A composition comprising extruded protein

Abstract

The present disclosure provides an extruded protein composition, particularly derived from soy, comprising protein (45-56%), crude fiber (1-2.5%), and sodium (<20 mg / 100g). The composition exhibits enhanced surface porosity, superior water absorption capacity, improved masala absorption capacity, reduced bulk density, and softer texture with average hardness of 1250-2600g and chewiness of 8500-20000 g.sec, synergistically delivering a well-rounded sensorial profile. The disclosure also provides a chemical-free extrusion method for preparation. The present disclosure eliminates the bland core and undesirable chewy texture of conventional soy chunks by arriving at a novel composition rather than using chemical additives, providing consumers with organoleptically superior, nutritionally beneficial plant-based protein.

Description

A COMPOSITION COMPRISING EXTRUDED PROTEINTECHNICAL FIELD

[0001] The present disclosure generally relates to the field of edible compositions. Specifically, the present disclosure provides extruded protein composition, which is organoleptically superior and at the same time is low in sodium exhibiting higher porosity, higher flavor / masala absorption characteristics, lesser beany taste and a softer and less chewy texture.BACKGROUND

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is a prior art.

[0003] India is a country with high protein deficiency and with significantly high proportion of vegetarian population. Soy is an affordable source of protein having substantial advantages. Amongst the plant sources of protein, soy has high protein content and the most well-balanced amino acid profile. As compared to the animal sources of protein, soy protein has advantages of higher dietary fibers, lower fat, nil cholesterol and lower cost. Soy protein is also environmentally more sustainable as compared to the animal -based sources.

[0004] Extruded soy products or soy chunks are made using well known extrusion technology whereby highly proteinaceous flour is converted into the desired extruded composition by the application of shear, heat and / or chemical processing. Considering the nutritional advantages, lower costs and environmental sustainability, extruded soy products or soy chunks is a popular food format for all sections of Indian population (adults and children) who consume them for fulfilling their daily protein requirements, as a meal or a snack.

[0005] Indian consumer’s delight in overall sensorial characteristics of soy chunks is a critical success factor for such products in the market. With advances in food science and technology, consumers are getting to taste different food products having a range of unique and differentiated organoleptic characteristics. With heightened sensory awareness, consumers now want better organoleptic characteristics for extruded soy protein or soy chunks as compared to the present market offerings.

[0006] Chemical processing free, extruded soy protein or soy chunks which are available in market have low porosity, they absorb less flavor / masala and have a hard, chewy mouthfeel.When a person consumes such a soy chunk, the masala comes out in the initial chews and in the subsequent chews, the typical beany taste of soy dominates on the taste buds. This results into non-rounded flavor / masala expression for the consumer with undesirable chewy characteristics and a bland core having soy beany taste. Such a problem is accentuated in bigger size (8-25 mm) extruded soy protein products which are preferred because they provide optimum mouth feel however, they typically take more number of bites to chew the product and noteably flavour / masala is more difficult to reach the core leading to a bland taste.

[0007] To improve the hard and chewy mouthfeel of extruded soy protein or soy chunks, it is a common industry practice to use pH modifying chemicals during processing such as caustic soda (NaOH), which play a critical role in reducing the density of soy chunks, apart from imparting other characteristics.

[0008] However, such chemical processing leads to addition of minerals such as Sodium in the proteinaceous matrix, which in-tum impacts the surface and bulk texturization characteristics of the product, leading to a soft texture, but lesser absorption of water / flavour.

[0009] Sodium hydroxide - caustic soda (NaOH), while increases porosity of the product, making it less chewy, absorption propensity thereof reduces. Additionally, the resultant extruded soy protein products are not be able to absorb flavour / masala to its core and hence, remains bland in taste having soy beany notes.

[0010] In addition, conscious consumers do not prefer product made from such chemical processing / additives. With increasing health concerns on heart diseases and high blood pressure, there are specific concerns regarding high amounts of sodium in diets.

[0011] Rigorous research has been done, over the course of decades, in an attempt to address the aforesaid deficiencies to arrive at the compositions having desired texture, mouth feel and sensorials. For instance, US3488770A, published in the year 1965, describes producing a product having the texture, appearance and coherence of cooked meat, which has less chewiness, higher porosity and more absorption capacity.

