texturate has a maximum deviation of 10% from an anisotropy index of one of chicken meat, in particular chicken breast, turkey meat, in particular turkey breast, and pork schnitzel.

27. Processed texturate comprising a proteinaceous texturate according to any one of claims 19 to 26, wherein the processed texturate has a moisture content by hydration of between 40% by weight and 110% by weight or in particular between 45% by weight and 70 % by weight or in particular more than 55 % by weight.

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