System and method for producing protein products on commercial scale

Abstract

A system and method for producing, on a commercial scale, plant or reconstituted meat based products, such as pet food products having a main protein body and chunks of a non-protein component, by pumping of a protein slurry (15) to a heating device, such as a vacuum supply unit pumping the protein slurry. The heating device includes a heated die passage (275) through which the slurry (15) is directed, with the slurry (15) being heated along both inner and outer surfaces while transitioning into a heated protein product (35) which flows out of a die head (130) with the chunk ingredients intact and dispersed about the main protein body.

Description

SYSTEM AND METHOD FOR PRODUCING PROTEIN PRODUCTS ON COMMERCIAL SCALEFIELD OF THE INVENTION

[0001] The invention generally pertains to systems and methods for producing, on a commercial scale, plant or meat based protein products, such as pet food products, having a main protein body incorporating chunks of at least one additional ingredient.BACKGROUND OF THE INVENTION

[0002] Animal or animal-based meats are relied upon as a protein source for many people. For others, meat analogues made with vegetarian or vegan ingredients are relied upon. Due to various production limitations, considerable efforts have been made in enhancing the commercial production of protein products. In particular, these efforts have resulted in significant advancements in the use of extrusion techniques in the production of protein products made from animal derived and / or non-animal derived protein sources. Considered important in producing these extruded products is the resulting products exhibiting characteristics, such as appearance and texture, similar to that of meat. Recent advancements have made this result possible, even at commercially acceptable rates. However, given the shearing and die extrusion operations employed with these known systems, there are limitations to the products being produced. For instance, the products produced have homogeneous bodies, even though it would be often preferable for chunks of at least one additional ingredient dispersed throughout the main bodies of the products, whether meat or non-meat protein products are being made.SUMMARY OF THE INVENTION

[0003] Provided herein is a system and method for producing, on a commercial scale, plant or meat (animal) based protein products, such as pet food products, having a main protein body incorporating chunks of at least one additional ingredient. In particular, the present invention deviates from current mass production trends by not relying on extrusion production processes, for instance high shear single or twin screw cooking extrusion, but rather the pumping of a protein slurry with chunks of one or more ingredients to a heating device. In a preferred embodiment of the invention, a vacuum supply unit is employed to pump the protein slurry, including both the main protein composition and the one or more additional chunk ingredients, to the heating device. The heating device includes a heated die passage through which the slurry is directed, enabling heating of the slurry from along both inner and outer radial surfaces while the slurry transitions into a heated protein product which flows out of the die with a main proteinaceous body incorporating chunks of the one or more additional ingredients, such as vegetables, intact.

[0004] Additional objects, features and advantages of the invention will become more readily apparent from the following detailed description wherein like reference numerals refer to corresponding parts in the several views.BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a flowchart illustrating the basic steps performed in accordance with an embodiment of the method of the invention.

[0006] Figure 2 is a perspective view of a product flow system employed in connection with an embodiment of the invention.

[0007] Figure 3 is a cross-sectional view of a portion of the product flow system of Figure 2.

[0008] Figure 4 is a perspective view showing a protein product being dispensed from the product flow system of Figure 2.

[0009] Figure 5 is a cross-sectional view of a portion of a product flow system constructed in accordance with another embodiment of the invention.

[0010] Figure 6 is a cross-sectional view of a portion of another product flow system constructed in accordance with a still further embodiment of the invention.DETAILED DESCRIPTION OF EMBODIMENTS

[0011] A protein product provided herein is produced by pumping a proteinaceous composition having a protein component, such as a plant or meat based protein component and an additive component constituted by chunks of at least one additional non-protein ingredient, such as a vegetable. In certain embodiments, a water component can also be added, as well as other additional ingredients, particularly one or more binders. The protein product provided herein typically has a protein content from about 15% to about 85% (e.g., from about 20% to about 80%, from about 30% to about 75% and the like), a moisture content greater than about 20%, and chunks of the at least one additional non-protein ingredient of about 5% to about 30% (e.g., from about 10% to about 25% or the like).