[0012] Another Patent document, US3965268A describes an extruded protein product, which asserts that presence of a mix of proteinaceous material and a sulfur containing organic compound, enhances the texture of the product synergistically, resulting in an open, cellular structure.

[0013] EP0385266B1 describes a process of reducing soy beany notes through hydration and acidification of whole soybeans to inactivate lipoxygenase enzyme.

[0014] US7541057B2 describes ready to eat high protein soy granules, which in an attempt to address some of the aforesaid problems proposes to reduce the size of the chunks / granules.

[0015] Despite of concerted efforts in the instant field, there still appears to be a need in the art for extruded soy product that allow much enhanced flavour / masala / water absorption capacity to the core, softer yet chewier texture with optimum mouth feel, desirable surface pore area and higher density, the effect of which lead to the consumer may provide the consumer an overall rounded taste of flavour / masala when consumed as cooked extruded soy chunks.

[0016] Hence, there is a long felt need in the art for an extruded protein composition, which has a higher porosity, higher absorption capacity and desirable textural characteristics of desirable softness and chewiness.OBJECTS OF THE PRESENT DISCLOSURE

[0017] An objective of the present disclosure is to provide an extruded protein composition, preferably derived from soy, with desired protein and crude fiber content, and significantly reduced sodium levels.

[0018] Another objective of the present disclosure is to provide extruded protein composition, for example, soy-based chunks, having, required bulk density, and moisture content for enhanced texture, flavor absorption capacity, and reduced chewiness.SUMMARY

[0019] In an aspect, the present disclosure relates to an extruded protein composition, preferably, derived from soy, which is organoleptically superior, having low concentration of sodium with well-rounded sensorial profile without the off-notes, achieved by having higher porosity, higher flavor absorption characteristics, and a softer, less chewy texture.

[0020] In an aspect, the present disclosure provides an extruded protein composition comprising protein in an amount ranging from 45% to 56% by weight of the composition, crude fiber in an amount ranging from 1% to 2.5% by weight of the composition, and sodium in an amount ranging from less than 20 mg per 100 grams, preferably 1-20 mg / 100 gm of the composition.

[0021] In another aspect, the present disclosure provides a method of preparing an extruded protein composition by preparing a mixture of plant derived flour and liquid, subjecting this mixture to an extrusion process, forming discrete pieces from the extruded composition, anddrying these pieces to obtain the final composition with desired characteristics including higher porosity, improved absorption capacity and softer texture.

[0022] In a further aspect, the present disclosure relates to a food product containing the extruded protein composition in combination with at least one food grade edible ingredient.

[0023] In another aspect, the present disclosure relates to a food product comprising extruded protein composition of the present invention wherein the extruded protein composition is soaked prior to incorporation into the final food product.

[0024] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments.BRIEF DESCRIPTION OF DRAWINGS

[0025] The accompanying drawings are included to provide a clear understanding of the present invention and a detailed description, and they constitute a part of this complete specification.

[0026] Figures 1A-1D illustrate exemplary closer snippets of a protein composition realized in accordance with an embodiment of the present disclosure; and of three commercially available market samples - termed as ‘2n’, ‘4f and ‘3s’, respectively.

[0027] Figures 2A-2D illustrate exemplary microscopic images of a protein composition realized in accordance with an embodiment of the present disclosure; and three commercially available market samples - termed as ‘2n’, ‘4f and ‘3s’, respectively.DETAILED DESCRIPTION

[0028] The following is a full description of the disclosure's embodiments. The embodiments are described in such a way that the disclosure is clearly communicated. The level of detail provided, on the other hand, is not meant to limit the expected variations of embodiments; rather, it is designed to include all modifications, equivalents, and alternatives that come within the spirit and scope of the present disclosure as defined by the attached claims. Unless the context indicates otherwise, the term "comprise" and variants such as "comprises" and "comprising" throughout the specification are to be read in an open, inclusive meaning, that is, as "including, but not limited to.".

[0029] When "one embodiment" or "an embodiment" is used in this specification, it signifies that a particular feature, structure, or characteristic described in conjunction with the embodiment is present in at least one embodiment. As a result, the expressions "in one embodiment" and "in an embodiment" that appear throughout this specification do notnecessarily refer to the same embodiment. Furthermore, in one or more embodiments, the specific features, structures, or qualities may be combined in any way that is appropriate.

