Methods and devices for producing a meat analogue product which mimics a naturally dispersed fiber structure

Abstract

Disclosed is a method of producing a meat analogue product, comprising: providing multiple elongate elements of a non-animal edible material, each elongate element having a longitudinal axis, the multiple elongate elements being arranged such that, for at least a majority of the elongate elements, their longitudinal axes are substantially parallel to each other; conveying the multiple elongate elements along a conveyor; controllably dropping the elongate elements from the conveyor onto a moving surface to thereby displace at least a majority of the elongate elements with respect to each other; the moving surface positioned at a different height than the conveyor and differing from the conveyor by at least one of: orientation, movement speed, and movement pattern.

Description

[0001] METHODS AND DEVICES FOR PRODUCING A MEAT ANALOGUE PRODUCT WHICH MIMICS A NATURALLY DISPERSED FIBER STRUCTURE

[0002] TECHNOLOGICAL FIELD

[0003] The present disclosure relates to systems and methods for producing a meat analogue product, and in particular to high-volume production of a meat analogue product which mimics a naturally dispersed fiber structure.

[0004] BACKGROUND

[0005] Publication WO2024013745A1 by the same applicants discloses” A method of fabricating an edible product, said method comprising: (a) obtaining a plurality of first edible layers comprised of a first edible material, each of said first edible layers having one or more soles being defined by being more resilient to shearing in a direction transverse to a longitudinal axis than along the longitudinal axis, each of said first edible layers defines a layer plane including said longitudinal axis; (b) obtaining a second edible material having adhesive properties; (c) dispensing a portion of the second edible material forming a first adhesive layer on top of one of said plurality of first edible layers; (d) forming a first stack of the first edible layers with the first adhesive layer between each two first edible layers, while having the longitudinal axes of most of the first edible layers substantially parallel to each other; and (e) slicing said first stack into a plurality of mats along one or more slicing planes, each of which being parallel to the longitudinal axis and angled to the layer plane of the first edible layers being crossed thereby, whereby each mat comprises a plurality of elongated sole strands from the first edible material with the second edible material inbetween”.

[0006] GENERAL DESCRIPTION

[0007] According to an aspect of some embodiments there is provided a method of producing a meat analogue product, comprising: providing multiple elongate elements of a non-animal edible material, each elongate element having a longitudinal axis, the multiple elongate elements being

[0008] 03097988\31-01 arranged such that, for at least a majority of the elongate elements, their longitudinal axes are substantially parallel to each other; conveying the multiple elongate elements along a conveyor; and controllably dropping the elongate elements from the conveyor onto a moving surface to thereby displace at least a majority of the elongate elements with respect to each other; the moving surface located at a height difference from the conveyor and differing from the conveyor by at least one of: orientation, movement speed, and movement pattern.

[0009] In some embodiments, the moving surface constitutes a second conveyor which moves linearly and is arranged at an orientation of between 90-180 degrees with respect to the conveyor.

[0010] In some embodiments, the moving surface constitutes a stacking surface which moves in a reciprocating movement pattern.

[0011] In some embodiments, controllably dropping displaces the elongate elements in at least one of the following maimers:

[0012] (a) the elongate elements are at least partially pivoted about their corresponding longitudinal axes;

[0013] (b) adjacent elongate elements are least partially spaced from each other; and

[0014] (c) an orientation of the elongate elements is modified such that their longitudinal axes are no longer parallel.

[0015] In some embodiments, controllably dropping displaces the elongate elements in all of the above manners (a-c).

[0016] In some embodiments, for an individual elongate element, the change in orientation according to (c) is expressed as an angle between an initial alignment of the longitudinal axis of the elongate element and an alignment of the longitudinal axis after the controlled drop.

[0017] In some embodiments, the angle is between 10-20 degrees.

[0018] 03097988\31-01 In some embodiments, the method further comprises dispensing additives from above the elongate elements such that exposed surfaces of the elongate elements are coated with the additives.

[0019] In some embodiments, the additives include adhesive materials allowing binding of elongate elements to each other.

[0020] In some embodiments, the multiple elongate elements are pre-cut from a sole of the non-animal edible material.

[0021] In some embodiments, the method further comprises stacking the elongate elements by gradually layering them.

[0022] In some embodiments, the method further comprises compressing the stacked elongate elements into a slab.

[0023] In some embodiments, the method further comprises weighing the slab.

[0024] In some embodiments, the method further comprises cutting the slab into slices.

[0025] In some embodiments, the method further comprises vacuum packing each of the slices.

[0026] In some embodiments, the method is applicable in a mass production line in which the rate of production is at least 500 kg / hour.

[0027] In some embodiments, a container is mounted on the moving surface and wherein controllably dropping comprises dropping the elongate elements from the conveyor into the container; wherein movement of the container by the moving surface causes walls of the container to shape a formed or forming stack of elongate elements in the container.

[0028] According to an aspect of some embodiments there is provided a meat analogue product produced by the method according to any of the previously described embodiments.

[0029] According to an aspect of some embodiments there is provided a system for producing a meat analogue product mimicking a naturally dispersed fiber structure, comprising: 03097988\31-01 a conveyor for conveying multiple elongate elements of non-animal edible material, each elongate element having a longitudinal axis; a moving surface located at height difference from the conveyor such that the elongate elements are controllably dropped from the conveyor onto the moving surface; the moving surface differing from the conveyor by at least one of: orientation, movement speed, and movement pattern; and a system controller which controls the movement of the conveyor and of the moving surface.

