Method for producing cookable, grillable or fryable meat- or fish-substitute products from vegetable components, and meat- or fish-substitute product

Abstract

The invention relates to a method for producing cookable, grillable or fryable meat- or fish-substitute products (1) from vegetable components, wherein a fibrous starting mass (2) is produced from a vegetable base material, is dispensed by an extruder (3) by wet extrusion in the form of a continuous strand (4), and after leaving the extruder (3) is cut into individual portions (5). The known methods have the disadvantage that it is not possible to produce three-dimensional products. The invention improves on this in that frozen strand sections for forming individual portions (5) are produced from the strand (4) and, as starting material, are subjected to a moulding process in a pressing device (6) individually or in a combination of two or more individual portions (5).

Description

Process for producing meat or fish substitutes from vegetable components that can be cooked, grilled or fried, and meat or fish substitute products.

[0001] Due to increasingly scarce resources, there is a growing need to replace animal products in the food sector with plant-based products. To protect animals and the environment, many consumers are increasingly demanding that they avoid meat or fish products. The invention relates to a process for producing meat or fish substitutes from plant-based components, as well as to a meat or fish substitute produced by such a process.

[0002] These processes are characterized by the fact that an input mass is produced from a plant-based material, which is then extruded by an extruder using the wet extrusion process as a continuous strand. After exiting the extruder, the resulting strand is divided into individual portions. These individual portions can then be used to produce the desired product, although due to the manufacturing process, these are two-dimensional products.

[0003] Proteins for the production of substitute products are known, for example, from WO 23017140 A1 as textured vegetable protein (TVP) with field bean protein and pea protein, wherein the textured vegetable protein in this case comprises at least 60% by weight of field bean protein and pea protein, based on the dry weight of the TVP.

[0004] A method of this type is known from DE 10 2017 223 829 A1 in connection with the description of a cooling nozzle for the production of extruded meat substitutes. In this process, a strand material is produced as a continuous material via the nozzle, and the continuous strand is shredded for further processing, for example, by cutting it into strips, cubes, or other geometries.

[0005] From WO 23275305 A1 a system for producing a protein-containing meat analogue is known, which comprises a nozzle and a flow path of the mass, wherein a cooling component is arranged downstream of the nozzle and the flow path runs through the cooling chamber.

[0006] The use of an extruder for producing a meat substitute product is known from EP 3 927 176 A1. The extrusion system described therein comprises an extruder and a nozzle, wherein the extruder is connected to the nozzle and is configured to direct a material comprising an animal protein from the extruder to the nozzle and through a fluid path extending through the short nozzle. The nozzle is configured to inject fat or a fat analogue into the material such that the fat or fat analogue remains embedded but visually distinguishable from the material comprising the animal protein when the fat or a fat analogue and protein material exit the nozzle.

[0007] The use of a twin-screw extruder to produce a strand material is known from EP 4 094 583 A1. Here, vegetable proteins from pulses, in particular pea protein, are used as the main source for twin-screw extrusion to produce a textured protein piece with a medium moisture content, which can be further processed by controlled hydration and coated with a batter, breading, or coating to produce an edible product.

[0008] WO 23 052 130 A1 discloses an extrusion system and a method for producing a meat analogue, comprising an extruder and a nozzle, wherein a nozzle of the extruder comprises a feed section with at least two ports for injecting a protein phase and a fat phase, a feed channel, an extrusion plane with side walls, and a nozzle outlet. The protein phase and the fat phase are conveyed from the feed section to an extrusion plane.

[0009] The substitute products produced using the known process have the disadvantage that their shape is usually a strict geometric basic form with smooth edges and surfaces, which consumers often perceive as artificial and unpleasant. Furthermore, they have a structure that is more reminiscent of tofu or other substitute products, but fails to create the impression of a real piece of meat or fish. This is significantly improved by the present invention. Technical task

[0010] The object of the invention is to create a method for producing a meat or fish substitute product from plant components, in which the greatest possible variety of shapes of the end product is possible and which, with sufficient firmness of the product, has the most pleasant possible consistency for the consumer both during preparation and consumption, in particular reminiscent of the fiber structure or the structure of pieces of meat or fish. Technical solution

[0011] This object is achieved according to the invention in that, as previously known, individual strand sections are first cut from the strand material, then these strand sections are frozen and the frozen strand sections are then divided into the individual portions. The still frozen individual portions are then subjected to a shaping process as input material, individually or in a combination of two or more individual portions. The shaping process is carried out using a pressing device which has at least one pressing ram and at least one abutment against which the pressing ram can be placed, and which is designed such that when the pressing ram is placed against the abutment, at least one cavity for shaping the input material remains between a pressing surface of the pressing ram and the abutment.