[0030] Unless the content clearly demands otherwise, the singular terms "a," "an," and "the" include plural referents in this specification and the appended claims. Unless the content explicitly mandates differently, the term "or" is normally used in its broad definition, which includes "and / or."

[0031] All processes described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0032] The headings and abstract of the invention provided herein are for convenience only and do not interpret the scope or meaning of the embodiments.

[0033] All publications herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0034] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description that follows, and the embodiments described herein, is provided by way of illustration of an example, or examples, of particular embodiments of the principles and aspects of the present disclosure. These examples are provided for the purposes of explanation, and not of limitation, of those principles and of the disclosure.

[0035] The present disclosure relates to an extruded protein composition, preferably, derived from soy, which is organoleptically superior, having low concentration of sodium with well- rounded sensorial profile without the off-notes, achieved by having higher porosity, higher flavor absorption characteristics, and a softer, less chewy texture.

[0036] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.DefinitionSov protein in the present context is a protein derived from soybeans, commonly used in food products for its high protein content and beneficial nutritional profile.Crude fiber in the present context is an indigestible portion of plant foods that aids in digestion. Crude fiber is a type of insoluble dietary fiber which remains as a residue after treatment with dilute acid and alkali.Water absorption capacity in the present context is the ability of a food product to absorb and retain water, impacting its texture and cooking properties. Water absorption capacity can be measured as set out in detail in the following paragraphs of the present disclosure.Surface pore area or pore area in the present context is the proportion of the product’s surface covered by pores vis-a-vis surface area not covered by pore, which affects its ability to absorb flavors and liquids. Surface pore area is higher when the number and size of pores increase. Surface pore area or pore area can be measured as set out in detail in the following paragraphs of the present disclosure.Average Hardness in the present context is a textural parameter and is a measure of how firm or soft a food product is, determined by the force required to compress it.Average Chewiness in the present context is a textural parameter and is a measure of the energy required to chew a food product, affecting its mouthfeel.Masala absorption capacity in the present context is the ability of a food product to absorb and retain masala or spice gravy (liquid or solid), impacting its texture and organoleptic properties. Masala absorption capacity can be measured as set out in detail in the following paragraphs of the present disclosure.Density in the present context can be measured in multiple ways (bulk density, skeletal density, true density).Bulk density is the mass of a product (soy chunk) per unit volume, which includes intra-pore volume as well as inter-void volume. Bulk density can be measured as set out in detail in the following paragraphs of the present disclosure.Intra-pore volume is the volume of pores within a chunk.Inter-void volume is the volume which is occupied between separate soy chunks in same container.Skeletal density is the mass of a product (soy chunk) per unit volume, including the intrapores volume, but excluding the inter-void volume, which is the volume occupied between two separate chunks.True density is also the mass of a product (soy chunk) per unit volume, but which excludes intra-pore volume and inter- void volume.In the present context, organoleptic properties are the sensory attributes of a food product, including taste, texture, appearance, and aroma, which contribute to the overall eating experience.Texturization in the present context is a process of altering the physical structure of a food product to improve its texture and mouthfeel.Flavor absorption in the present context is the ability of a food product to absorb and retain flavors from added seasonings or marinades.Mouthfeel in the present context is the physical sensations in the mouth produced by a food product, including its texture, temperature, and astringency.

[0037] The present disclosure is on a premise, at least in part, of surprising observation(s) by inventors of the instant application that incorporation / presence of sodium in an amount ranging from 1 to 20 mg, and fiber content in the amount of 1 % to 2.5% in an extruded protein composition (for example, soy-chunks) affords dramatic improvement as regards the number and size of pores, and a lesser bulk density, amongst other parameters, which ultimately translates to absorption of and retention of more amount of water while maintaining optimum structure. Greater number of pores together with larger sized pores ultimately leads to a higher surface pore area vis-a-vis surface area not covered by pores, which leads to a higher water absorption capacity of the extruded composition.

