Crustacean seafood analogs

Abstract

A process for preparing a heat-stable crustacean seafood analog product, the process comprising forming a colloidal system comprising water, non-animal protein, and an edible crosslinkable polymer; forming the colloidal system into a shape; at least partially freezing the shape at a temperature of less than or equal to 0°C for a time sufficient to achieve an at least partially frozen shape; and subjecting the at least partially frozen shape to an aqueous source of monovalent, divalent, and / or trivalent cations, wherein during step d) the edible crosslinkable polymer is ionically crosslinked with the monovalent, divalent, and / or trivalent cations to form a heat-stable shape.

Description

[0001] CRUSTACEAN SEAFOOD ANALOGS

[0002] TECHNICAL FIELD

[0003] The present disclosure relates to heat-stable crustacean seafood analogs and methods of making the same.

[0004] BACKGROUND

[0005] Consumers are increasingly interested in health and sustainability aspects of their diets. Meat and seafood reduction diets have gained popularity, leading to an increase in plant-based food products.

[0006] However, one of the chief problems of current crustacean seafood analogs is that they do not adequately replicate the texture and mouthfeel of crustacean meat, such as shrimp meat or lobster meat. The structure of crustacean meat, and the behavior of certain proteins therein, are unique in texture. This has generally made it difficult to replicate in crustacean seafood analog products. Expectations of crustacean seafood analogs have risen, as consumers are no longer willing to compromise on texture or mouthfeel at the expense of good intentions.

[0007] Disclosed herein are improved compositions and methods which more accurately replicate the characteristics that consumers value in the consumption of crustacean seafood analogs and which overcome the shortcomings and drawbacks of current crustacean seafood analogs.

[0008] SUMMARY

[0009] In one embodiment, a process for preparing a heat-stable crustacean seafood analog product comprises: a) forming a colloidal system comprising water, non-animal protein, and an edible crosslinkable polymer; b) forming the colloidal system into a shape; c) at least partially freezing the shape at a temperature of less than or equal to 0°C for a time sufficient to achieve an at least partially frozen shape; and d) subjecting the at least partially frozen shape to an aqueous source of monovalent, divalent, and / or trivalent cations, wherein during step d) the edible crosslinkable polymer is ionically crosslinked with the monovalent, divalent, and / or trivalent cations to form a heat-stable shape.

[0010] In another embodiment, a heat-stable crustacean seafood analog product comprising about 0.01% to about 30% non-animal protein, about 0.01% to about 20% edible polymer irreversibly crosslinked with about 0.01% to about 20% monovalent, divalent and / or trivalent cations, based on the total weight of the heat-stable crustacean seafood analog product, wherein the analog product has the shape of a crustacean, and wherein the analog product substantially replicates real crustacean meat in terms of mouthfeel, texture and / or taste.

[0011] These and other features, aspects and advantages of specific embodiments will become evident to those skilled in the art from a reading of the present disclosure.

[0012] DETAILED DESCRIPTION

[0013] The following text sets forth a broad description of numerous different embodiments of the present disclosure. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. It will be understood that any feature, characteristic, component, composition, ingredient, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, composition, ingredient, product, step or methodology described herein. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.

[0014] It should be understood that when a range of values is described in the present disclosure, it is intended that any and every value within the range, including the end points, is to be considered as having been disclosed. For example, “a range of from 50 to 100” of a component is to be read as indicating each and every possible number along the continuum between 50 and 100. It is to be understood that the inventors appreciate and understand that any and all values within the range are to be considered to have been specified, and that the inventors have possession of the entire range and all the values within the range.

[0015] In the present disclosure, the term “about” used in connection with a value is inclusive of the stated value and has the meaning dictated by the context. For example, it includes at least the degree of error associated with the measurement of the particular value. One of ordinary skill in the art would understand the term “about” is used herein to mean that an amount of “about” of a recited value produces the desired degree of effectiveness in the compositions and / or methods of the present disclosure. One of ordinary skill in the art would further understand that the metes and bounds of “about” with respect to the value of a percentage, amount or quantity of any component in an embodiment can be determined by varying the value, determining the effectiveness of the compositions for each value, and determining the range of values that produce compositions with the desired degree of effectiveness in accordance with the present disclosure. The term “about” is further used to reflect the possibility that a composition may contain trace components of other materials that do not alter the effectiveness or safety of the composition.

[0016] As used in this specification, the terms "comprises," "comprising," “contains,” “containing,” "includes," "including," "has," or "having," are all open-ended expressions and are intended to cover apparatus, compositions, methods, processes, products, or systems that comprise a recited list of components, elements, and features, and any and all additional components, elements and features that are not expressly recited. The terms "includes," "including," "has," or "having" are not intended to have a more narrow construction, interpretation, or meaning than the terms “comprises” or “comprising.”

[0017] As used in the present specification, the term "or" refers to an inclusive “or” and not to an exclusive “or”. For example, the phrase “A or B” is satisfied by any one of the following: A is present and B is not present, A is not present and B is present, and both A and B are present.

[0018] As used in the present specification, "a" or "an" is employed to describe components, elements, features and method / process steps of various illustrative embodiments disclosed herein. The use of “a” or “an” should be interpreted to include one or more than one.

[0019] As used in the present specification, any of the terms “illustratively,” "preferably," "commonly," and "typically" are not intended to, and do not, limit the scope of the claimed embodiments, or to imply that certain features are critical, essential, important, or required to the structure or function of the claimed processes and resulting meat analog products. Rather, these terms are merely intended to identify particular aspects of an embodiment or to emphasize alternative or additional features that may or may not be utilized in a particular embodiment.