[0012] The present invention deviates from current mass production trends, particularly by not relying on high-shear extrusion production processes, but rather a non-disruptive low shear pumping with laminar flow of a protein slurry with chunks of the one or more additional ingredients through a heating device. As detailed below, in a preferred embodiment of the invention, a vacuum supply unit is employed to pump the protein slurry, including both the main protein composition and the one or more additional chunk ingredients, to the heating device. The heating device includes a heated, preferably annular, die through which the slurry is directed, enabling heating of the slurry from along both inner and outer radial surfaces while the slurry goes through the die and transitions into a heated protein product which flows out of the die with a main proteinaceous body incorporating the one or more additional non-proteiningredients in chunk form. That is, the additive food chunks in the outputted product remain intact, i.e., in accordance with the invention, “intact” means visually intact so as to be readily, visibly recognizable, from its additive form entering the slurry, in the final product. Essentially, the resulting product has the additive food chunks cooked but still in their substantially identical non-cooked chunk form.

[0013] As indicated above, the protein slurry, which has a batter, dough or other high viscosity consistency so could also be defined as a protein batter mix, includes at least a protein component and a non-protein component. The protein component includes at least one nonanimal derived protein, animal derived protein, or mixtures thereof. A non-animal derived protein can be derived from any appropriate non-animal source (e.g., plant, algae, bacteria, fungi, yeast, and the like). Examples of non-animal derived proteins include, but are not limited to, crude mixtures of proteins (e.g., grain flour, legume flour, yeast extract, algae extract, and the like), or partially or fully purified proteins in the form of protein concentrates or protein isolates (e.g., zein, gluten, soy or pea protein isolate, soy or pea protein concentrate, and the like). An animal derived protein can be derived from any appropriate animal source (e.g., meat, egg, dairy, and the like) from any appropriate animal (e.g., poultry, bovine animals, pigs, horses, fish, sheep, goats, deer, and the like). Examples of animal derived proteins include, but are not limited to, crude mixtures of proteins (e.g., mechanically deboned meat, surimi, minced meat, meat paste, and the like), or partially or fully purified proteins (e.g., gelatin, casein, whey, albumin, milk protein isolate, and the like). An animal derived or non-animal derived protein for use in a process provided herein can be a derivative (e.g., isomer, hydrolysate, salt form) of a natural protein. The non-protein component can be constituted by numerous non-animal based ingredients, such as fruits, vegetables, cereals, legumes and the like. In addition to the protein and non-protein components, other additives can be incorporated in the slurry to adjust the viscosity, gelling properties, water binding properties, oil binding properties, solubility, emulsifying properties, cohesiveness, texture, flavor, aroma, color, appearance and / or the like. In some embodiments, these further additives can include, without limitation, a watercomponent, a carbohydrate component, a lipid component, a pH adjusting agent, a flavoring agent, a coloring agent, a macronutrient, a micronutrient, a vitamin, a mineral, and the like.

[0014] With particular reference to the flowchart of Figure 1, the basic flow parameters for the production process of the invention are shown. Initially, a protein component, a nonprotein component and potentially a water component, as well as various other optional ingredients, as referenced above, are mixed in step 10. This mixing operation is preferably conducted in an automated process, such as with a batch mixing apparatus commonly known in the art, to produce a slurry 15 which is then pumped at step 20 to a die apparatus 25. The slurry 15 is heated as it flows through die apparatus 25 as represented by step 30. Although the pumping operation can be performed in various ways and with different types of equipment to create a stream comprising a proteinaceous composition, it is preferable to employ vacuum pumping, particularly using a Vemag™ device made by Vemag Maschinenbau GmbH, to ensure a consistent pressure / volume controlled flow. Optionally, a flow divider or flow restrictor can be installed between the pump and the heating device to control and maintain a balanced product flow across the cross-section of the heating device. Upon completing heating step 30, a protein product 35 in accordance with the invention is produced and dispensed at 40, after which the protein product 35 can be suitably further processed and packaged as represented by step 50.