[0038] Accordingly, an aspect of the present disclosure relates to an extruded protein composition comprising: protein in an amount ranging from 45% to 56% by weight of the composition, crude fiber in an amount ranging from 0.5% to 2.5%, and preferably, 1% to 2.5% by weight of the composition, and sodium in an amount of less than 20 mg per 100 grams, preferably, ranging from 1-20 mg / 100 gm of the composition.

[0039] In some embodiments, the protein comprises soy protein made from defatted soybeans.

[0040] In some embodiments, the composition is in the form of discrete pieces having a size of 8 mm to 25 mm, for example, ranging from 8-20 mm or 10-25 mm or 10-20 mm. This size range is advantageous for achieving the most desired texture and absorption properties, as pieces larger than 25 mm may exhibit challenges in flavor penetration to the core.

[0041] In some embodiments, the composition comprises moisture in an amount of 3.5% to 8.5% by weight of the composition.

[0042] In some embodiments, the crude fiber comprises soy crude fiber.

[0043] In some embodiments, composition comprises one or more nutrients selected from vitamins, minerals, and combinations thereof.

[0044] In some embodiments, the composition exhibits a bulk density in a range of 0.15 to 0.18 g / ml.

[0045] In some embodiments, the composition has a surface pore area in a range of 15% to 37%.

[0046] In some embodiments, the composition has a water absorption capacity in a range of 3.0 to 5.0.

[0047] In an exemplary aspect, the present disclosure provides a method of preparing an extruded protein composition. The method comprises preparing a mixture comprising a plant derived flour and a liquid; subjecting the mixture to an extrusion process to form an extruded composition; forming discrete pieces from the extruded composition; and drying the discrete pieces to obtain the extruded protein composition.

[0048] In some embodiments, the extrusion process is carried out using water and steam without use of any chemicals such as caustic soda. The method may further comprise passing the dried discrete pieces through one or more processing equipment selected from a group comprising: an abraser, a grader, a sorter, and combinations thereof to obtain pieces of desired size and quality.

[0049] In an exemplary aspect, the extrusion process comprises applying heat at a temperature between 45°C and 95°C with die temperature at about 45°C. This processing condition may help achieve the desired porosity and texture characteristics that contribute to the unique texture leading to superior sensorial properties of the final product.

[0050] In an exemplary aspect, the plant derived flour comprises defatted soy flour having a protein content of at least 50% by weight. The use of high-protein starting material may contribute to the overall protein content of the final extruded composition.

[0051] In an exemplary aspect, the present disclosure provides a food product comprising the extruded protein composition and at least one food ingredient for combining with the extruded protein composition. The at least one food ingredient may be selected from a group comprising of carbohydrates, fats, spices, carriers and combination thereof. Carbohydrates may be selected from starch, sugar, cellulose and combinations thereof. Spices may be selected from the group consisting of spice mixtures, sauce bases, gravy mixes, and flavorenhancers. Carriers may be selected from group comprising water, oil, emulsions and combinations thereof.

[0052] In an exemplary aspect, the extruded protein composition is soaked in at least one carrier at a temperature between 80°C and 100°C for a period of 4 to 6 minutes before being combined with the at least one additional food ingredient. This step allows the extruded protein composition to achieve optimal texture and flavor absorption properties prior to final food preparation.

[0053] The present disclosure addresses the issue of extruded protein products or soy chunks having a non-rounded flavor and undesirable chewy texture with a bland soy beany core. When a person consumes conventional extruded protein products, the masala or flavor typically comes out in the initial chews, and in subsequent chews, the typical taste of soy dominates, resulting in a non-rounded flavor expression with undesirable chewy characteristics and a bland core. This problem is particularly pronounced in larger sized (8-25 mm) extruded soy protein products, as they require more chewing and flavor penetration to the core is more challenging.

[0054] The food products prepared using the extruded protein composition of the present disclosure offer consumers a significantly improved eating experience, with better flavor penetration throughout the product, reduced chewiness, and absence of the typical bland core found in conventional products. These improvements make the products more appealing and acceptable to a wide range of consumers, facilitating increased protein consumption through plant-based sources.EXAMPLES

[0055] The present invention is further explained in the form of the following examples. However, it is to be understood that the following examples are merely illustrative and are not to be taken as limitations upon the scope of the invention.