[0030] In some embodiments, the moving surface constitutes a second conveyor which moves linearly and is arranged at an orientation of between 90-180 degrees with respect to the conveyor.

[0031] In some embodiments, the moving surface constitutes a stacking surface which moves in a reciprocating movement pattern.

[0032] In some embodiments, the system further comprises a cutting machine for cutting a sole of edible protein material into the elongate elements.

[0033] In some embodiments, the controller is programmed to control the relative movement speeds of the conveyor and the moving surface so as to cause the elongate elements to bounce from the conveyor to the moving surface.

[0034] In some embodiments, the system further comprises an applicator located above the surface for dispensing at least one of adhesives and fat additives onto exposed, upwardly facing surfaces of the elongate elements.

[0035] In some embodiments, the system further comprises a compressor for compressing the stacked elongate elements into a slab.

[0036] In some embodiments, the system further comprises a container mounted on the moving surface in which the elongate elements are stacked; wherein movement of the container by the moving surface causes walls of the container to shape a formed or forming stack of elongate elements in the container.

[0037] 03097988\31-01 In some embodiments, the moving surface comprises a container into which the elongate elements drop; and the system further comprises: a closed passageway positioned below the container, such that the elongate elements are released from the container into the closed passageway; and a pusher mechanism configured to be advanced, at least in part, into the closed passageway, thereby condensing and advancing the elongate elements along the passageway.

[0038] In some embodiments, the system further comprises a cutting element positioned at an exit opening of the closed passageway for separating the elongate elements into slabs or blocks.

[0039] In some embodiments, the closed passageway comprises a tapering section adjacent to the exit opening.

[0040] In some embodiments, the system is configured to continuously advance the elongate elements along the passageway.

[0041] According to an aspect of some embodiments there is provided a meat analogue product which mimics a naturally dispersed fiber structure, comprising: a slab constructed of multiple elongate elements of edible vegetarian protein materials which are stacked, adhered to each other, and compressed into a block; at least a majority of the multiple elongate elements being dispersed such that longitudinal axes of adjacent elongate elements intersect each other.

[0042] In some embodiments, for the majority of the multiple elongate elements, an angle between longitudinal axes of adjacent elongate elements is between 10-20 degrees.

[0043] In some embodiments, the edible protein materials comprise textured vegetable protein.

[0044] In some embodiments, the slab further comprises: edible fat additives, edible coloring additives, edible adhesives.

[0045] 03097988\31-01 In some embodiments, the slab is shaped during production thereof using a mold.

[0046] In some embodiments, the slab is frozen in a vacuum pack which consolidates the compressed elongate elements and preserves the slab.

[0047] In some embodiments, there is provided a meat analogue product comprising a slice of the slab, formed by slicing the slab along a longitudinal direction corresponding with that of the elongate elements.

[0048] In some embodiments, there is provided a meat analogue product comprising a slice of the slab formed by slicing the slab along a direction which is substantially perpendicular to that of the elongate elements.

[0049] According to an aspect of some embodiments there is provided a method of producing a meat analogue product, comprising: providing shreds of an edible vegetarian material; mixing the shreds with fluid additives to form a mass; grinding the mass into continuous elongate strands conveyed by a conveyor; and controllably dropping the strands from the conveyor onto a moving surface to thereby: at least partially pivot a majority of the strands about their corresponding longitudinal axes; space at least some of the strands from each other; and / or change an orientation of at least some of the strands such that their longitudinal axes are no longer parallel.

[0050] According to an aspect of some embodiments there is provided a system for producing a meat analogue product mimicking a naturally dispersed fiber structure, comprising: a mixer for mixing shreds of an edible vegetarian material with fluid additives to form a mass; a grinder which grinds the mass into continuous elongate strands;

[0051] 03097988\31-01 a conveyor for moving the strands, the conveyor being constructed with a height difference with respect to a moving surface which is configured for reciprocating movement and on which the elongate strands are stacked.

[0052] As referred to herein, a controller or control circuitry may comprise a computer controller configured to perform operations in accordance with a set of instructions stored on a memory readable by the controller, which may be executed by a central processing unit (CPU), one or more processors, processor units, microprocessors, etc. In some examples, the controller or control circuitry can include one or more mechanism controllers or any other suitable means for controlling elements of modules and / or systems as described herein.

[0053] The term meat, as will be mentioned hereinafter, relates to animal tissue and more specifically to cattle meat (beef). The term "analogue meat" or “meat analogue” as will be mentioned hereinafter, relates to a foodstuff product having similar internal arrangement of elements from a non-animal, optionally vegetarian origin.

[0054] It is noted that the production lines shown are non-limiting examples of machinery and a factory layout which can be used for carrying out the methods described herein. Any other suitable machinery or arrangement thereof is also contemplated.

[0055] As referred to herein, the term “controllably dropping” intends to cover a process in which elements (e.g. the elongate elements of edible vegetable material) are intentionally transferred from a first surface to a second, generally lower surface. During the drop, the elongate elements are at least partially subjected to gravitational forces. A height difference between the first and second surfaces can be selected so as to, on the one hand, be sufficient to cause the elongate elements to be displaced and / or dispositioned (e.g. with respect to each other and / or with respect to the surface); and on the other hand to limit the displacement to a certain extent, for example, for avoiding a situation in which the elongate elements are uncontrollably dispersed (for example, elements would be too spaced apart from each other, their longitudinal orientation would change by more than, for example, 60 degrees, or 90 degrees). In some examples, the first surface is a conveyor along which the elongate elements are conveyed. The conveyor speed can be set to a level sufficient to cause the elements to be launched

[0056] 03097988\31-01 during the transfer to the second surface. This may contribute to the desired displacement of the elements, for example, increase the number of elements which are caused to pivot about their own longitudinal axis during the drop, space elements apart from each other, etc.