[0015] As indicated above, a known vacuum pumping unit is preferably employed in connection with the basic pumping step 20. This unit is shown best in Figure 2, including a supply hopper 100 and a base control unit 110. Important to the invention is the modification to this known pumping unit wherein, at an outlet of this device, there is mounted die apparatus 25 including an elongated tube 125 into which slurry 15 is introduced and in which heating step 30 is performed. As will be detailed more fully below, tube 125 defines an annular flow channel for heating slurry 15. More specifically, the annular flow channel has both inner and outer jackets or pathways for the flow of a heating medium along the channel, thereby establishing an overall heated annular die. As shown in this figure, an outer jacket heating medium return line 150 is fluidly connected to an outer jacket heating medium supply line 165, while an inner jacket heating medium supply line 160 is fluidly connected to an inner jacket return line 170, to providea continuous flow of a heating medium for performing the heating necessary to produce protein product 35. Once the components of slurry 15 are heated and congealed, dispensing step 40 for protein product 35 occurs from die head 130, which can be integrally formed with tube 125 or, more preferably, constituted by an insert secured to tube 125. In the embodiment shown, protein product 35 is dispensed through a plurality of openings, one of which is indicated at 180, with the various openings 180 being circumferentially spaced about a central plate 185 connected by a plurality of thin radial supports 190.

[0016] Figure 3 shows a cross-section of a portion of elongated tube 125. Tube 125 is defined by an outer conduit 200. In accordance with the invention, outer conduit 200 is provided with an outer jacket 210, preferably extending annularly about outer conduit 200. Outer jacket 210 includes an outlet port 215 to which return line 150 is attached, and an inlet port 220 to which supply line 165 is attached. In the embodiment shown, outlet and inlet ports 215 and 220 are spaced at basically opposite ends along the length of tube 125. Within the confines of outer jacket 210 is provided an interior, close-ended conduit 240 having an internal divider 245 which establishes an inner jacket with an inlet passage 250 leading to a return passage 255. Fluidly connected to inlet passage 250 is supply line 160 and fluidly connected to return passage 255 is return line 170.

[0017] As shown, interior conduit 240 includes a conical portion 260 remote from central plate 185. With this construction, within outer conduit 200 is established an annular die passage 275 into which slurry 15 is pumped. Although not separately labeled in Figure 3, in the embodiment depicted, die head 130 constitutes a separate component having an annular sleeve extending into and attached to outer conduit 200 by clamps (shown in Figure 4), while an O-ring is interposed between outer jacket 210 and die head 130.

[0018] During operation, slurry 15 is pumped into tube 125 and, beyond conical portion 260, flows into annular die passage 275, thereby being directly exposed to both outer jacket 210 and interior conduit 240. At the same time, a heated fluid medium, such as hydraulic fluid, is caused to flow through both outer jacket 210 and interior conduit 240. More specifically, for outer jacket 210, a heated fluid medium is introduced at inlet port 220 through supply line 165,with the heated fluid medium being forced to flow annularly through outer jacket 210 toward outlet port 215 and return line 150. This fluid is then re-heated and recycled in a controlled manner. In this way, slurry 15 is heated within annular die passage 275 through outer jacket 210. At the same time, a similar heating operation occurs along the interface between slurry 15 and interior conduit 240, with a heated fluid medium being introduced through supply line 160 to flow through inlet passage 250 and then return passage 255, before exiting return line 170 for reheating and recycling. In this manner, due to the annular die passage 275 being exposed to both inner and outer radial heating sources, an inner and outer heated annular die arrangement is advantageously established to provide for high-capacity production of protein product 35.