[0020] The present disclosure is based on the surprising discovery that an improved texture, mouthfeel and overall shape can be achieved in crustacean seafood analog products using the disclosed methods and formulations. In addition, the textural properties of crustacean seafood analog products obtained by the disclosed methods correspond very well to the muscle texture of crustaceans and allow the replication of different shapes through a forming (e.g., molding) process. Accordingly, the disclosed formulation and preparation process provides for the production of natural, white, vegan crustacean seafood analogs that substantially replicate real crustacean meat in terms of mouthfeel, texture and / or taste. In an exemplary embodiment, an improved texture, mouthfeel and overall shape is achieved by a process including a forming (e.g., molding) and consecutive freezing step.

[0021] A “crustacean seafood analog product” is a food product that does not include crustacean meat, but approximates the aesthetic properties (for example, appearance, flavor, texture and mouthfeel) of crustacean meat, such as shrimp meat, mussel meat, crab meat and lobster meat. Disclosed is a process for preparing a heat-stable crustacean seafood analog product, the process comprising: a) forming a colloidal system comprising water, non-animal protein, and an edible crosslinkable polymer; b) forming the colloidal system into a shape; c) at least partially freezing the shape at a temperature of less than or equal to 0°C for a time sufficient to achieve an at least partially frozen shape; and d) subjecting the at least partially frozen shape to an aqueous source of monovalent, divalent, and / or trivalent cations, wherein during step d) the edible crosslinkable polymer is ionically crosslinked with the monovalent, divalent, and / or trivalent cations to form a heat-stable shape.

[0022] The phrase “heat-stable” refers to analog products that retain their shape when cooked as intended, for example, they do not disintegrate or dissolve when cooked on a frying pan. Slight changes in shape are acceptable provided they do not affect the preparation or the overall visual impression of the prepared analog product.

[0023] Colloidal System

[0024] In some cases, the colloidal system comprises water, non-animal protein, and an edible crosslinkable polymer. The components of the colloidal system may be added separately, sequentially or simultaneously to form the colloidal system.

[0025] In certain embodiments, the colloidal system comprises about 0.01% to about 50%, or 0.01% to about 30%, or about 0.1% to about 20%, or about 1% to about 10%, or any individual number within these ranges, of non-animal protein, based on the total weight of the colloidal system.

[0026] As used herein, the term “non-animal protein” refers to protein preparations made from raw materials including, but not limited to, plant protein material, grain (rice, millet, maize, barley, wheat, oat, sorghum, rye, teff, triticale, amaranth, buckwheat, quinoa); legume or pulses (soybean, sesame, mung beans, chickpeas, garbanzo, peas, fava beans, lentils, lima beans, lupins, peanuts, pigeon peas, runner beans, kidney beans, navy beans, pinto beans, azuki beans, cowpea, black-eyed peas); seed and oilseed (black mustard, India mustard, rapeseed, canola, safflower, sunflower seed, flax seed, hemp seed, poppy seed, pumpkin, chia, sesame); nut (almond, walnut, Brazil, Macadamia, cashews, chestnuts, hazelnuts, pine, pecans, pistachio and gingko); algal (kelp, wakame, spirulina, chlorella); mycoprotein or fungal protein; insects and leaf protein.

[0027] The non-animal protein may comprise at least one of: grain protein, legume protein, seed protein, nut protein, algal protein, mycoprotein, leaf protein, or insect protein.

[0028] In certain embodiments, the grain protein comprises at least one of rice, millet, maize, barley, wheat, oat, sorghum, rye, teff, triticale, amaranth, buckwheat, or quinoa. In certain embodiments, the legume protein comprises at least one of soybean, sesame, mung beans, chickpeas, garbanzo, peas, fava beans, lentils, lima beans, lupins, peanuts, pigeon peas, runner beans, kidney beans, navy beans, pinto beans, azuki beans, cowpea, or black-eyed peas.

[0029] In certain embodiments, the seed protein comprises at least one of black mustard, India mustard, rapeseed, canola, safflower, sunflower seed, flax seed, hemp seed, poppy seed, pumpkin, chia, or sesame.

[0030] In certain embodiments, the nut protein comprises at least one of almond, walnut, Brazil, Macadamia, cashews, chestnuts, hazelnuts, pine, pecans, pistachio or gingko.

[0031] According to certain embodiments, the processes and formulations disclosed herein include non-animal protein comprising plant protein. Exemplary plant proteins include soy protein and pea protein. Without limitation, suitable soy protein isolates are commercially available from Danisco A / S (Copenhagen, Denmark) under the designation SUPRO® EX 37 HG IP. Without limitation, a suitable textured soy protein is commercially available from Danisco A / S (Copenhagen, Denmark) under the designation SUPRO®MAX 5010. In certain embodiments, the non-animal protein comprises plant protein isolates and / or textured plant protein. In certain embodiments, the formulations and processes disclosed herein utilize at least two different non-animal proteins, for example, soy protein and pea protein. In certain embodiments, the colloidal system comprises vegetable protein isolate and textured vegetable protein in a weight ratio of about 2: 1.

[0032] In some cases, the process comprises preparing a non-animal protein base using about 1% to about 10% soy protein isolate, for example, SUPRO® ES 37 HG IP, from Danisco A / S (Copenhagen, Denmark) and 16-20% water, based on the total weight of the colloidal system. The process may comprise adding appropriate amounts of water and soy protein isolate into a bowl chopper and cutting with full vacuum until the soya protein isolate is suspended; pouring the suspension into a vacuum bag and applying vacuum; cooking to a core temperature of about 82°C; and cooling the material overnight at approximately 4°C.

[0033] The non-animal protein may be textured and / or non-textured. Textured proteins provide a certain texture, mouthfeel and / or appearance, as opposed to non-textured proteins, which can be added in the form of flour, concentrate, and / or isolate. In some cases, flour comprises at least about 50% protein, concentrate comprises at least about 70% protein, and isolate comprises at least about 90% protein.

[0034] In certain embodiments, the process comprises preparing a non-animal protein base using about 1% to about 5% textured vegetable protein, for example, (SUPRO® max 5010, from Danisco A / S (Copenhagen, Denmark) and 4-8% water. The process may comprise weighing out and hydrating the textured vegetable protein with water; packing the mixture in a vacuum bag and applying full vacuum; cooking to a core temperature of approximately 82°C; and cooling overnight at approximately 4°C.