[0012] In the forming process, the frozen individual portions or the composite of several individual portions are formed via the press ram and the abutment into the meat or fish substitute product that can be cooked, grilled or fried and has the desired contour and desired fiber pattern of the fibrous input material. Beneficial effects

[0013] The invention now makes it possible to produce virtually any desired shape. Molding processes for producing food products that, for example, resemble a piece of natural muscle meat are known from EP 3 128 847 B1 or WO 2009 052 865 A1.

[0014] In these well-known pressing processes, pieces of natural muscle meat, either one piece at a time or several as a composite of individual pieces, are placed in a mold and then pressed to form a compact shape. Depending on the contours of the mold, a coherent piece is created, bound together by proteins, which is very similar to a piece cut from a piece of muscle meat. However, prior weight optimization and uniform shaping during the pressing process make it possible to produce pieces of the same weight under the same preparation conditions. This not only prevents weight fluctuations but also prevents overcooking of pieces that are too thin or undercooking of thick pieces, for example, when the pieces are prepared together in a commercial kitchen.

[0015] When manufacturing meat or fish substitutes from plant-based components, it was previously assumed that a uniform basic product structure was unavoidable, dictated by the mass emerging from the extruder. The invention now makes it possible to preserve the fiber orientation of a fibrous plant-based input material and incorporate it into the forming process during the final product manufacturing process. This allows for the creation of a similar impression to that of the fibers of a meat product. This gives the final product, namely the meat or fish substitute, a significantly more valuable appearance during preparation and consumption.

[0016] While pressing muscle meat and fish with a pressing device as described above is feasible for a person skilled in the art because binding forces arise from the released proteins and the existing fiber structure of the meat or are already present, this is not necessarily the case with plant-based, protein-containing substitutes. Therefore, a person skilled in the art initially assumes that forming a frozen product and subsequent cooking after thawing is not possible because the product will subsequently disintegrate. The invention now changes this by initially preserving the fiber structure and, in particular, taking it into account during the forming process.

[0017] By using a pressing forming machine instead of the cutting machines previously used, any contours can now be produced in addition to the smooth, often unnatural-looking edges and shapes.

[0018] First, the plant-based material is used as the input product in the wet extrusion process to produce a strand material that continuously emerges from the extruder nozzle. In this respect, this first step is no different from the previously known processes mentioned above. The strand material is then divided into shorter pieces, i.e., individual portions. In this process, the fiber structure is preserved and respected. By using an extruder, fibers of the plant-based material automatically align radially to the screw axis of the extruder, resulting in a circular fiber pattern in the front area of ​​the screw due to the mass being conveyed forward in a helical and circular flow direction and the associated flow direction.

[0019] The extruder is preferably designed so that the above-mentioned orientation of the plant fibers remains unchanged in the space in front of the screw and upon exiting the nozzle. This results in a circular orientation of the fibers in the strand drawn from the extruder, parallel to the plane perpendicular to the exit direction. Due to the special nature of the extrusion process, the fibers are arranged along a circular path in the strand material.

[0020] Fiber alignment can be optimized by controlling the temperature in the extruder or during strand withdrawal from the extruder. For example, it is possible to heat the extruder to improve the flowability of the fibrous material, resulting in a targeted and improved alignment of the fibers in the flow direction (coiled around the extruder screw axis).

[0021] To prevent the fibers from becoming parallel to each other again in the pressure chamber adjacent to the screw and upstream of the extruder nozzle from being deflected from their circular path by the forward flow through the nozzle, along the withdrawal direction, this area can be cooled, for example. It is also possible to cool the withdrawn strand to improve the dimensional stability of the strand material before freezing. At the same time, this also further fixes the fiber structure within the material.

[0022] Avoiding a reversal of the flow of the plant-based material processed by the extruder in the extruder and during withdrawal from the nozzle ensures that the input material in the pressure chamber of the extruder between the tip of the extruder screw and the front housing or nozzle is pressed out of the nozzle in a straight line without reorientation of the fibers in the withdrawal direction.

[0023] Another preferred variant of the process uses a twin-screw extruder, whereby fiber orientation is also achieved in the aforementioned plane perpendicular to the exit direction of the strand material. The fiber orientation in the strand material can be optimized by adjusting the pressure and space in front of the screw, as well as the choice of the exit nozzle geometry.