[0019] The actual temperature and / or viscosity of the product stream within annular die passage 275 can be adjusted to adjust flow behavior, flow balance, or other stream properties, such as heating rate, gelling, setting, and structure formation, etc. in the die depending on the product being produced. For example, a stream can have a temperature from about 20° C to about 210° C. In some embodiments, a stream can have a temperature from about 100° C to about 150° C. In other embodiments, a stream can have a temperature from about 50° C to about 160° C, from about 70° C to about 145° C, or the like. In addition, the radial dimension of flow passage 275 can vary, with one preferred size being approximately 11 mm. It should also be recognized that the inner radial and the outer radial heating streams can be readily established to heat at different temperatures, with separate heated fluid streams or a common heated fluid supply with multiple flow paths. Furthermore, other heat sources instead of fluid heat sources could be employed. In any case, important in connection with the invention is the ability to retain the chunky nature of the non-protein component as protein product 35 is pumped through die openings 180 as shown in Figure 4, representing the dispensing step 40 of Figure 1. As shown, the flow of protein product 35, which can be produced at various rates, includes chunks of the additional ingredient(s), such as carrots 300 and peas 305, clearly visually distinguishable from the main proteinaceous body 320, as will be further discussed below.

[0020] As depicted, protein product 35 is dispensed about supply line 160 and return line 170 in the embodiment of Figure 4. Figure 5 shows a variation wherein internal radial conduitsare employed to enable the repositioning and reorientating of these supply and return lines. Basically, a flow adapter 500 is interposed between the vacuum pumping unit and the tube 1125. More specifically, a first clamp 525 is used to fix flow adapter 500 to the vacuum pumping unit and a second clamp 535 is used to secure flow adapter 500 to tube 1125. With like reference numerals to the Figure 3 arrangement, tube 1125 includes corresponding outer jacket 210, outer conduit 200, inlet port 215, outlet port 220 and annular die passage 275 structure. However, instead of employing inlet and return passages 250 and 255 separated by internal divider 245, tube 1125 includes additional concentric passages, i.e., a centrally concentric inlet passage 1250 and a return passage 1255 directly concentric to annular die passage 275, i.e., between inlet passage 1250 and annular die passage 275. Inlet passage 1250 is in fluid communication with a supply line 1160 having a supply port 1165 built into flow adapter 500, while return passage 1255 is in fluid communication with a return line 1 170 and a return port 1175. With this arrangement, heating fluid is introduced into supply line 1160 through a hose or the like (not shown) at supply port 1165 to travel substantially the entire length of tube 1125, then is redirected at a connecting port 1185 to flow out through return passage 1255, then return line 1170 and return port 1175. This overall arrangement still provides for the plurality of ports 180 (basically an annular output opening aside from the thin supports 190 as referenced in Figure 2).

[0021] In addition to changing the internal heating configuration for the tube, the length of the heating and food product dispensing system can be varied, such as to further control the heating / cooking parameters for the product. That is, an elongated tubing system could be employed with multiple heating zones or two or more modular heating units could be employed along the length of the overall tubular cooking assembly to establish separate heating circuits which can operate at different temperatures. This could be important depending on the composition employed, for instance to address potential water / steam flash off upon exiting which could lead to undesirable product expansion. Therefore, it may be desirable to initially heat the composition to a high temperature to accelerate heat transfer and allow higher rates, while a subsequent heat circuit would condition the product down to desired exit temperaturesand prevent flash off, with product exit temperatures preferably being at or above 85 °C, more preferably between about 85 °C - 93 °C.

[0022] By way of example, Figure 6 illustrates an exemplary configuration wherein multiple heating tubes 1125 are interconnected to establish successive heating stages for the protein mass. Although the number could certainly vary, the Figure 6 embodiment conveys how successive tubes 1125 can easily be clamped directly together to extend the overall tube length. This interconnection can be done in various ways, such as with two identically constructed tubes 1125 connected through another, interposed flow adapter 500 and multiple clamps (not separately labeled). In this fashion, multiple successive heating or cooking stages can be created for operation at different temperatures, such as particularly set forth below with reference to the mass production of a particularly preferred product. In addition, although not shown, the heating stages could be followed by one or more cooling stages for the resulting product.