[0057] It is noted that in some cases, “controllably dropping” can refer to a scenario in which the second surface is not lower than the first surface, rather, the second surface can be similar in height or even higher than the first surface; and the controlled dropping occurs at the end of a transfer path of the elongate elements between the end of the first surface and the second surface. The transfer path can take the form of a ballistic-type trajectory, with the dropping occurring at a descending portion (downward arc) of the transfer path. In an example of such arrangement, the first surface is an inclined conveyor which functions as a ramp that causes the elongate elements to be “shot off’ the end of the conveyor.

[0058] As described above, in the general case of “controllably dropping”, the second surface would be lower than at least the end of the first surface, and the elongate elements would be subjected, at least partially, to gravitational forces causing them to fall onto the second surface due to the height differences.

[0059] BRIEF DESCRIPTION OF THE DRAWINGS

[0060] In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which:

[0061] FIGs. 1A-B are flowcharts of exemplary methods for producing a meat analogue mimicking a naturally dispersed fiber structure, according to embodiments of the present disclosure;

[0062] FIG. 2 is a flowchart of an exemplary method of preparing an extrudate for use in the production of the meat analogue product, according to embodiments of the present disclosure;

[0063] FIG. 3A schematically illustrates an example of controlled dropping of elongate elements during the production of the meat analogue product, according to embodiments of the present disclosure;

[0064] 03097988\31-01 FIG. 3B schematically illustrates another example of controlled dropping of elongate elements during the production of the meat analogue product, according to embodiments of the present disclosure;

[0065] FIG. 4 schematically illustrates the process of producing the meat analogue product according to the method of FIG. 1 A;

[0066] FIG. 5 shows a part of a production line for producing the meat analogue product according to the method of FIG.1 A, according to embodiments of the present disclosure;

[0067] FIGs. 6A-B show a part of the production line of FIG.5, and an enlarged view of the conveyor arrangement for controllably dropping the elongate elements and changing their conveying direction, according to embodiments of the present disclosure;

[0068] FIG. 7 shows a part of a production line including a grinder for producing the meat analogue product according to the method of FIG. IB;

[0069] FIG. 8 shows an example of a slab building and / or shaping station for use in a production line according to embodiments of the present disclosure;

[0070] FIG. 9 shows an example of a split conveyor of a production line, according to embodiments of the present disclosure;

[0071] FIGs. 10A-B show an example of a continuous slab building and / or shaping station for use in a production line, according to embodiments of the present disclosure.

[0072] DETAILED DESCRIPTION OF EMBODIMENTS

[0073] FIGs. 1A-B are flowcharts of exemplary methods for producing a meat analogue mimicking a naturally dispersed fiber structure, according to embodiments of the present disclosure.

[0074] Generally, in the described methods, materials of a vegetarian origin (such as textured vegetable protein (TVP), which is typically formed of soy flour, are processed into a meat analogue, which is commonly packed and provided as a block-shaped slab or as thinner, e.g. steak shaped, slices.

[0075] The described methods can be implemented by a factory production line involving the use of conveyors and other machinery which is suitable to provide a high throughput. In some examples, the production lines described herein are intended to

[0076] 03097988\31-01 produce about 300-700 Kg of meat analogue from about 200-550 Kg of source material, per hour.

[0077] Referring now to FIG. 1A, at 101, a sole of source material, such as TVP (for example shaped as a rectangular cracker or pallet), is hydrated with fluids, for example, with a coloring solution, flavoring agents, water, or others.

[0078] At 103, the soles are aligned with respect to each other and / or with respect to the conveyor, for example so that a long axis of the sole is aligned with the conveying direction. In some embodiments, the soles are vibrated to align and balance them, potentially reducing the spaces between adjacent soles.

[0079] At 105, the soles are cut to elongate elements, such as strands, by a cutting machine, and continue their movement along the conveyor. In some cases, due to the original shape of the sole and the cutting preferences, each of the elongate elements has a height H which is longer than its width W (as further shown in FIG. 3) In some examples, the width of each elongate element is between 1-4 mm.

[0080] At 107, the elongate elements are controllably dropped, for example onto a second conveyor, for changing their arrangement, as will be further described below. The second conveyor can be arranged, according to some embodiments, at an angle with respect to the first conveyor, for example at a 90 degree angle. One of the intended effects of controllably dropping the elements, along with the change in angle between conveyors, is to cause the elongate elements (e.g. a majority thereof) to at least partially pivot about their respective longitudinal axis. By that, the elongate elements are pivoted such that their height dimension now faces upwards, instead of their width dimension.

[0081] At 109, additives are dispensed, for example, applied from an applicator located above the conveyor. The dispensed additives fall onto the exposed surfaces of the elongate elements, and adhere onto them; additionally or alternatively, additives (such as oil) become trapped in between adjacent elongate elements, or otherwise come into contact with the elongate elements. The additives commonly include an adhesive, such as gluten or a gluten-based adhesive, optionally along with flavoring agents, oil, nutritious additives or others. In some cases, the additives include microorganisms, such as food yeast or other fermentation related additives.

[0082] Optionally, during dispensing of additives, the elongate elements are vibrated or otherwise shaken to bring to a more homogenous distribution of additives.