[0024] The nozzle is preferably designed as a cooling nozzle, wherein the product channel of the cooling nozzle can, for example, have a height of between 35 mm, preferably between 10 mm and 25 mm. Compared to previously known cooling nozzles, it is advantageous to use a nozzle in which the product channel has a larger discharge gap. This increases design freedom in the subsequent pressing process. Due to the compressive stress in the pressing process, the individual fibers of material separate from one another slightly during forming, resulting in a particularly pleasant impression in the sense of a loose, fluffy product. After forming, the product can be cooked traditionally in a pan or on a grill or processed in another way.

[0025] The consideration and targeted alignment of fiber orientation during the production of individual portions intended for further processing is an aspect of the present invention, as is the use of fibrous base material instead of a uniform, more ground or shredded input material. The circular fiber orientation described above is preferably used, although there are also applications where a preferred fiber orientation parallel to the draw-off direction should be set. Ultimately, this depends on the further processing.

[0026] Parallel alignment can be achieved by appropriately modifying the extruder exit area and, if necessary, by using a movable screw within the extruder, as is known from injection molding in plastics technology. For example, the area upstream of the extruder can be large and, if necessary, additionally heated, resulting in a preferential flow of a free-flowing material through the nozzle parallel to the screw's rotational axis and the withdrawal direction. This flow and the flow path are then shaped so that the originally circularly arranged fibers can orient themselves in the direction of flow. Combing devices, intermediate nozzles, or other flow guidance profiles or devices can optimize this.

[0027] The strand material drawn or extruded from the extruder in this way is then fed for further processing according to the invention. There are various options for this.

[0028] In the simplest case, the strand material is divided into individual portions. These portions are then frozen, preferably deep-frozen. Freezing has the advantage that, on the one hand, the individual frozen portions can be handled more easily by a handling system and, on the other hand, the fiber orientation in the individual portions is fixed. The frozen individual portions are then fed into the forming process, i.e., they are pressed into shape in a mold cavity or on a flat abutment with a smooth or contoured surface of a press ram. This allows the desired contour to be created. As with the known processes, shapes of typical steaks, schnitzels, but also sausages or pieces of fish, particularly in fillet form, can be produced here.

[0029] The individual portions can be frozen after cutting the strand material and then sent for further processing. Preferably, they are deep-frozen to a temperature of -16 °C or lower. Alternatively, the strand material can be frozen before being cut into individual portions and then cut. This can be done, as is the case with fish fingers, using band saws or appropriate knives or bending devices.

[0030] The only important aspect of the process according to the invention is that individual portions can be fed into the frozen state for further processing and that these portions were produced while maintaining the fiber orientation. How the fiber orientation is then utilized ultimately depends on the desired end product.

[0031] Another advantage of fiber orientation is that the strength of the fibers to hold the composite together can be utilized during the pressing process. This makes it less likely that an individual portion whose fibers extend laterally outward will break during the forming process, even if this only occurs during the forming process due to the flow of the material in the mold. If the fibers are aligned parallel to the contact pressure, the product can fall apart much more easily.

[0032] One aspect of the invention is the use of the fiber structure to optimize the cohesion of the product during forming as well as to improve the visual and haptic impression of the finished product.

[0033] In another possible application of the process, the plant materials are first extruded from the extruder as described above, resulting in a circular fiber orientation. This strand material is then also cut lengthwise into individual portions, with these individual portions also exhibiting the circular fiber structure in cross-section, i.e., when viewed from the cut surface.

[0034] However, with this version of the process, the individual portions can then be divided lengthwise again, so that the resulting pieces have a fiber structure resembling a semicircle, which, after being placed in the mold, ends up with the cut edge of the circle at the bottom or top. By pressing down the press ram, the fibers are then aligned laterally outward and in the direction of a straight line. This means, however, that they can still retain their cohesive function, as they are not compressed or torn by the press.

[0035] In addition to processing the protein-containing input material, other substances can be added to the extruder or to the input material prior to feeding it. These can be fats or fat-like substances, as already described in the above-mentioned prior art. These substances can be used to improve the substance and flavor of the final product or to modify the flow properties of the material in the extruder and during subsequent drawing off. Depending on the application, animal material, frozen water, protein, marinades, or spices can also be added.

[0036] The feed can be made directly into the extruder, for example, through lateral inlet channels in the space between the screw and the extruder barrel. It is also possible to feed the additional materials into the space in front of the screw or, particularly if coating the strand material with a material is desired (as is common in the manufacture of electrical cables), to add them within the cooling nozzle during the extrusion process.

[0037] Finally, multiple extruders can be used to prepare different materials, which are then combined via a piping system to a common dispensing nozzle to produce a strand material with a mixed material distribution across its cross-section. This allows for the creation of different flavors, for example. An outer layer can also be created, which, for example, can be added with anti-stick agents to prevent the product from sticking to the hot surface or burning during subsequent frying or grilling.