[0035] In certain embodiments, the crustacean seafood analog product comprises textured nonanimal protein that has been subjected to a texturization treatment. Advantageously, the inventors have found that crustacean seafood analog products prepared by the disclosed processes exhibit improved crustacean-like visual appearance and texture without any extrusion step. Accordingly, in certain embodiments, the disclosed method does not include an extrusion step.

[0036] Texturization of protein is the development of a texture or a structure via a process involving temperature changes, and / or shear and the addition of water. Textured vegetable proteins (TVPs) can be defined as food products made from edible protein sources and characterized by having structural integrity and identifiable texture such that each unit will withstand hydration in cooking and other procedures used in preparing the food for consumption. A majority of TVPs produced today are produced by extrusion technology. These TVPs are often rehydrated with 60-65% moisture and blended with other ingredients including, but not limited to, binders, meats, other TVPs, flavors, excipients, fats, oils, or seasonings.

[0037] In certain embodiments, non-animal protein is placed in a vacuum sealable bag containing water and vacuum sealed for about 15 seconds and allowed to rest until the non-animal derived protein is partially or completely hydrated. The non-animal derived protein is at least partially hydrated for a period of time ranging from about 10 to about 30 minutes, or about 15 to about 25 minutes, or about 15 to about 20 minutes.

[0038] In certain embodiments, the non-animal protein is added to the colloidal system in an amount of at least 5% by weight, or at least 6% by weight, or at least 7% by weight, based on the total weight percent of the step a) ingredients. In certain embodiments, the non-animal derived protein is added to the colloidal system in an amount of about 2% to about 50% by weight, or about 3% to about 30% by weight, or about 5% to about 10% by weight, based on the total weight of the step a) ingredients.

[0039] In some cases, the non-animal protein is present in an amount of at least 2% by weight, or at least 3% by weight, or at least 4% by weight, or at least 5% by weight, or at least 6% by weight, based on the total weight percent of the crustacean seafood analog product. In certain embodiments, the non-animal protein is present in an amount of about 1% to about 50% by weight, based on the total weight of the crustacean seafood analog product. In certain embodiments, the non-animal derived protein is present in an amount of about 2% to about 30% by weight, based on the total weight of the crustacean seafood analog product. In certain embodiments, the non-animal derived protein is present in an amount of about 3% to about 15% by weight, based on the total weight of the crustacean seafood analog product.

[0040] According to certain embodiments, the process comprises cooking the non-animal protein before adding it to the colloidal system. In certain exemplary embodiments, non-animal protein is chopped into pieces and cooked to a core temperature of about 82°C and thereafter chilled over night at a temperature of about 4°C. The non-animal protein may be added to water and subjected to a chopping treatment until the non-animal protein is fully suspended in the water. The non-animal protein can be cooked according to techniques known in the art. In certain embodiments, the non-animal protein is transferred to a vacuum-sealed bag and cooked. According to certain embodiments, the non-animal protein is cooked in water at a constant temperature, such as about 85°C, under vacuum (sous-vide) until a core temperature of about 82°C is reached. In certain embodiments, cooked and chilled non-animal protein is added to the colloid system. The term “chilled” in this context refers to a temperature of about 2°C to about 6°C.

[0041] The non-animal protein may be added to the colloidal system to increase total protein content in consideration of the animal benchmark or NutriScore system, which assigns a color- coded letter grade (a green A for healthiest to a red E for unhealthiest) for food items based on the nutritional profile of the food. In certain embodiments, the non-animal protein comprises finely minced textured soya / pea flakes that have been extruded, and therefore are not functional in terms of imparting texturization to the analog product.

[0042] In certain embodiments, the formulations and processes disclosed herein are substantially free of animal-derived ingredients. As used herein, the phrase “substantially free” means that the formulations and processes disclosed herein include less than 5%, or less than 4%, or less than 3%, or less than 2%, or less than 1%, or less than 0.5% animal-derived ingredients. In certain embodiments, the formulations and processes disclosed herein are free of animal-derived ingredients. In certain embodiments, the crustacean seafood analog product obtained by the disclosed processes is vegan.

[0043] In certain embodiments, the colloidal system comprises about 0.01% to about 20%, or about 0.1% to about 10%, or about 0.5% to about 5%, or any individual number within these ranges, of an edible crosslinkable polymer, based on the total weight of the colloidal system.

[0044] The edible crosslinkable polymer may comprise a water-soluble polysaccharide. In certain embodiments, the edible crosslinkable polymer comprises pectin, carrageenan, alginate, gellan, or combinations thereof. In certain embodiments, the alginate comprises at least one of: sodium alginate, ammonium alginate, potassium alginate, or propylene glycol alginate. In certain embodiments, the alginate comprises sodium alginate. In certain embodiments, the colloidal system further comprises about 0.001% to about 10%, or about 0.01% to about 5%, or about 0.1% to about 1%, or any individual number within these ranges, of a starch, based on the total weight of the colloidal system. Without limitation, suitable starches include wheat starch, com starch, rice starch, oat starch, potato starch, and combinations thereof. In certain embodiments, the colloidal system comprises potato starch.

[0045] In certain embodiments, the colloidal system further comprises about 0.001% to about 10%, or about 0.01% to about 5%, or about 0.1% to about 1%, or any individual number within these ranges, of dextrose, based on the total weight of the colloidal system.

[0046] In certain embodiments, the colloidal system further comprises about 0.001% to about 5%, or about 0.01% to about 1%, or about 0.1% to about 0.5%, or any individual number within these ranges, of maltodextrin, based on the total weight of the colloidal system.