[0083] 03097988\31-01 At 111, the coated elongate elements are controllably dropped again, while being layered to form a slab. In some embodiments, during layering of the elongate elements, a stacking surface onto which the elongate elements drop from the conveyor is moved in a different pattern than the conveyor, which moves generally linearly. For example, the stacking surface is moved in a back and forth, reciprocating movement pattern. The reciprocating movement of the stacking surface, along with the drop, cause a further change in the arrangement of elongate elements, while more evenly distributing the elements on the surface and / or on top of each other. In some embodiments, the reciprocating movement is performed along an axis which is generally perpendicular to a longitudinal axes of the elongate elements. In some embodiments, parameters of the reciprocating movement pattern such as stroke length and / or frequency are selected based on, for example, a rate in which the elongate elements drop onto the surface, a rate in which dispensing of additives is carried out, and / or other factors. In some embodiments, the stroke length is selected as a function of a desired width dimension of the slab being built from the elongate elements. In some cases, the frequency is selected, on one hand, to be high enough so as to increase the throughput of the production line; and on the other hand to be low enough so as to prevent the elongate elements from crumbling, breaking or otherwise changing shape. In some examples, the frequency is between 2Hz-4Hz; and the stroke length= (desired width of slab)X 1.25. In a specific example, the desired width of the slab is 120 mm, the stroke length is 150mm, and the frequency is 3Hz.

[0084] It is noted that in some embodiments, steps 107 and 111 constitute only a single controlled dropping action, in which the parallel elongate elements are transferred from the conveyor onto the moving surface, while step 109 (dispensing of additives) is carried out simultaneously with the transfer of elements.

[0085] At 113, the stack of elongate elements, which are now at least partially adhered to each other, is weighed, and at 115, the stack is compressed into a slab. Weighing the slab can provide for producing slabs of a similar size (for example having a target weight). Weighing may also provide a measure of control over the amount of additives added to an original weight of the vegetable material. It is noted that weighing may be performed at additional or alternative steps of the process.

[0086] 03097988\31-01 In some embodiments, the stack is placed in a mold for being shaped into a slab (e.g. block shaped); additionally or alternatively, compression is applied onto the stack, for example from the top and / or onto the sides of the stack, by suitable machinery, to shape the slab, for example into a block. In some embodiments, the stacked slab is covered with fat, optionally applied by an applicator. Optionally, the slab is then placed in a freezer.

[0087] At 117, optionally, the slab is sliced into multiple slices (e.g. steaks). Slicing can be performed in a direction that is perpendicular to the long axis of the elongate elements of the stack, or in a direction which is parallel to the long axes of the elongate elements of the stack. In some embodiments, the slab can be cut into designated shaped, e.g. cut into multiple small cubes.

[0088] At 119, each slice (or the slab, if it was not sliced) is inserted into a package (e.g. a thermoform package), and vacuum is applied. In some cases, the slice is further shaped and solidified by the vacuum tight package.

[0089] Referring now to FIG. IB, in this exemplary method, at 121, the source material (e.g. TVP crackers) is hydrated, for example as described with respect to 101 above.

[0090] At 123, the hydrated source material is shred into small bits.

[0091] At 125, the bits are mixed with additives, such as coloring, flavoring agents, oil, fat, nutritious additives and / or other ingredients.

[0092] At 127, the formed mass of shreds and additives is passed through a grinder and dispensed as elongate elements, for example, as thin continuous strands. In some embodiments, the elongate elements are dispensed as a single layer, in which the strands extend parallel to each other on a single plane. In some embodiments, the strands are dispensed such that they are at least partially spaced apart from each other.

[0093] At 129, additives, such as adhesives, are dispensed onto the elongate elements. Due to the elongate elements being spaced apart, a greater surface area of each elongate element can be coated by the additives. Optionally, at least some of the additives become trapped in between elongate elements. At 131, the elongate elements are controllably dropped while being layered on top of each other to form a slab. In some embodiments, during layering of the elongate elements, a stacking surface onto which the elongate elements drop from the conveyor is moved in a back and forth reciprocating movement pattern. The reciprocating movement pattern of the stacking

[0094] 03097988\31-01 surface can cause the elongate elements, especially when formed as continuous strands, to form a “loop” or a fold once being turned to the opposite direction. When the reciprocating movement is repeated, multiple loops (folds) can be formed by the same elongate element. In some embodiments, the reciprocating movement is performed along an axis which is generally parallel to the longitudinal axes of the elongate elements. In some embodiments, parameters of the reciprocating movement pattern such as stroke length and / or frequency are selected based on, for example: a rate in which the strands drop onto the surface, which may further depend on a rate of extrusion of the strands from the grinder; a rate in which dispensing of additives is carried out, and / or other factors. In some embodiments, the stroke length is selected as a function of a desired length dimension of the slab being built from the folded strands. In some cases, the frequency is selected, on one hand, to be high enough so as to increase the throughput of the production line; and on the other hand to be low enough so as to prevent the folded strands from crumbling, breaking or otherwise changing shape. In some examples, the stroke length= the desired length of the slab, and the frequency is between 0.5Hz-1.5 Hz. In a specific example, the length of the slab is 250mm, the stroke length, similarly, is 250mm, and the frequency is 1 Hz.

[0095] Optionally, the slab that is formed on the stacking surface is then weighed.

[0096] Steps 133, 135 and 137 are for example as described above with respect to 115, 117, and 119.

[0097] FIG. 2 is a flowchart of an exemplary method of preparing an extrudate for use in the production of the meat analogue product, according to embodiments of the present disclosure.