[0038] Further features of the invention will become apparent from the following description of advantageous embodiments with reference to the drawings. The figures show: Fig.1

[0039] a schematic representation of an apparatus for carrying out the method according to the invention and Fig.2

[0040] a flow chart with the essential process steps.

[0041] Figure 1 shows a schematic view of a possible device with which the method according to the invention can be implemented.

[0042] In the illustrated embodiment, the processing line is essentially composed of three to four components. First, a fibrous input mass 2 is introduced into an extruder 3 via an inlet hopper. In this context, "fibrous" means that the plant fibers have been at least partially, preferably largely, and particularly preferably completely preserved during the production of the input mass 2. The input mass 2 can, of course, also be a mixture of several products, with at least one of these products having a preserved fiber structure.

[0043] The extruder 3 explodes the input material 2 toward a discharge nozzle, from which a strand 4 is drawn off via a discharge device. The extruder 3 can have heated or cooled zones. The discharge nozzle can be a cooling nozzle that cools the strand material to improve dimensional stability and fix the fiber orientation upon discharge from the extruder 3.

[0044] The stranded material 4 is then fed to a separation station, which divides the stranded material 4 into individual portions 5. This can be done using knives, band saws, laser cutting systems, or bending machines. Further measures can also be provided in this area; in particular, the stranded material 4 can also be coated in an intermediate storage step, for example, with fat, breading, or other ingredients specified by the recipe.

[0045] In the illustrated embodiment, the separation station is followed by a plate freezer, which deep-freezes the individual portions 5. The individual portions 5 are then fed to a pressing device 6, where they are placed into a mold cavity serving as a support 8 via a handling system not shown in detail here. They are then converted into the desired, application-specific shape via a pressing ram 7. The starting product of the process is then the meat or fish substitute 1 made from a protein-containing plant material. This meat or fish substitute 1 can then be further processed using conventional cooking methods.

[0046] Figure 2 shows the essential steps of the method according to the invention, which can be carried out, for example, using the device shown in Figure 1, again as a flow chart. First, the fibrous plant base material is produced as the input product in the form of fibrous input mass 2. This is fed into an extruder 3, in this case a twin-screw extruder, either in its pure form or as a mixture with similar or other products. The extruder 3 produces a strand 4 with a circularly oriented fiber orientation in cross-section. This strand 4 is then divided into individual strand sections, with the fibers lying at least partially, preferably predominantly, in the cutting plane or in a plane parallel thereto.

[0047] In this way, individual portions 5 are produced, which are subsequently deep-frozen, possibly after optional pre-forming. The deep-frozen individual portions 5 are then formed into a three-dimensional final product with the desired shape in a pressing device 6 by means of a pressing ram 7 and an abutment 8 against which the pressing ram 7 can be adjusted. Examples

[0048] The process according to the invention can be used to produce, for example, substitutes for meat pieces, minced meat pieces (meatballs, meatballs, cevapcici, etc.), and fish-like pieces in any shape. These can be, for example, the classic shapes known from meat processing or even small pieces, such as goulash-style, for immediate preparation or as part of a skewer. Due to the improved cohesion of the individual pieces via the fibers, a greater variety of three-dimensional shapes can be produced, and more complex shapes, such as a skewer for later grilling, can be realized without the problem of the product falling apart during preparation by the end customer or in a commercial kitchen.

[0049] The invention relates to the commercial production of meat or fish substitutes in the food industry. It is used to produce products for the final consumer or for further processing in the food industry.