[0047] In certain embodiments, the colloidal system further comprises about 0.01% to about 20%, or about 0.1% to about 15%, or about 1% to about 10%, or any individual number within these ranges, of a plant-based fat, for example vegetable oil, based on the total weight of the colloidal system. In certain embodiments, the plant-based fat comprises algal oils, insect oils and / or vegetable-derived oils. Without limitation, and only by way of illustration, suitable vegetable oils include almond oil, avocado oil, canola oil, coconut oil, corn oil, cottonseed oil, flaxseed oil, hazelnut oil, illipe oil, linseed oil, palm oil, palm kernel oil, peanut oil, pecan oil, pumpkin seed oil, oat oil, olive oil, rapeseed oil, safflower oil, sesame oil, shea oil, soybean oil, sunflower oil, walnut oil, and mixtures thereof. In some cases, the plant-based fat comprises coconut oil.

[0048] In certain embodiments, the process comprises preparing a colloidal system comprising an edible crosslinkable polymer, a starch, water, dextrose, a vegetable oil, and optionally a source of cations. The process may comprise weighing out the dry matter into a container and dry-blending; melting the vegetable oil; weighing out water; pouring the water and vegetable oil into a cutter bowl; adding the dry mixture and vacuum cutting until the mixture is homogeneous and all ingredients are in solution; and adding non-animal protein to the colloidal system.

[0049] In certain embodiments, step a) compromise forming a colloidal system comprising water, non-animal protein, an edible crosslinkable polymer, a plant-based fat, and at least one of starch, maltodextrin, or dextrose, and further optionally a source of monovalent, divalent, and / or trivalent cations. In certain embodiments, the source of monovalent cations comprises at least one of sodium or potassium. In certain embodiments, the source of divalent cations comprises at least one of calcium, magnesium, or zinc. In certain embodiments, calcium comprises a calcium salt, which may comprise at least one of calcium chloride, calcium lactate, or calcium carbonate. The process comprises forming the colloidal system into a shape. In certain embodiments, the shape comprises a crustacean shape selected from at least one of: a shrimp shape, a prawn shape, a mussel shape, a crab shape, a lobster shape, or a crayfish shape. In some cases, step b) comprises molding the colloidal system formed in step a) into a shape. In certain embodiments, the molding process utilizes a mold having the approximate shape of a crustacean, e.g., a shrimpshaped mold.

[0050] The process comprises at least partially freezing the shape formed in step b). The shape may be at least partially frozen according to techniques known in the art. The process may comprise at least partially freezing the shape under slow freeze processing, for example, at a temperature of about -10°C to about -30°C for about 1 hour to about 12 hours, or any individual number within these ranges. In certain embodiments, step c) does not include a blast-freezing. Blast freezing is the process of pushing very cold air over a food product in order to freeze it as quickly as possible.

[0051] In some cases, the process comprises at least partially freezing the shape at about 0°C to about -35°C for about 1 hour to about 24 hours, or any individual number within these ranges.

[0052] In some cases, the process comprises at least partially freezing the shape at about -10°C to about -25°C for about 3 hours to about 12 hours, or any individual number within these ranges.

[0053] In some cases, the process comprises at least partially freezing the shape at about -15°C to about -25°C for about 5 hours to about 10 hours, or any individual number within these ranges.

[0054] In certain embodiments, step c) of the process comprises subjecting the at least partially frozen shape to freeze structuring or freeze alignment treatment, which involves the creation of a stable particle suspension or a slurry which is then subjected to temperatures at which the dispersing fluid (e.g., water) freezes. The freezing can occur from one or several sides of the dispersion which, in the case of water, leads to the formation of anisotropic ice crystals perpendicular to the freezing surface. These ice crystals push the dispersed solid phase aside to form areas of accumulated particles, such as the non-animal protein. The texturized shape created during the freeze structuring process can be stabilized, commonly either by employing heat, freeze-drying, gelling agents or non-solvents. In some cases, the at least partially frozen shape is subjected to a freeze-drying treatment.

[0055] In freeze structuring, an aqueous mixture or slurry of proteins is frozen to generate structure. When heat is extracted from a uniformly mixed slurry, it results in an isotropic structure. However, if heat is removed unidirectionally without mixing, the alignment of ice crystal needles produces anisotropic structures. The size of the ice crystal needles can be adjusted by controlling the freezing temperature and rate. For the production of distinct fibrous products, the proteins need to exhibit good solubility before freezing, and during the freezing process, they undergo a transition to insolubility. Following freezing, an additional step (such as freeze-drying or the addition of calcium chloride) can be carried out to achieve the desired properties of the structured product.

[0056] In certain embodiments, the process comprises unidirectionally freezing the shaped colloidal system of step b) to form ice crystals capable of inducing an anisotropic physical (preferably textural) structure to the shaped product. In some cases, the crustacean seafood analog product disclosed herein mimics the anisotropic properties such as texture behavior of real crustacean meat.

[0057] In the case of anisotropic foods, the properties of the food product are direction dependent. Crustacean meat or flesh is known to be an anisotropic food due to its fibrous nature. For example, the presence of fiber bundles in crustacean meat results in different values of texture profile as well as thermal conductivity, when measured parallel to the fibers versus perpendicular to them. In some examples, the anisotropic physical property is a textural property, such as hardness, gumminess, chewiness, young module, cohesiveness and adhesiveness. The anisotropic textural profile can be determined by techniques known in the art, e.g. using Texture Profile techniques. For example, a texturometer (also know as texture profile analyzer — TP A) applies a test where a product sample is compressed twice and the force-time curves are analyzed to provide texture profile analysis (TP A) parameters for the sample. Scales have been developed for rating the degree of chewiness, gumminess, cohesiveness and adhesiveness of the sample, as perceived by a sensory panel, even for crustacean meat [Szczesniak et al. The Texturometer — A New Instrument For Objective Texture Measurement, Journal of Food Science, Volume 28, pp 390-396 (1963), the content of which is incorporated herein by reference].