[0056] In accordance with the present disclosure, defatted soy flour was prepared from soybeans sourced from Niger.Example 1: Composition and Characteristics of Extruded Soy Protein (WEI)

[0057] The extruded soy protein product of the present disclosure comprises protein at a concentration of about 45-56%, crude fiber at a concentration of less than about 2.5%, sodium at a concentration of less than about 20 mg / lOOg, preferably about 1-20 mg / 100 gm, surface pore area greater than about 15%, water absorption capacity greater than about 3, andmasala absorption capacity greater than about 4. The specific composition and physical properties of a working example are detailed in Table A below.Table A: Example 1 (WE 1) - Composition and Physical Properties

[0058] 1000 kg of defatted soy flour having about 54 gm of soy protein / 100 gm, 2.2 gm of crude fibers / 100 gm, 6 mg of sodium / 100 gm, and 6 gm of moisture / 100 gm was mixed with 250 liters of water along with steam to prepare a dough. The dough was then mixed in by the help of mixer at ambient temperature.

[0059] The conditioned dough was then fed into a single screw extruder at a feed rate of 25 kg / minute. The extruder barrel was maintained at temperature zones of 95°C - 45°C from feed to die end, with die temperature at 45°C. The extrudate emerging from the die was immediately cut into discrete pieces of desired length using a rotating cutter operating at 50 rpm. The hot extruded pieces were then conveyed to a continuous belt dryer where they were dried at 120°C air temperature for 30 minutes.

[0060] The dried extruded pieces were then passed through rotatory and vibratory sieves in sequence. The chunks with desired size were collected as the final extruded soy protein composition.Water Absorption Capacity:

[0061] This test was performed on representative samples.

[0062] For water absorption determination, 100 ml of water was measured and transferred to a 250 ml glass vessel. The water was heated with a covered aluminum lid on a heating plate set at 200°C until reaching boiling temperature (100°C), verified with a thermometer to be98-100°C. At boiling point, 10g of chunks were added and boiled uncovered for 10 minutes while maintaining 98-99°C temperature.

[0063] The chunks were then removed and placed on a mesh strainer, moved vertically (with up & down motion) five times to drain water. The drained chunks were placed in uniform containers and kept for 10 minutes before weighing. Water Absorption Capacity was determined using the formula: (Final weight - Initial weight) / Initial weight.Masala Absorption Capacity:

[0064] 25 g dry chunks were weighed. Chunks were boiled in water three times the dry chunks volume for 5 minutes. Chunks were filtered and cooled for 10 minutes. The chunks were squeezed and weighed. Gravy was weighed (1: 1 as per weight of squeezed chunks). 1.2 times water of squeezed chunks weight was added to the gravy. Igm salt and chilli powder each were added and the gravy mixture was boiled. The chunks were added and cooked for 4 minutes. The mixture was transferred to a bowl and rested for 15 minutes. Chunks were removed from gravy and sieved to remove excess gravy (interchange 3 sieves with 5 horizontal and vertical movements each). Weight of chunks was noted down. Masala Absorption Capacity was calculated as (Final weight of Chunks-Dry weight of Chunks) / (Dry weight of Chunks).Surface Pore Area:

[0065] Soya chunk was placed under 10X microscope. Picture of each surface of chunk was taken. Number of pores were counted. Pore radius and axis were measured by scale on screen and divided by 10.

[0066] Area of each pore was calculated as: Round pores - 7ir2 (r - radius), Ellipse pores - n X a X b (a - length of axis, b - length of axis). Area of each chunk was determined by dividing Soya chunk surface into many triangles. Each side of triangle was measured using vernier caliper. Area of each triangle was calculated using Heron's formula: Area = "Vs (s - a) (s - b) (s - c) where s is half the perimeter, or (a + b + c) / 2. From pore area and chunk area, non pore area was calculated.Average Hardness and Chewiness:

[0067] For sample preparation, soy chunk to water was taken in the ratio of 1:25 (w / w). The water was taken in a bowl and boiled (use induction stove set at power of 1300W). After the water starts boiling, the induction stove power was reduced to 600W. The weighed soyachunks were added into the boiling water and timer was started. Chunks were boiled in waterfor 5 min. After 5 minutes, the induction stove was stopped. Excess water was drained out using a strainer without squeezing. Chunks were washed in room temperature water for 2 times without squeezing the chunks. Chunks were transferred to a strainer and held for two minutes to strain the remaining excess water without squeezing. The chunks were used for texture analysis.