[0050] 1 meat or fish substitutes

[0051] 2 Fibrous input mass

[0052] 3 extruders

[0053] 4 strands

[0054] 5 individual portions

[0055] 6 Pressing device

[0056] 7 press stamps

[0057] 8 abutments Patent documents

[0058] WO 23 017 140 A1

[0059] DE 10 2017 223 829 A1

[0060] WO 23 275 305 A1

[0061] EP 3 927 176 A1

[0062] EP 4 094 583 A1

[0063] WO 23 052 130 A1

[0064] EP 3 128 847 B1

[0065] WO 2009 052 865 A1

Claims

A method for producing meat or fish substitutes (1) from vegetable components that can be cooked, grilled, or fried, wherein a fibrous input mass (2) is produced from a vegetable base material, which is output by an extruder (3) in the wet extrusion process as a continuous strand (4) and, after exiting the extruder (3), is divided into individual portions (5) that are processed into the meat or fish substitute product (1), characterized in that individual strand sections are first cut from the strand (4) to form individual portions (5), then the individual portions (5) are frozen, or the strand (4) is first frozen and then sawn or cut into individual strand sections to form frozen individual portions (5), and then the frozen portions (5) thus produced are subjected to a shaping process as input material, individually or in a composite of two or more individual portions (5).wherein the forming process is carried out with a pressing device (6) which has at least one pressing ram (7) and at least one abutment (8) against which the pressing ram (7) can be placed, and which is designed such that when the pressing ram (7) is placed against the abutment (8), at least one cavity for receiving the input product remains between a pressing surface of the pressing ram (7) and the abutment (8), and wherein in the forming process, the frozen input product is placed into the pressing device (6) via the pressing ram (7) and the abutment (8) to form the boilable, grillable, or roastable meat or fish substitute product (1) with the desired contour and is then formed such that the produced meat or fish substitute product (1) has a predetermined, desired fiber structure of the substitute product. Method for producing meat or fish substitute products (1) from vegetable components according to claim 1, characterized in that the individual portions (5) are pre-formed by cutting, embossing or in another way before freezing and pressing in the pressing device (6). Method for producing meat or fish substitute products (1) from plant components according to claim 1 or claim 2, characterized in that the meat or fish substitute product (1) which can be cooked, grilled or fried is deep-frozen after the forming process. Method for producing meat or fish substitute products (1) from plant components according to one of the preceding claims, characterized in that the input mass (2) contains protein-rich plant products, in particular from pulses, soy, mushrooms or the like, wherein a protein-containing wet extrudate is produced from the components in the extruder (3). Method for producing meat or fish substitute products (1) from plant components according to one of the preceding claims, characterized in that a rectangular nozzle with a width and a height of at least 10 mm and a maximum of 150 mm, preferably with a width between 30 mm and 150 mm and with a height of at least 50 mm to a maximum of 150 mm, is used as the extruder nozzle. Method for producing meat or fish substitute products (1) from plant components according to one of the preceding claims, characterized in that the strand product (4) is cut into strand sections so that individual portions (5) are produced which have a length between 300 mm and 700 mm, preferably between 400 mm and 600 mm and particularly preferably between 450 mm and 500 mm. Method for producing meat or fish substitute products (1) from vegetable components according to one of the preceding claims, characterized in that the individual portions (5) are deep-frozen at a temperature of -16°C or lower. Method for producing meat or fish substitute products (1) from plant components according to one of the preceding claims, characterized in that the strand sections are cut in the longitudinal direction of the strand product (4) so that longitudinal sections with a longitudinal cut surface in the longitudinal direction are obtained, wherein the individual portions (5) are divided out in the transverse direction from the halves of the strand product thus produced, in particular cut or folded, so that the portions (5) have cross-sectional areas and a longitudinal cut surface. Method for producing meat or fish substitute products (1) from plant components according to the preceding claim, characterized in that in the forming process the individual portions (5) are positioned in the pressing device (6) in such a way that the pressing ram (7) is subsequently moved against the longitudinal cutting surface and the pressing force acts directly on the longitudinal cutting surface. Method for producing meat or fish substitute products (1) from plant components according to claim 7, characterized in that in the forming process the individual portions (5) are placed with the longitudinal cut surface on the abutment (8) so that pressing force acts indirectly as a reaction force on the longitudinal cut surface. Method for producing meat or fish substitute products (1) from vegetable components according to one of the preceding claims, characterized in that the frozen portions (5) are shaped such that the meat or fish substitute product (1) has a flat or contoured underside and / or a flat or contoured upper side. Method for producing meat or fish substitute products (1) from vegetable components according to one of the preceding claims, characterized in that the meat or fish substitute product (1) is subjected to an additional treatment before or after forming, in particular marinated, breaded or otherwise coated. Method for producing meat or fish substitute products (1) from plant components according to one of the preceding claims, characterized in that, during the production of the strand material (4) by means of extrusion, the fibers of the input mass (2) in the strand material (4) are aligned in such a way that they are arranged in a circle in a plane perpendicular to a discharge direction in which the strand material leaves the extruder (3). Method for producing meat or fish substitute products (1) from plant components according to the preceding claim, characterized in that the strand sections are inserted into the cavity of the pressing device (6) in such a way that the fibers are arranged in a plane which is arranged at right angles to a pressing force applied by the pressing ram (7). Method for producing meat or fish substitute products (1) from plant components according to claim 13, characterized in that the strand sections are inserted into the cavity of the pressing device (6) in such a way that the fibers are arranged in a flat or curved plane which is arranged parallel to a pressing force applied by the pressing ram (7). Meat or fish substitute product (1), characterized in that it is produced by a process according to one of the preceding claims.

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