[0023] In connection with the overall food production process, Figure 6 illustrates numerous additional features of the overall invention. First, various thermocouples or other temperature sensing elements, such as sensors 1300 and 1305, can be provided along each tube 1125, such as at spaced temperature sensing inserts 1310 to measure food product temperatures, with the sensors 1300 and 1305 being linked to a controller or CPU 1325 employed in connection with controlling the inner and outer radial operational heating temperatures along the length of the tubes 1125 through separately regulated heat flow controllers 1340-1344. In this fashion, the desired cooking conditions can be effectively and precisely controlled as the protein mass moves through the system. That is, the temperature and / or rate of the heating fluid delivered to the inner and outer concentric passages can be separately controlled for each tube 1125. Figure 7 also illustrates the inclusion of a dump valve 1350, exemplarily shown mounted just prior to protein product 35 being dispensed. Dump valve 1350 is also preferably linked and controlled through CPU 1325. Since the invention is preferably employed in mass producing food for consumption, regulating the operational temperatures and providing for dumping product which is not being produced according to set standards as measured through the use of the temperature sensors are advantageous control features. Certainly, various dump valves couldbe provided at strategic locations from the start of the tube to along the overall length thereof with, by way of example, the dump valve 1350 just prior to the dispensing location for the food product can be advantageously, automatically activated to redirect food product to a secondary outlet 1355 which has not reached a desired cooking temperature during production.

[0024] Regardless of the number of heating stages or exact heat assembly configuration, upon exiting the system, the dispensed protein product 35 is ready to be further processed, including any desired cutting, including shredding or the like, such as with the inclusion of a cutting unit 1360 having a rotating blade unit 1365 at the outlet. Thereafter, the protein product 35 can be cooled and packaged, either alone or in combination with one or more other components such as a sauce or gravy, condiments or the like in a sealed package (step 50 of Figure 1), for later consumption. As is widely known in the art, such packaging includes, but is not limited to, cans, glass or plastic containers, pouches (e.g., a stand-up resealable pouch or other type package) or the like. Although a wide range of food items can be made with the system and method detailed above, a preferred use is the production of pet foods which, in addition to providing a healthy portion of protein, establishes a well-rounded meal with the inclusion of added chunks of vegetables, fruits, etc. However, human food products with additive ingredient chunks could also be produced.

[0025] By way of a particular example, a high protein pet food (i.e., a protein content of from about 15% to about 85%) is made having one or more main protein component(s), such as from chicken, beef and / or fish, and one or more additive chunks, such as vegetables, e.g., carrots, peas, diced potatoes or the like. Initially, the various components are mixed as discussed above to form a slurry having an effective viscosity due to the addition of a binder to establish a balanced, laminar flow within the system during which, with the channeling of the proteinaceous mass, the proteins become aligned which advantageously enhances overall product texture. Using an exemplary, multi-stage cooking operation, the temperatures are controlled to establish different cooking stages in successive tube sections. For instance, a first cooking zone can be operated at about between 190-300 °F (87.8-148.9 °C) and then a second cooking zone can be created to establish a food appropriate exit temperature, i.e., less than 190 °F (87.8° C), such asabout 162-170 °F (72.2-76.7 °C) or lower. The targeted less than 190 °F (87.8 °C) temperature was particularly employed in connection with producing the pet food as it is below the boiling point to avoid steam flashing off and potential product blowing out the die. Certainly, the residence time / rate in the die will affect the overall cooking, but it should be noted that the invention can be advantageously employed to produce the cooked high protein food product at a rate of even up to about 5000 Ibs / hr, with a particularly effective rate for this exemplary product being in the range of about between 1000 - 2000 Ibs / hr.