[0098] In some embodiments, production begins with a source material which is already provided in the form of soles (e.g. TVP crackers or pallets), for example as described above. Additionally or alternatively, the production line comprises an extruder for forming soles as part of the process, from a source material in the form of powder.

[0099] At 201, protein powder is mixed with additives, such as coloring, flavoring agents, oils, adhesives or others.

[0100] At 203, the mix is hydrated with fluids, e.g. water, to form a pliable mass or dough. 03097988\31-01 At 205, the mass is pushed through an extruder and shaped by the extruder into a continuous substantially flat extrudate.

[0101] At 207, the continuous extrudate is cut at several locations, perpendicularly to its long axis, to form rectangular soles. The extrudate can be processed other than to form rectangular soles, for example, it can be cut at several locations parallel to its long axis to form elongate strips; such strips can be then braided.

[0102] At 209, the soles cut from the extrudate are further processed, for example as described above in FIG. 1A or FIG. IB. Optionally, before being further processed, the soles are dried and / or placed in a freezer and / or otherwise stored.

[0103] In some embodiments, the size of the extrudate (e.g. width, length) can be selected per the need. In this case, there may not be a need to cut the extrudate. A potential advantage of avoiding cutting may include reducing the amount of waste, such as of unusable material resulting from cutting.

[0104] FIG. 3A schematically illustrates controlled dropping of elongate elements during the production of the meat analogue product, according to embodiments of the present disclosure.

[0105] In some embodiments, controlled dropping of elongate elements is performed at one or more times along the production line (see for example 107, 111 in FIG. 1A), for changing the arrangement of the elongate elements with respect to each other (and optionally with respect to the surface on which they are located). As shown, a plurality of elongate elements 301 are moved along a first conveyor 303. The elongate elements are arranged such that their long axes are substantially parallel to each other, after being cut (from the sole) by a cutting machine. In the enlarged view of an elongate element, it can be observed that its length L is significantly longer than its height H; and the height is longer than its width W.

[0106] Due to a height difference between the end of the first conveyor 303 and a second conveyor 307, the elongate elements are at least partially subjected to gravitational forces and drop from the first conveyor to the second conveyor, as schematically indicated by arrow 305.

[0107] In some embodiments, movement of the first conveyor is increased in speed towards the drop, to accelerate the elongate elements. This can cause the elongate

[0108] 03097988\31-01 elements, rather than simply fall onto the second conveyor, to be forcefully accelerated, as if they were “shot” from the first conveyor to the second.

[0109] In some embodiments, the drop is performed simultaneously to a change in conveying direction, with the second conveyor being arranged at an angle of, for example, 90 degrees with respect to the first conveyor.

[0110] In some embodiments, the controlled drop is between a conveyor and a stacking surface, on which the elongate elements are layered. Optionally, the stacking surface moves in a reciprocating motion during the layering.

[0111] This set up of the production line is intended to produce one or more of the following changes in the arrangement of elongate elements, which optionally take place simultaneously:

[0112] (a) at least partially pivot a majority of the elongate elements (e.g. 70%, 80%, 90%. 99% of the elements), each being pivoted about its longitudinal axis. Due to the pivoting, a surface of the elongate element which is exposed upwards (i.e. faces away from the conveyor) is changed, for example instead of the width dimension facing upwards, the longer height dimension faces upwards following the pivoting. By that, a larger surface of the elongate elements is exposed upwards, and it can be beneficial to apply the adhesives (which are commonly dusted from an applicator located above the conveyor) onto that larger surface;

[0113] (b) space at least some of the elongate elements from each other, increasing a distance D between the longitudinal axes (such as axes 309a, 311) of adjacent elements;

[0114] (c) change an orientation of at least some of the elongate elements such that their longitudinal axes are no longer parallel. In some examples, the change in orientation of the longitudinal axis after the drop (309b) and the longitudinal axis before the drop (309a) is at an angle a of between 10-20 degrees, 10-30 degrees, 5-25 degrees or intermediate, higher or lower range. The height of the drop is set so that the change in orientation, on the one hand, will not be too vast, causing the elements to be too disoriented (for example, a 60 degree or 90 degree change may interfere with the desired dispersion); and on the other hand, will not be too limited (for example, a 2

[0115] 03097988\31-01 degree angle) which will maintain the elongate elements substantially parallel to each other.

[0116] FIG. 3B schematically illustrates another example of controlled dropping of elongate elements during the production of the meat analogue product, according to embodiments of the present disclosure. In the example shown, multiple elongate elements 351 are conveyed along a first conveyor 353, and are then controllably dropped onto second surface 355, which moves in a back and forth reciprocating motion. In this manner, the elongate elements are at partially subjected to gravitational forces as well as to inertial forces, resulting in one or more following of the above described changes (a)-(c).

[0117] In general, an arrangement which is suitable to provide such controlled dropping can include a second surface (which is optionally a conveyor) which differs from the first conveyor in one or more : orientation of the surface (for example, the second surface extends at an angle of between 90-180 degrees with respect to the conveyor); speed of movement of the second surface; and / or the pattern of movement, for example, the second surface moves in a reciprocating motion, vibrates, and / or other pattern which differs from a generally linear movement of the first conveyor.

[0118] FIG. 4 schematically illustrates the process of producing the meat analogue product according to the method of FIG. 1 A.