[0058] The process further comprises subjecting the at least partially frozen shape to an aqueous source of monovalent, divalent, and / or trivalent cations, wherein during this step the edible crosslinkable polymer is ionically crosslinked with the monovalent, divalent, and / or trivalent cations to form a heat-stable shape. The term “subjecting” in this context means applying the aqueous source of monovalent, divalent, and / or trivalent cations to the at least partially frozen shape, such as, for example, by introducing, dispensing, diffusing, exposing, and the like.

[0059] In some cases, the process comprises forming a solution comprising about 0.1% to about 10% a source of cations and at least 80%, or at least 90% water. In the certain embodiments, the process comprises weighing dry ingredients and water separately; and adding a source of cations, for example, calcium lactate, to water and mixing until dry ingredients are fully dissolved.

[0060] In some case, the process comprises at least partially thawing the at least partially frozen shape in an aqueous medium comprising the source of monovalent, divalent, and / or trivalent cations for a time sufficient to achieve crosslinking between the edible crosslinkable polymer and monovalent, divalent, and / or trivalent cations.

[0061] In some case, the process comprises subjecting the at least partially frozen shape to an aqueous medium comprising a source of monovalent, divalent, and / or trivalent cations at about 3°C to about 30°C or about 3°C to about 20°C or 5°C to about 15°C for about 30 minutes to about 48 hours, or about 1 hour to about 48 hours, or about 6 hours to about 48 hours, or any individual number within these ranges.

[0062] In some case, the process comprises subjecting the at least partially frozen shape to an aqueous medium comprising a source of monovalent, divalent, and / or trivalent cations at about 3 °C to about 20°C for about 5 hours to about 36 hours, or any individual number within these ranges.

[0063] In some case, the process comprises subjecting the at least partially frozen shape to an aqueous medium comprising a source of monovalent, divalent, and / or trivalent cations at about 5°C to about 15°C for about 10 hours to about 30 hours, or any individual number within these ranges.

[0064] In certain embodiments, the source of monovalent cations comprises at least one of sodium or potassium. In certain embodiments, the source of divalent cations comprises at least one of calcium, magnesium, or zinc. In certain embodiments, the source of trivalent cations comprises iron. In certain embodiments, calcium comprises a calcium salt, which may comprise at least one of calcium chloride, calcium lactate, or calcium carbonate.

[0065] The source of a source of monovalent, divalent, and / or trivalent cations may be in a solution with an edible salt. Edible salts may include those typically employed in the food and beverage industry and include chlorides, sulphates, phosphates, gluconates, sodium, citrates, carbonates, acetates and lactates.

[0066] The process may further comprise adding a flavorant. In certain embodiments, the process comprises adding a flavorant to the shape after step d). By “flavorant”, it is meant a composition created by a flavorist using methods known to the skilled person that may be a mixture of tastants, aroma compounds and / or sensates. The flavorant may be a liquid, gel, colloid, or particulate solid, for example, an oil, an extract, an oleoresin, or the like. In certain embodiments, flavorants may include any one or more food-grade flavorants that do not substantially dissolve in water.

[0067] Without limitation, and only by way of illustration, the flavorants may include fish flavor, seafood flavors (including, for example, salmon, tuna, lobster, clam, crab, mussel, scallop, shrimp, oyster), seasonings, spices, herbs, sweet tastants, salty tastants, umami tastants, taste enhancers, taste modifiers, and the like. Examples of suitable flavorants include natural flavors, artificial flavors, spices, seasonings, and the like. Exemplary flavorants include synthetic flavor oils and flavoring aromatics and / or oils, oleoresins, essences, and distillates, and a combination comprising at least one of the foregoing. Generally, any flavorant such as those described in "Chemicals Used in Food Processing", Publication No 1274, pages 63-258, by the National Academy of Sciences, can be used.

[0068] In certain embodiments, at least one flavorant is dissolved in cold water to form a flavour brine. In certain embodiments, after the shapes have been subjected to, for example, thawed in, the aqueous source of monovalent, divalent, and / or trivalent cations, the shapes and the flavour brine may be added to a container that is subjected to heat treatment. For example, the material may be heated to about 80°C to about 90°C for about 30 minutes, or until a core temperature of about 82°C is reached for about 20 minutes. Subsequent to the heating step, the shapes may be subjected to a blast freezing treatment and stored in a freezer.

[0069] In certain embodiments, at least one flavorant is added after step d) in an amount of about 0.1% to about 10% by weight, or about 0.3% to about 5% by weight, based on the total weight of the analog product. In one example, the crustacean seafood analog product may include a flavorant in an amount from about 0.3% to about 5%, or any individual number within the range, by weight of the product.

[0070] In some cases, the process comprises preparing a flavour brine comprising about 0.5% to about 10% flavorant and 95-97% water. The process comprises weighing flavour and dissolving in cold water; adding 50% flavour brine to shaped analog products; cooking at 85 °C for approximately 30 minutes until a core temperature of 82 °C is reached; and blast freezing the shaped analog products and storing in the freezer.

[0071] In certain embodiments, subsequent to step d), the process comprises cooking the shape at about 80°C to about 90°C for about 30 minutes followed by an optional freezing step. According to certain embodiments, the process comprises freezing the cooked shape. The shape may be frozen according to techniques known in the art. Various methods such as air-blast freezing, liquefied gas freezing, and brine freezing methods may be utilized. In certain embodiments, the shape is rapidly frozen using standard air-blast freezing techniques.

[0072] Advantageously, the presently disclosed process enables the texturization of a plant-based system at temperatures where no Maillard browning reactions occur, which would otherwise create browning tones which are not characteristic to the white flesh of crustaceans. Controlling Maillard reactions has been a central and major challenge in food industry, because aroma, taste and sensorial properties as well as colour are all strongly affected by Maillard chemistry. During the Maillard reaction a wide range of reaction products is formed with significant importance for amongst others the taste of foods. The chemistry underlying the Maillard reaction is very complex. It involves not one reaction pathway but a whole array of various reaction cascades. The Maillard reaction is most commonly known as the reaction of an amino group of e.g. an amino acid, peptide or protein, with the keto group of a sugar, followed by other, more complex changes which result eventually in the formation of a variety of volatiles and non-volatiles.