[0026] It is considered extremely advantageous in connection with the invention that the additive chunks maintain their structural integrity throughout the entire process such that the additive chunks are still visually recognizable in the final product. This result is achieved by creating a gentle laminar flow with minimal mechanical shear within the uniform annular die passage. Therefore, this overall production arrangement is quite distinct from and completely avoids the use of single, twin or the like type extruders as would typically be employed in the industry when producing such a food product. In fact, in the production of the high protein pet food made with peas and cubed carrots as additive chunks, the size of the post-cooked pea and carrot chunks are essentially identical (no statistically significant loss of size) to their pre-cooked sizes as evidenced in Table 1 below which means, in accordance with the invention, the additive chunks remain intact throughout the product forming process, i.e., cooked but still in their substantially identical non-cooked chunk form.Table 1

[0027] Although described with reference to preferred embodiments of the invention, it should be understood that various changes and / or modifications can be made without departing from the invention as encompassed by the scope of the following claims. That is, from the description given, it will be appreciated that the invention can be practiced with embodiments other than those disclosed such that the disclosed embodiments are presented for purposes of illustration and not limitation. For instance, although illustrating tubes, conduits, passages, channels, etc., which are generally circular in cross-section such that various components are related in a radial direction, it should be understood that various other geometric configurations could be employed. In addition, even though the invention has been described in connection to providing for the controlled heating of a food mass, the invention could also be employed in connection with cooling a mass or, first heating and then subsequently cooling.

[0028] To emphasize certain advantages in strategically employing significant product cooling prior to cutting at the end of the die, by way of a particular example, a system including five stages was employed in making a fresh pet food product with discernible additive component chunks, with three heating sections followed by two cooling sections before reaching a die exit. Employing such a multiple, successive heating section arrangement has been found to enhance proper cooking of the food. For instance, the three heating sections / zones embodiment would include a first slow heat zone to establish the desired laminar flow, desired drag flow against the annular die passage wall and improved striation, followed by second and third heating zones for complete cooking of the meat. Thereafter, the food mass would proceed through the two cooling zones or stages in which the temperature is gradually decreased while maintaining a balanced flow and retaining available fluids in the product. In one tested embodiment, such a long die can effectively be operated with low back pressure, e.g., less than 100 psi (689.5 kPa). To this end, pressure sensors could also be incorporated into the system, preferably with signals being sent to the controller, for regulating internal section pressures. While the prior example discussed above provided for a controlled temperature reduction to reach, for example, the less than 190 °F (76.7 °C) mark, the multiple cooling sections described here enables a smoother cooling of the product to a temperature below the 190 °F (76.7 °C) mark, such as down to about 175 °F (79.4 °C), but more preferably below a flash point to about 100 °F (37.8 °C) or even down to 60 °F (15.5 °C), prior to reaching the die exit. This particular arrangement was found to provide a few further benefits, including enhanced liquid absorption by the food prior to the die exit, retention of a striated meat-like structure, and an overall food cohesiveness advantageous to the cutting operation. The process is also applicable to a wide range of products, which can be provided as fresh, refrigerated or frozen products. In addition, the products can take various forms, including retorted, dehydrated and dried products. In the case of pet foods, the products can constitute meals or treats.

[0029] In any case, based on the above, it should be readily apparent that the present invention can take various forms in connection with commercially mass producing a wide range of meat and meat-like products containing additive chunks of non-meat components whosestructure remains intact throughout the production process. Still, although described with reference to various embodiments of the invention, it should be understood that various changes and / or modifications can be made to the system and process described without departing from the invention. For instance, it is possible to provide for concurrent or counterflow of the heated fluid mediums, or even provide a non-heated or cooled modular tube section(s).

Claims

CLAIMS1. A method of producing a protein product comprising: mixing a protein component and a non-protein component to establish a slurry, with the non-protein component being provided in chunks; pumping the slurry into a die passage of a die apparatus; heating the slurry, as the slurry passes within the die passage, from at least one of inner and outer heating sources to convert the slurry into a protein product; and dispensing the protein product, with the chunks of the non-protein component intact, through one or more die openings of the die apparatus.

2. The method of claim 1, wherein the method is performed without employing screw extrusion.

3. The method of claim 1, wherein the protein component is constituted by a plant or meat based protein component and the non-protein component is constituted by fruits, vegetables, cereals, legumes or combinations thereof.