[0068] For measurement using Texture Analyser (Stable Micro Systems), the objective was finding the Hardness and chewiness of cooked soya chunks by using knife blade. TA Settings were: Option: Return to Start, Pre-Test Speed: 1.0 mm / s, Test Speed: 1.0 mm / s, Post-Test Speed: 10 mm / s, Distance: 25 mm, Trigger Force: Auto - 50g, Accessory: Knife Edge with Slotted Insert (HDP / BS) using 5kg load cell.

[0069] The Slotted Insert was secured on the Heavy-Duty Platform. The Knife Edge was attached to the load cell carrier and lowered into the slotted insert. The Heavy-Duty Platform was repositioned so that there is no contact between the blade and slot surfaces and a 'blank' test run as a check. The blade was then raised to allow placement of the sample. Cooked samples were placed centrally under the Knife Edge.

[0070] Once the trigger force of 50g has been attained, the probe proceeds to penetrate the sample to the specified distance. The probe then returns to its start position. The maximum force was taken as an indication of the hardness and chewiness parameter was measured as the total positive area under the curve during testing. For hardness result was expressed as Maximum force ('Hardness' (+ / - S.D.) (g). For chewiness result was expressed as Area under the curve Chewiness' (+ / - S.D.) (g .sec).Bulk Density:

[0071] This test was performed on Representative sample.

[0072] The 500ml Plastic beaker was placed on weighing scale and scale was tared. Chunks were filled in the plastic beaker till the 500ml mark without pressing or shaking the beaker. The weight of the chunks was noted. Bulk density was calculated using the formula: b.d. = M / V, Where M = Mass of chunks in the 500ml plastic beaker till the 500ml mark, V = Volume of the beaker (500ml).Example 2: Synergistic Effect of Composition

[0073] It was surprisingly found that predetermined concentrations of crude fiber and sodium are essential to achieve desired textural properties, flavour / masala / water absorption capacity, and surface pore area. The synergistic effect of these components was concludedthrough comparative analysis of working examples (WE) and non-working examples (NWE) as shown in Table B.Table B: Comparative Analysis of Working and Non-Working ExamplesNon-working Examples 1 and 2 represent commercially available soy chunk products in market. Non-working Example 1 corresponds to market sample ”2n” - a chemical-free extruded soy product, while Non-working Example 2 corresponds to market sample "3s" - a caustic-treated soy product (sodium hydroxide processed).

[0074] Surprisingly, it could be noted, as clearly evident from Table B that a meagre 0.4% reduction in crude fiber content (from 2.7% to 2.31%) leads to a dramatic increase in surface pore area from 8-9% to 21-22%. Consequently, it was concluded that sodium content less than about 20 mg / 100 gm and crude fiber content in the range of 1% to 2.5% by wt. of the composition, when incorporated in the compositions, it affords dramatic improvement in the desired characteristics owing to strong synergism / functional reciprocity therebetween.Table C: Additional Working ExamplesExample 3: Comparative Sensory Evaluation

[0075] Sensory evaluations were conducted with 200 people in four different geographies (800 people in total) comparing chunks of the present invention (la) versus two commercially available market samples (2n, 3 s). The results are presented in Tables 1-4 below.Table 1: Overall Likeability ScoresNote: All four datasets are from different geographies, la - soy chunks of present invention, 2n - market sample soy chunks, 3s - market sample soy chunks. NA - not applicable as two products compared at a time.Table 2: Pre-cooking Parameters EvaluationNote: All four datasets are from different geographies. Same sample codes as Table 1.Table 3: Cooking Stage Parameters - Cleaning / Boiling and CookingNote: All four datasets are from different geographies. Same sample codes as Table 1.Table 4: Post-Cooking Texture EvaluationNote: All four datasets are from different geographies. Same sample codes as Table 1.