[0119] In accordance with some embodiments, a sole of vegetable protein 401 is hydrated with fluids 403 (optionally, the sole is soaked in a coloring solution, water, or other fluids). The wet (hydrated) sole 405 is then conveyed into a cutting machine which cuts the sole into multiple elongate elements 407, which remain substantially parallel to each other.

[0120] The elongate elements at 409 are shown after they had been controllably dropped and their conveying direction was changed (in this example, by 90 degrees). As can be observed, the drop caused the elongate elements to: (a) pivot (e.g individual elements each being pivoted about its own long axis, such that a thicker side surface is now facing upwards); and (b) change orientation, such that the long axes of adjacent elements are no longer parallel to each other. In some embodiments, the change in orientation occurs in a majority of the elongate elements out of the total elongate

[0121] 03097988\31-01 elements, for example in 60%, 70%, 95% of the elongate elements. In some embodiments, the change in orientation involves a rotation of the long axis of an element by no more than 40 degrees, 30 degrees, 20 degrees with respect to the original alignment of the axis. In this manner, the group of elongate elements is maintained as having a general long axis La which is longer than the width axis Wa.

[0122] In the next step, the elongate elements are coated with additives 411, such as adhesives, oil, flavoring, or others, which are typically dispensed from above the conveyor. This step can be performed prior or simultaneously to layering the elongate elements in a stack 413, by controllably dropping them again. In some cases, the stacking surface on which the elongate elements pile up moves in a reciprocating motion, potentially causing a further change in the arrangement of the elongate elements, e.g. balancing their spatial distribution across the stacking surface. The reciprocating motion may also be advantageous for dispersing the additives so as to more uniformly coat the elongate elements.

[0123] The stack of elongate element is then compressed, as shown at 415. In some cases, compression is performed to bind the elongate elements to each other, increase the density of the stack and solidify the stack. Compression force can be applied, for example, onto opposite sides of the stack in a direction which is parallel to axis Wa (as indicated by arrows 417); in a top to bottom and / or bottom to top direction of the stack (not shown); and / or in a direction which is parallel to axis La (not shown). In some cases, the stack is placed in a mold, e.g. a box shaped mold, and optionally compressed within.

[0124] The compressed, shaped stack (the formed slab) can then be sliced into individual slices (e.g. steaks). Such slices can be cut in a direction which is generally parallel to axis Wa, as schematically shown in 419; or in a direction which is generally parallel to axis La, as schematically shown in 421.

[0125] In the resulting slices, the elongate elements (cut portions thereof) are dispersed in a non-homogeneous, partially random manner, mimicking the natural bundle arrangement of muscle fibers in meat. The adhesives and oil which are added during production are interspersed throughout the slice, mimicking the natural distribution of fat in a meat slice. The end product therefore resembles the look, feel and texture of

[0126] 03097988\31-01 meat, and maintains its structural characteristics also when cooked (fried, boiled, grilled, steamed, etc.)

[0127] The individual slices can then be packed and optionally placed in a cooled storage until use.

[0128] FIG. 5 shows a part of a production line for producing the meat analogue product according to the method of FIG.1 A, according to embodiments of the present disclosure.

[0129] In the shown example, a conveyor 501 transfers the soles of vegetable protein to balancing conveyors 503 and thereafter to a cutting machine 504. The cutting machine is configured to shred the soles into elongate elements, e.g. strips. Settings of the cutting machine are selected for determining at least the width (see W, FIG. 3) of the elongate elements (with the length and the height commonly being a factor of the sole itself).

[0130] The elongate elements are then conveyed towards a ramp 505 from which they are controllably dropped into a second conveyor 507 which is arranged at a 90 degree orientation with respect to the first conveyor.

[0131] The second conveyor 507 then leads the elongate elements into a balancing and weighing station 509, from which they are transferred to a slab building and / or shaping station, schematically indicated 511. An example of such slab building and / or shaping station is shown in FIG.8, described below. Once a ready slab is formed, it is transferred to a packaging station (not shown).

[0132] Continuing to FIGs. 6A-B, ramp 505 from which the elongate elements are controllably dropped (or “shot”, after being driven by the ramp) is shown in an enlarged view in FIG. 6B. In some embodiments, a height difference at the interface between the end of the ramp (end of first conveyor 501) and the second conveyor 507 is, for example, of at least several millimeters. The height difference can be selected taking into account one or more of: properties of the elongate elements (type of material, size of elements, etc.); the relative speed of movement of the first and second surfaces; any inclination angle, if exists, of the first surface and / or the second surface; any orientation angel, if exists, between the first and second surfaces; and / or other parameters.

[0133] 03097988\31-01 In some embodiments, the conveying speed along the ramp is increased, causing the elongate elements to accelerate.

[0134] Returning now to FIG. 6A, the second conveyor 507 leads the elongate elements to a slab building and / or shaping station 511. Station 511 can include modules for compressing the slab (e.g. compressor arms); modules for cutting the slab into thinner slices, if needed; and / or modules for shaping the slab.

[0135] FIG. 7 shows a part of a production line including a grinder for producing the meat analogue product according to the method of FIG. IB.

[0136] In the shown example, a mass of protein “dough” (comprised of the sole shreds, additives and / or hydration) is fed into a grinder 801, and dispensed from the grinder as elongate elements, for example in the form of long, continuous thin strands (e.g. having a width of between 1-5 mm). A first conveyor 803 leads the strands towards a controlled drop to a second conveyor (or surface) 805. The second conveyor (or surface) is configured to move in a reciprocating back-and-forth movement while the strands are layered thereon. The formed stack of layered strands is transferred to a weighing and compressing station 807 in which compression arms 809 apply pressure onto the stack to form a slab.