4. The method according to any one of claims 1-3, wherein the protein product is produced to have about 15% to about 75% protein, a moisture content greater than about 20%, and about 5% to about 30% of the non-protein component.

5. The method according to any one of claims 1-3, wherein the heating is performed by utilizing one or more heated fluid mediums as the at least one inner and outer heating sources.

6. The method of claim 5, wherein the heated fluid medium is directed to an inner heating conduit through a flow adapter providing both inlet and outlet ports of the inner heating conduit.

7. The method of claim 1, wherein the protein product is a pet food including a main proteinaceous body and chunks of the non-protein component entirely or partially contained in the main proteinaceous body.

8. The method of claim 1, wherein the die passage is annular and formed in at least first and second tube sections which are interconnected and include separate sets of inner and outer heat channels for providing distinct product heating zones.

9. The method of claim 8, wherein the heating is performed in multiple successive heating stages.

10. The method of claim 9, wherein the multiple successive heating stages are followed by at least one cooling stage which provides for dispensing of the protein product through the one or more die openings at between 60-175 °F (15.5-79.4 °C).

11. The method according to any one of claims 8-10, further comprising: at least first and second temperature sensors configured to sense temperatures of the protein product in the first and second tube sections, respectively; and a controller configured to receive temperature signals from the first and second temperature sensors for use in controlling production of the protein product.

12. The method of claim 11, further comprising sensing a pressure within at least one of the first and second tube sections for use in controlling production of the protein product.

13. The method of claim 11, further comprising opening a dump valve, through the controller, to redirect protein product from the one or more die openings based on a signal received from at least one of the first and second temperature sensors.

14. A system for producing protein products comprising: a mixer for receiving a protein component and a non-protein component in forming a proteinaceous slurry, wherein the non-protein components include additive food chunks; at least one tube including: a die passage for a flow of the proteinaceous slurry; at least one of an outer jacket provided about the die passage to establish an outer heat channel about the die passage and an inner conduit extending concentric to the die passage to establish an inner heat channel for the die passage; a pump; and at least one opening leading from the die passage wherein, in operation, the system is configured to heat the proteinaceous slurry directed by the pump through the die passage to convert the proteinaceous slurry into a protein product, having the additive food chunks intact, and dispense the protein product through the at least one opening.

15. The system of claim 14, which is void of a high shear single or twin screw extruder.

16. The system of claim 14, wherein the system includes both the outer heat channel and the inner heat channel, with one or more heated fluid mediums being configured to be directed through the inner heat channel and the outer heat channel to cook the proteinaceous slurry.

17. The system of claim 16, wherein the outer jacket includes an inlet port configured to receive a flow of the one or more heated fluid mediums and an outlet port for a return flow of the one or more heated fluid mediums.

18. The system of claim 17, wherein the inlet and outlet ports are spaced from each other along a length of the at least one tube.

19. The system according to any one of claims 16-18, wherein the inner conduit includes an inlet port configured to receive a flow of the one or more heated fluid mediums and an outlet port for a return flow of the one or more heated fluid mediums.

20. The system of claim 19, further comprising a flow adapter providing both the inlet and outlet ports of the inner conduit.

21. The system of claim 19, wherein the inner and outer heat channels are configured to receive a common heated fluid medium.

22. The system of claim 14, wherein the at least one tube is annular and includes at least first and second tube sections which are interconnected and provide distinct product heating zones.

23. The system of claim 22, wherein the at least one tube includes multiple successive heating sections.

24. The system of claim 23, wherein the successive heating sections is followed by at least one cooling section configured to provide for dispensing of the protein product through the at least one opening at between 60-175 °F (15.5-79.4 °C).

25. The system according to any one of claims 14-22, further comprising: at least first and second temperature sensors configured to sense temperatures of the protein product in the first and second tube sections, respectively; and a controller configured to receive temperature signals from the first and second temperature sensors for use in controlling the system.

26. The system of claim 14, further comprising a cutting unit provided adjacent the at least one opening.

Images