[0073] Food color is one of its most sensory attributes, as it plays an important role in food quality and affects how consumers evaluate other sensory and non-sensory features. Product color can influence customer acceptability and price, and many food industries - including the seafood industry - consider it a critical quality parameter.

[0074] As crustaceans have a typically white flesh, analogues should replicate this characteristic as closely as possible. Clean label whiteners for meat / fish analogues are not sufficient to achieve the desired white appearance in products with high non animal protein, such as vegetable protein, content. Titanium dioxide is currently the only whitener option, but is not well perceived by consumers. Therefore, a texturisation method that does not create additional browning tones is needed in the art and provided for the first time by the disclosed invention.

[0075] For the purposes of the present invention, color is defined according to a value on the CIELAB color system, which is based on the XYZ color system, defined by the Commission Internationale de 1'Eclairage (CIE system) to provide a manner of objectively representing perceived color and color differences. X, Y and Z can be expressed in a variety of manners, or “scales,” one of which is the Hunter scale. The Hunter scale has three variables, L, a, and b, which correlate mathematically to X, Y and Z, and is described by Robertson, A. R. in “The CIE 1976 Color Difference Formulas,” Color Research Applications, vol. 2, pp. 7-11 (1977).

[0076] The analog products of the present invention may be analyzed with a MINOLTA® CR- 200 Chroma Meter, which generates values for L, a, and b. The CIELAB, or CIE L* a* b*, color system represents quantitative relationship of colors on three axes: L* value indicates lightness, and a* and b* are chromaticity coordinates. On the color space diagram, L* is represented on a vertical axis with values from 0 (black) to 100 (white). The invention provides in another of its aspects, a crustacean seafood analog product free of a white colorant having an L* value of about 60 to about 100, or about 70 to about 90, or any individual number within these ranges.

[0077] The disclosed processes may be used to prepare a wide variety of crustacean seafood analog products, including hybrid fish comprising a plant-originated substance with cultured fish cells or fish substitute products. According to certain embodiments, the crustacean seafood analog is a vegetarian food product. In other embodiments, the crustacean seafood analog is a vegan food product containing only plant-derived components and no animal-derived components. Also disclosed are crustacean seafood analog products obtained and / or obtainable by the processes disclosed herein. In certain embodiments, the crustacean seafood analog products substantially replicates real crustacean meat in terms of mouthfeel, texture and / or taste. The phrase “substantially replicates” refers to crustacean seafood analog products having at least 80%, or at least 85%, or at least 90, or at least 95%, or at least 99% of the mouthfeel, texture and / or taste of real crustacean meat.

[0078] Also disclosed is a heat-stable crustacean seafood analog product comprising about 0.01% to about 30% non-animal protein, about 0.01% to about 20% edible polymer irreversibly crosslinked with about 0.01% to about 20% monovalent, divalent and / or trivalent cations, based on the total weight of the heat-stable crustacean seafood analog product, wherein the analog product has the shape of a crustacean, and wherein the analog product replicates real crustacean meat in terms of mouthfeel, texture and / or taste.

[0079] In certain embodiments, the heat-stable crustacean seafood analog product comprises about 0.1% to about 20% non-animal protein, about .1% to about 10% edible polymer irreversibly crosslinked with about .1% to about 10% monovalent, divalent and / or trivalent cations, based on the total weight of the heat-stable crustacean seafood analog product.

[0080] In certain embodiments, the heat-stable crustacean seafood analog product comprises about 1% to about 10% non-animal protein, about 1% to about 5% edible polymer irreversibly crosslinked with about 1% to about 5% monovalent, divalent and / or trivalent cations, based on the total weight of the heat-stable crustacean seafood analog product.

[0081] In some cases, the shaped analog product replicates real crustacean meat in terms of mouthfeel, texture and / or taste. In certain embodiments, the crustacean shape is selected from at least one of shrimp shapes, prawn shapes, mussel shapes, crab shapes, lobster shapes, or crayfish shapes.

[0082] Various non-animal proteins provide undesirable off-notes. Particularly, undesirable off- notes are the beany, bitter, grassy, astringent, earthy, chalky, and rancid off-notes from pea and soy proteins. The term “off-note” refers to an unpleasant flavour and after taste that develops over time after consumption of consumables. The addition of maskers will block, mask or modify the off-notes and make them less apparent or unnoticeable. Non-animal proteins will thereby lose their beany / bitter / grassy / astringent / earthy / chalky / rancid taste.

[0083] According to one embodiment, suitable masking agents for use in accordance with the present disclosure include fatty acids including, but not limited to, nonanoic acid, decanoic acid, dodecanoic acid, tetradecanoic acid, hexadecanoic acid, oleic acid, octanoic acid, 9-decenoic and hexanoic. In another embodiment, suitable masking agents include carbonyls including, but not limited to, acetone, acetyl propionyl, 2-heptanone, 2-nonanone, 2-undecanone and cis-4-heptenal.

[0084] In another embodiment, suitable off-note blocking compounds include sulfur, including, but not limited to, isothiocyanates, methyl sulfide, diallyl disulfide, propenyl disulfide, dimethyl sulfide, dimethyl trisulfide and extracts of alliaceous ingredients. In another embodiment, the sulfur components may be found in sulfur containing oils such as, for example, garlic oil, onion oil, mustard oil and horseradish oil.

[0085] In another embodiment, suitable masking agents include sweet browns including, but not limited to, maltol, vanillin, cyclopentenolone, furaneol, vanilla extracts, vanilla derivatives, caramel extracts and condensed milk derivatives.

[0086] In another embodiment, suitable masking agents include esters including, but not limited to, ethyl cyclohexanoate, ethyl succinate, ethyl lactate, ethyl caprate, ethyl dodecanoate, ethyl myristate, ethyl palmitate and ethyl oleate.