[0076] The sensory evaluation results in Tables 1-4 clearly demonstrate that the composition realized in accordance with an embodiment of the present disclosure (la) achieved significantly higher scores across all parameters compared to market samples (2n, 3s). The overall likeability shown in Table 1 was consistently higher therefor across all geographies. Table 2 shows that consumers distinctly noted higher porosity for the composition of the present disclosure (72% vs 9%, 72% vs 33%, 58% vs 17%, 67% vs 21%), which correlates with the surface pore area of 15-37% experimentally calculated in Table A versus 8.6% and 9.2% for non-working examples in Table B. Tables 3 and 4 demonstrate superior performance in water absorption, softness, shape retention, gravy absorption, and texture parameters, confirming that the unique composition delivers a softer, more porous, less chewy product with higher flavour / water / masala absorption.Example 4: Microscopic and Visual Analysis

[0077] Microscopic examination (10X magnification) revealed distinct differences between the composition of the present disclosure and market products. Figure 1A and Figure 2A show the soy chunk of the present disclosure (la) with high amount of pores throughout the surface, having larger pore size with deep, truncated pores evenly distributed across the chunk surface area. In contrast, Figure IB and Figure 2B show market product 2n with lower amount of pores, very small pinhole pores that are not truncated, and fewer large pores. Figure 1C and Figure 2C show market product 4f with similar deficiencies - lower amount of pores, smaller pores that are not truncated, fewer large pores, and more non-pore area. Figure ID and Figure 2D show market product 3s (made using caustic-NaOH) also having smaller pores that are not truncated, lower amount of total pores leading to higher non-pore area, and lower amount of larger pores.

[0078] The inferior pore characteristics of market products (Figures IB, 1C) are due to not having the required concentrations of fiber, sodium, and / or protein as specified herein. Figure ID illustrates that even with higher sodium content (more than 20mg per 100g from pH modifying agents such as caustic soda), the product still has lesser number of pores and lacks the water absorption capacity due to reduced water absorption on the surface.

[0079] The foregoing examples are merely illustrative and are not to be taken as limitations upon the scope of the invention. Various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art and may be made without departing from the scope of the invention.ADVANTAGES OF THE INVENTION

[0080] The present invention provides an extruded protein composition with optimized protein, crude fiber, and sodium content that delivers superior nutritional and functional properties.

[0081] The present invention provides extruded protein products with higher surface pore density, enhanced flavor and masala absorption capacity, lower bulk density, and improved textural characteristics of softness and reduced chewiness.

[0082] The present invention provides a method for preparing extruded protein compositions without chemical processing.

[0083] The present invention provides a solution for developing organoleptically superior extruded protein products with well-rounded sensorial profile without off-notes.

Claims

We Claim:

1. An extruded protein composition comprising: a) protein in a range of 45% to 56% by weight of the composition; b) crude fiber in a range of 1% to 2.5% by weight of the composition; and c) sodium in a range 1-20 mg / 100 gm of the composition.

2. The extruded protein composition as claimed in claim 1, wherein the protein comprises soy protein made from defatted soybeans.

3. The extruded protein composition as claimed in claim 1, wherein the composition is in the form of discrete pieces having a size of 8 mm to 25 mm.

4. The extruded protein composition as claimed in claim 1, wherein the composition comprises moisture in an amount of 3.5% to 8.5% by weight of the composition.

5. The extruded protein composition as claimed in claim 1, wherein the crude fiber comprises soy crude fiber.

6. The extruded protein composition as claimed in claim 1, wherein the composition comprises nutrient selected from the group comprising vitamins, minerals, and combinations thereof.

7. The extruded protein composition as claimed in claim 1, wherein the composition has a surface pore area in a range of 15% to 37%.

8. The extruded protein composition as claimed in claim 1, wherein the composition has a water absorption capacity in a range of 3.0 to 5.0.

9. A method of preparing an extruded protein composition as claimed in claims 1-8, the method comprising: a) preparing a mixture comprising plant derived flour and liquid; b) subjecting the mixture to an extrusion process to form an extruded composition; c) forming discrete pieces from the extruded composition; and d) drying the discrete pieces to obtain the extruded protein composition.

10. The method as claimed in claim 9, wherein the extrusion process comprises applying heat at a temperature between 45°C and 95°C.

11. The method as claimed in claim 9, further comprising passing the dried discrete pieces through processing equipment selected from the group consisting of an abraser, a grader, a sorter, and combinations thereof.

12. The method as claimed in claim 9, wherein the plant derived flour is defatted soy flour having a protein content of at least 50% by weight.

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