[0137] FIG. 8 shows an example of a slab building and / or shaping station for use in a production line according to embodiments of the present disclosure.

[0138] In some embodiments, a slab building and / or shaping station (also generally addressed 511 above) can include an arrangement of two surfaces (optionally, one or both being conveyors), 851 and 853 respectively, which are located at a height difference with respect to each other. A container 855 is mounted on surface 853. In use, elongate elements being transferred along conveyor 851 controllably drop into the container 855, in which they are stacked. In some embodiments, container 855 is moved in a reciprocating movement (either by a suitable mechanism attached to the container itself and / or by moving surface 853, on which the container is located). During this reciprocating movement, the forming (or formed) stack of elongate elements 857 is pushed by the inner walls of the container, which compress and align the stack into a shaped slab (e.g., block shaped slab).

[0139] 03097988\31-01 FIG. 9 shows an example of a split conveyor of a production line, according to embodiments of the present disclosure. In some embodiments, a conveyor line 901 is split into two (or more) conveyor lines 903, 905. The split lines can extend parallel to each other, in a horizontal alignment (e.g. side to side) or in a vertical alignment (e.g. one above the other). In such configuration, the production rate can be increased, and separate control can be provided over the split lines (e.g. moving one line faster than the other).

[0140] FIGs. 10A-B show an example of a continuous slab building and / or shaping station for use in a production line, according to embodiments of the present disclosure. FIG. 10A shows a side view of the station, and FIG. 10B shows a vertical cross section view of the station.

[0141] In the shown example, a conveyor 1001 leads the elongate elements 1003 towards a container 1005, into which the elongate elements are dropped, for example as described hereinabove. Container 1005 may be configured for movement, for example in a reciprocating movement pattern, which may be effective to more evenly distribute the elongate elements in the container. In some examples, a dispenser of additives (e.g. coloring, adhesives, flavoring materials) may be provided above the container.

[0142] The elongate elements are then released from the bottom of container 1005 into a funnel entry 1007 of a closed passageway 1009. The passageway may be L-shaped, as shown, or may be otherwise formed (e.g. as a straight linear conduit).

[0143] Due to the surrounding walls of the passageway, the elongate elements generally maintain their substantially parallel alignment, and are prevented from rotating in a manner that would cause, for example, elongate elements to become perpendicular to each other or otherwise vastly transverse each other. The walls of the passageway act as a shaping frame for shaping the elongate elements together into an elongate block form as they travel through the passageway.

[0144] As further shown, in some examples, a pusher mechanism 1011 which includes, for example, a pusher rod, a piston, or the like, is configured to be advanced into the passageway to push elongate elements 1003 in direction 1021 as well as condense and compact the elongate elements. The pusher mechanism can move back and forth into

[0145] 03097988\31-01 the passageway, each time advancing and condensing a different batch of elongate elements which is received through the funnel entry 1007. In some cases, the passageway may include a narrowing or tapering segment 1013 which can further compress the elongate elements as they are pushed along the passageway. At an exit 1015 from the passageway or at a location spaced apart from the exit, a cutting element 1017 such as a knife or a guillotine may be positioned, for separating the packed elongate elements into slabs or blocks 1019. Optionally, some of the elongate elements which are located at an end face of a slab or block, and are not in a parallel orientation to the cutting element, are partially cut by the cutting element. In some cases, the packed elongate elements exit the passageway in the form of a continuous long slab, which is cut or otherwise separated into shorter slabs or blocks further down the production line.

[0146] In some cases, the described station provides for a continuous production flow in which the elongate elements continue moving into and through the passageway, as they are pushed by the pusher mechanism.

[0147] 03097988\31-01

Claims

CLAIMS:

1. A method of producing a meat analogue product, comprising: providing multiple elongate elements of a non-animal edible material, each elongate element having a longitudinal axis, the multiple elongate elements being arranged such that, for at least a majority of the elongate elements, their longitudinal axes are substantially parallel to each other; conveying the multiple elongate elements along a conveyor; and controllably dropping the elongate elements from the conveyor onto a moving surface to thereby displace at least a majority of the elongate elements with respect to each other; the moving surface located at a height difference from the conveyor and differing from the conveyor by at least one of: orientation, movement speed, and movement pattern.

2. The method according to claim 1, wherein the moving surface constitutes a second conveyor which moves linearly and is arranged at an orientation of between 90-180 degrees with respect to the conveyor.

3. The method according to claim 1, wherein the moving surface constitutes a stacking surface which moves in a reciprocating movement pattern.

4. The method according to any one of the preceding claims, wherein controllably dropping displaces the elongate elements in at least one of the following manners:(a) the elongate elements are at least partially pivoted about their corresponding longitudinal axes;(b) adjacent elongate elements are least partially spaced from each other; and(c) an orientation of the elongate elements is modified such that their longitudinal axes are no longer parallel.

5. The method according to claim 4, wherein controllably dropping displaces the elongate elements in all of the above manners (a-c).03097988\31-016. The method according to claim 4 or claim 5, wherein, for an individual elongate element, the change in orientation according to (c) is expressed as an angle between an initial alignment of the longitudinal axis of the elongate element and an alignment of the longitudinal axis after the controlled drop.

7. The method according to claim 6, wherein the angle is between 10-20 degrees.

8. The method according to any one of the preceding claims, further comprising dispensing additives from above the elongate elements such that exposed surfaces of the elongate elements are coated with the additives.