[0087] In another embodiment, suitable masking agents include sweeteners including but not limited to, steviol glycosides such as rebaudiosides; rebusodide, swingle extract, mogroside V, erythritol, glucosylated steviol glycosides, honey distillates and sugar distillates.

[0088] In another embodiment, suitable masking agents include lactones including, but not limited to, gamma decalactone, delta decalactone, delta dodecalactone, gamma undecalactone and massoia lactone.

[0089] In another embodiment, masking agents include juice derivatives including, but not limited to, strawberry, cucumber, apple, cherry, kiwi and apricot.

[0090] According to one embodiment, suitable masking agents for use in accordance with the present disclosure include terpenes including, but not limited to, fenchol, terpineol, caryophyllene, bisabolene, famoscene and farnesol. In another embodiment, suitable terpenes include, but are not limited to, carotenes (such as, for example, alpha -carotene, beta -carotene, gamma -carotene, delta -carotene, lycopene, neurosporene, phytofluene, phytoene), and xanthophylls (such as, for example, canthaxanthin, cryptoxanthin, aeaxanthin, astaxanthin, lutein, rubixanthin); monoterpenes (such as, for example, limonene, perillyl alcohol); sesquiterpenes (such as, for example, caryophyllene, P-caryophyllene, zingiberene); saponins; lipids including: phytosterols, campesterol, beta sitosterol, gamma sitosterol, stigmasterol, tocopherols (vitamin E), and omega -3, -6, and -9 fatty acids (such as, for example, gamma-linolenic acid); triterpenoids (such as, for example, oleanolic acid, ursolic acid, betulinic acid, moronic acid); alpha-pinenes, cis-beta-ocimenes and bisabolenes (such as alpha-bisabolene and gamma- bisabolene). In one example, the crustacean seafood analog product may include a masking agent in an amount from about 0.1% to about 0.3%, or any individual number within the range, by weight of the product.

[0091] EXAMPLES

[0092] The following examples are given solely for the purpose of illustration and are not to be construed as limitations of the present disclosure, as many variations of the invention are possible without departing from the spirit and scope of the present disclosure.

[0093] Shrimp Analog Base Material

[0094] A vegan shrimp analog base material was prepared according to the following process. The following weight percentages of ingredients are based on the total weight of the shrimp analog base material, i.e., the combination of Phases 1, 2 and 3.

[0095] Phase 1 - A solution was prepared using 2-6% sodium alginate, 0.5 to 5% potato starch, 50-60% water, 0,5-5% dextrose, 0,5-10% sunflower oil, and 3-15% coconut fat as ingredients.

[0096] Method

[0097] 1. Weigh out the dry matter into a container and dry-blend;

[0098] 2. Weigh out the coconut fat and melt;

[0099] 3. Weigh out water and vegetable oil;

[0100] 4. Pour the water, vegetable oil and melted coconut oil into a cutter bowl;

[0101] 5. Add the dry mixture and vacuum cut until the mixture is homogeneous and all ingredients are in solution; and

[0102] 6. Add phases 2 and 3, as described below.

[0103] Phase 2 - A non-animal protein base was prepared using 4-5% soy protein isolate (SUPRO® ES 37 HG IP, from Danisco A / S (Copenhagen, Denmark) and 16-20% water.

[0104] Method

[0105] 1. Add appropriate amounts of water and soy protein isolate into the bowl chopper and cut with full vacuum until the soya protein isolate is completely suspended; 2. Pour into a vacuum bag and apply vacuum;

[0106] 3. Cook to a core temperature of about 82°C; and

[0107] 4. Let cool overnight at approximately 4°C.

[0108] Phase 3 - A non-animal protein base was prepared using 2-4% textured vegetable protein (SUPRO® max 5010, from Danisco A / S (Copenhagen, Denmark) and 4-8% water.

[0109] Method

[0110] 1. Weigh out and hydrate the textured vegetable protein with water;

[0111] 2. Pack the mixture in a vacuum bag and apply full vacuum;

[0112] 3. Cook to a core temperature of approximately 82°C; and

[0113] 4. Cool overnight at approximately 4°C.

[0114] The shrimp analog base material was then formed into a shrimp shape using a mold. The shrimp shape was then frozen at -20°C for 12 hours.

[0115] Cation Solution

[0116] A cation solution was prepared using 1-3% source of divalent cation (i.e., calcium lactate), 0.1-% salt, and 96-99% water.

[0117] Method

[0118] 1. weigh dry ingredients and water separately;

[0119] 2. add salt and calcium lactate to water and mix until dry ingredients are fully dissolved.

[0120] The frozen shrimp shape was added to the cation solution and stored at 4°C for approximately 48 hours.

[0121] Flavour Brine

[0122] A flavour brine was prepared using 3-5% shrimp flavorant commercially available from Givaudan Flavors Corporation of Cincinnati, Ohio, and 95-97% water. Method

[0123] 1. Weigh flavour and dissolve in cold water;

[0124] 2. Add 50% flavour brine to shrimp analogs;

[0125] 3. Cook at 85 °C for approximately 30 minutes until a core temperature above 82 °C is reached;

[0126] 4. Blast freeze shrimp analogs and store in freezer.

[0127] Sensory evaluation was carried out on the shrimp analog products prepared by the above process by eleven trained expert panelists. The panel performed a blind evaluation of the texture and mouthfeel of the shrimp analog products prepared by the above inventive process, as compared to conventional shrimp analogs that were not made according to the above process. The panel concluded that the shrimp analog products prepared by the inventive process replicated the texture and mouthfeel of real shrimp meat significantly better than shrimp analogs prepared according to conventional methods. In particular, the shrimp analog products prepared by the above-described inventive process were deemed to provide a springiness and moisture similar to real shrimp meat. The color of the shrimp analog products prepared by the inventive process present was analyzed with a spectrophotometer, and CIELAB L* values were determined. Advantageously, despite not using a white colorant, the shrimp analog product prepared by the inventive process had L* values of 77.71 and 78.22, which is characteristic of the typically white flesh of crustacean meat.