9. The method according to claim 8, wherein the additives include adhesive materials allowing binding of elongate elements to each other.

10. The method according to any one of the preceding claims, wherein the multiple elongate elements are pre-cut from a sole of the non-animal edible material.

11. The method according to any one of the preceding claims, further comprising stacking the elongate elements by gradually layering them.

12. The method according to claim 11, further comprising compressing the stacked elongate elements into a slab.

13. The method according to claim 12, further comprising weighing the slab.

14. The method according to claim 12 or claim 13, comprising cutting the slab into slices.

15. The method according to claim 14, comprising vacuum packing each of the slices.

16. The method according to any one of the preceding claims, wherein the method is applicable in a mass production line in which the rate of production is at least 500 kg / hour.

17. The method according to any one of the preceding claims, wherein a container is mounted on the moving surface and wherein controllably dropping comprises dropping the elongate elements from the conveyor into the container; wherein movement of the container by the moving surface causes walls of the container to shape a formed or forming stack of elongate elements in the container.03097988\31-0118. A meat analogue product produced by the method according to any one of the preceding claims.

19. A system for producing a meat analogue product mimicking a naturally dispersed fiber structure, comprising: a conveyor for conveying multiple elongate elements of non-animal edible material, each elongate element having a longitudinal axis; a moving surface located at height difference from the conveyor such that the elongate elements are controllably dropped from the conveyor onto the moving surface; the moving surface differing from the conveyor by at least one of: orientation, movement speed, and movement pattern; and a system controller which controls the movement of the conveyor and of the moving surface.

20. The system according to claim 19, wherein the moving surface constitutes a second conveyor which moves linearly and is arranged at an orientation of between 90-180 degrees with respect to the conveyor.

21. The system according to claim 19, wherein the moving surface constitutes a stacking surface which moves in a reciprocating movement pattern.

22. The system according any one of claims 19-21, further comprising a cutting machine for cutting a sole of edible protein material into the elongate elements.

23. The system according to any one of claims 19-22 wherein the controller is programmed to control the relative movement speeds of the conveyor and the moving surface so as to cause the elongate elements to bounce from the conveyor to the moving surface.

24. The system according to any one of claims 19-23, further comprising an applicator located above the surface for dispensing at least one of adhesives and fat additives onto exposed, upwardly facing surfaces of the elongate elements.

25. The system according to any one of claims 19-24, further comprising a compressor for compressing the stacked elongate elements into a slab.03097988\31-0126. The system according to any one of claims 19-25, further comprising a container mounted on the moving surface in which the elongate elements are stacked; wherein movement of the container by the moving surface causes walls of the container to shape a formed or forming stack of elongate elements in the container.

27. The system according to claim 19, wherein the moving surface comprises a container into which the elongate elements drop; and wherein the system further comprises: a closed passageway positioned below the container, such that the elongate elements are released from the container into the closed passageway; and a pusher mechanism configured to be advanced, at least in part, into the closed passageway, thereby condensing and advancing the elongate elements along the passageway.

28. The system according to claim 27, further comprising a cutting element positioned at an exit opening of the closed passageway for separating the elongate elements into slabs or blocks.

29. The system according to claim 28, wherein the closed passageway comprises a tapering section adjacent to the exit opening.

30. The system according to claim 27, wherein the system is configured to continuously advance the elongate elements along the passageway.

31. A meat analogue product which mimics a naturally dispersed fiber structure, comprising: a slab constructed of multiple elongate elements of edible vegetarian protein materials which are stacked, adhered to each other, and compressed into a block; at least a majority of the multiple elongate elements being dispersed such that longitudinal axes of adjacent elongate elements intersect each other.

32. The meat analogue product according to claim 31, wherein, for the majority of the multiple elongate elements, an angle between longitudinal axes of adjacent elongate elements is between 10-20 degrees.03097988\31-0133. The meat analogue product according to claim 31 or claim 32, wherein the edible protein materials comprise textured vegetable protein.

34. The meat analogue product according to any one of claims 31-33, wherein the slab further comprises: edible fat additives, edible coloring additives, edible adhesives.

35. The meat analogue product according to any one of claims 31-34, wherein the slab is shaped during production thereof using a mold.

36. The meat analogue product according to any one of claims 31-35, wherein the slab is frozen in a vacuum pack which consolidates the compressed elongate elements and preserves the slab.

37. A meat analogue product comprising a slice of the slab of claim 31, formed by slicing the slab along a longitudinal direction corresponding with that of the elongate elements.

38. A meat analogue product comprising a slice of the slab of claim 31, formed by slicing the slab along a direction which is substantially perpendicular to that of the elongate elements.

39. A method of producing a meat analogue product, comprising: providing shreds of an edible vegetarian material; mixing the shreds with fluid additives to form a mass; grinding the mass into continuous elongate strands conveyed by a conveyor; and controllably dropping the strands from the conveyor onto a moving surface to thereby: at least partially pivot a majority of the strands about their corresponding longitudinal axes; space at least some of the strands from each other; and / or change an orientation of at least some of the strands such that their longitudinal axes are no longer parallel.

40. A system for producing a meat analogue product mimicking a naturally dispersed fiber structure, comprising: a mixer for mixing shreds of an edible vegetarian material with fluid additives to form a mass;03097988\31-01a grinder which grinds the mass into continuous elongate strands; a conveyor for moving the strands, the conveyor being constructed with a height difference with respect to a moving surface which is configured for reciprocating movement and on which the elongate strands are stacked.03097988\31-01

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