[0128] While the heat-stable crustacean seafood analog product, and methods of making heatstable crustacean seafood analog products have been described in connection with various embodiments, it is to be understood that other similar embodiments may be used or modifications and additions may be made to the described embodiments for performing the same function. Furthermore, the various illustrative embodiments may be combined to produce the desired results.

[0129] Although process steps or the like may be described in a sequential order, such processes may be configured to work in alternate orders. In other words, any sequence or order of steps that may be described in this disclosure does not, in and of itself, indicate a requirement that the steps be performed in that order. The steps of described processes may be performed in any order practical. Further, some steps may be performed simultaneously despite being described or implied as occurring non-simultaneously (e.g., because one step is described after the other step).

Claims

What is claimed is:

1. A process for preparing a heat-stable crustacean seafood analog product, the process comprising: a) forming a colloidal system comprising water, non-animal protein, and an edible crosslinkable polymer; b) forming the colloidal system into a shape; c) at least partially freezing the shape at a temperature of less than or equal to 0°C for a time sufficient to achieve an at least partially frozen shape; and d) subjecting the at least partially frozen shape to an aqueous source of monovalent, divalent, and / or trivalent cations, wherein during step d) the edible crosslinkable polymer is ionically crosslinked with the monovalent, divalent, and / or trivalent cations to form a heat-stable shape.

2. The process according to claim 1 further comprising adding monovalent, divalent, and / or trivalent cations to step a).

3. The process according to claim 1, wherein the colloidal system comprises about 0.01% to about 30% non-animal protein and about 0.01% to about 20% edible crosslinkable polymer, based on the total weight of colloidal system.

4. The process according to claim 1, wherein the colloidal system comprises at least two different non-animal proteins.

5. The process according to claim 1, wherein step c) comprises at least partially freezing the shape at a temperature of about -10°C to about -30°C for about 1 hour to about 12 hours.

6. The process according to claim 5 comprising unidirectionally freezing the shaped colloidal system to form ice crystals capable of inducing an anisotropic structure to the crustacean seafood analog product.

7. The process according to claim 6, wherein the at least partially frozen shape is subjected to a freeze-drying treatment.

8. The process according to claim 1, wherein step d) comprises at least partially thawing the at least partially frozen shape in an aqueous medium comprising the source of monovalent, divalent, and / or trivalent cations.

9. The process according to claim 8 comprising thawing the at least partially frozen shape in the aqueous medium at about 3 °C to about 30°C for about 30 minutes to about 48 hours.

10. The process according to claim 1, wherein the edible crosslinkable polymer comprises a water soluble polysaccharide.

11. The process according to claim 1, wherein the edible crosslinkable polymer comprises an alginate.

12. The process according to claim 11, wherein the alginate comprises at least one of: sodium alginate, ammonium alginate, potassium alginate, or propylene glycol alginate.

13. The process according to claim 1, wherein the source of monovalent cations comprises at least one of: sodium or potassium.

14. The process according to claim 1, wherein the source of divalent cations comprises at least one of: calcium, magnesium, or zinc.

15. The process according to claim 14 comprising a calcium salt, a magnesium salt, or combinations thereof.

16. The process according to claim 15, wherein the calcium salt comprises at least one of calcium chloride, calcium lactate, or calcium carbonate.

17. The process according to claim 1 further comprising adding at least one flavorant after step d).

18. The process according to claim 1 further comprising cooking the shape at about 80°C to about 90°C for about 20 minutes to about 30 minutes after step d).

19. The process according to claim 1 comprising cooking the non-animal protein until a core temperature of about 82°C is achieved before adding the non-animal protein to the colloidalsystem of step a).

20. The process according to claim 1, wherein the non-animal protein comprises at least one of grain protein, legume protein, seed protein, nut protein, algal protein, mycoprotein, leaf protein, or insect protein.

21. The process according to claim 20, wherein the grain protein comprises at least one of rice, millet, maize, barley, wheat, oat, sorghum, rye, teff, triticale, amaranth, buckwheat, or quinoa; wherein the legume protein comprises at least one of soybean, sesame, mung beans, chickpeas, garbanzo, peas, fava beans, lentils, lima beans, lupins, peanuts, pigeon peas, runner beans, kidney beans, navy beans, pinto beans, azuki beans, cowpea, or black-eyed peas; the seed protein comprises at least one of black mustard, India mustard, rapeseed, canola, safflower, sunflower seed, flax seed, hemp seed, poppy seed, pumpkin, chia, or sesame; the nut protein comprises at least one of almond, walnut, Brazil, Macadamia, cashews, chestnuts, hazelnuts, pine, pecans, pistachio or gingko.

22. The process according to claim 1, wherein the crustacean seafood analog product is vegan.

23. The process according to claim 1, wherein no Maillard reaction occurs.

24. The process according to claim 1, wherein the process does not include a white colorant.

25. The process according to claim 1, wherein the crustacean shape is selected from at least one of: a shrimp shape, a prawn shape, a mussel shape, a crab shape, a lobster shape, or a crayfish shape.

26. A crustacean seafood analog product obtainable by the process according to claim 1.

27. The crustacean seafood analog product according to claim 26, wherein the crustacean seafood analog product replicates real crustacean meat in terms of mouthfeel, texture and / or taste.

28. A heat-stable crustacean seafood analog product comprising about 0.01% to about 30% non-animal protein, about 0.01% to about 20% edible polymer irreversibly crosslinked with about 0.01% to about 20% monovalent, divalent and / or trivalent cations, based on the total weight of the heat-stable crustacean seafood analog product, wherein the analog product has the shape of acrustacean, and wherein the analog product replicates real crustacean meat in terms of mouthfeel, texture and / or taste.