A method for preparing a plant-based extrudate rich in vegetable and / or fruit contents

Abstract

A method is provided for preparing a plant-based extrudate, the method comprising steps of: a) feeding an extruder barrel with a dry mixture comprising: i) 12 to 45 wt% of plant protein isolate and / or plant protein concentrate; and ii) 0 to 15 wt% of a vegetable and / or fruit powder, b) injecting the following components into the extruder barrel at a location down-stream of the feeding location of step a): iii) 15 to 80 wt% of vegetable and / or fruit purée; iv) 0 to 55 wt% of water; v) 0 to 3 wt% of vinegar; vi) 0 to 10 wt%, preferably 1.5 to 5 wt% of liquid oil, fat or a combination thereof, and c) extruding the mixture after steps a) and b) through a cooling die, wherein the moisture content of the vegetable and / or fruit purée is 80 to 95 wt% of the total content of the vegetable and / or fruit purée, and the total moisture content of the extruded plant-based extrudate is 50 to 80 wt%.

Description

[0001] A METHOD FOR PREPARING A PLANT-BASED EXTRUDATE RICH IN VEGETABLE AND / OR

[0002] FRUIT CONTENTS

[0003] TECHNICAL FIELD

[0004] The invention relates generally to a method for preparing a plant-based extrudate for food products. More specifically, the present invention relates to a method for preparing a plant-based extrudate for food products rich in vegetable and / or fruit contents.

[0005] BACKGROUND OF THE INVENTION

[0006] Plant-based food products are increasing in the market as a protein source alternative to meats. Plant-based food products currently available in the market are often perceived too expensive and processed, and lacking varieties in taste, textures and appearances. Further, they do not meet the recent consumers' need to include more vegetables and fruits in their diet.

[0007] There are some commercial plant-based food products claiming to be high in fiber and protein. However, most of the existing products does not contain a high amount of vegetables and / or fruits as the first ingredient on the product label, and their textures are generally rubbery, stringy or tough, that are unappealing and unpalatable to consumers.

[0008] There are currently no plant-based products with vegetables and / or fruits as the most prominent and therefore first ingredient on the product label available on the market. There is a clear need for new products which encourage vegetable / fruit consumption, having a new texture and sensory qualities as well as appearance more appealing to consumers, and that are easy to cook, fresh, and healthy.

[0009] SUMMARY OF THE INVENTION

[0010] The present invention relates to the manufacture of a plant-based extrudate with vegeta bles / fruits as the most prominent ingredient. By adapting the protein content, types and contents of vegetables / fruits, and the moisture content, the present invention can provide plant-based extrudates with varied textures, ranging from a protein fibrous texturization common in meat analogues to a novel protein gelation texturization.

[0011] The present invention enables formation of a dense and fibrous structure which is commonly used in meat analogues / substitutes, with improved juiciness and chewiness as well as a palatable colourful appearance and nutritional benefits by rich vegetable / fruit contents.

[0012] Notably, the present invention enables formation of a novel gel-like structure through aggregation and crosslinking of a protein, resulting in a three-dimensional network structure with trapped water. The technical hurdle that has been overcome is the creation of a protein gel network in a vegetable / fruit matrix. Aside water, vegetables / fruits are mainly composed of carbohydrates which are thermodynamically incompatible with proteins. The protein phase maintains the gel network and is diluted in the vegetable / fruit carbohydrate phase. The inventors have surprisingly been able to obtain an extrudate with a protein continuous phase which includes a discontinuous vegetable / fruit polysaccharide phase.

[0013] The present invention utilizes a wet extrusion equipped with a cooling die to create a protein extrudate with a large amount of vegetables / fruits. This inventive approach diverges from conventional methods, offering a distinctive process that combines benefits of the wet extrusion with incorporation of a large amount of vegetables / fruits. This unique combination not only enhances the textural attributes of the final product but also introduces a novel dimension to the utilization of wet extrusion technology in developing plant-based extrudates.

[0014] The present invention presents a solution to the challenge of developing plant-based products with an appealing texture and structure, particularly when utilizing wet extrusion. The novel approach of incorporating a large amount of vegetables / fruits into the wet extrusion process aims to overcome limitations in existing methods, providing a means to create a plant-based extrudate with enhanced texture and sensory qualities. By leveraging this inventive technique, the present invention offers a solution to the need for more diverse and palatable plant-based products, effectively advancing the field of plant-based food technology. Accordingly, an embodiment of the invention proposes a method for preparing a plant-based extrudate, the method comprising steps of: a) feeding an extruder barrel with a dry mixture comprising: i) 12 to 45 wt% of at least one plant protein ingredient selected from the group consisting of plant protein flour, plant protein powder, plant protein isolate, plant protein concentrate and a mixture thereof; and ii) 0 to 15 wt% of a vegetable and / or fruit powder which is different from the at least one plant protein ingredient, b) injecting the following components into the extruder barrel at a location downstream of the feeding location of step a): iii) 15 to 80 wt% of vegetable and / or fruit puree; iv) O to 55 wt% of water; v) 0 to 3 wt% of vinegar; vi) 0 to 10 wt%, preferably 1.5 to 5 wt% of liquid oil, fat or a combination thereof, and c) extruding the mixture after steps a) and b) through a cooling die, wherein the moisture content of the vegetable and / or fruit puree is 80 to 95 wt% of the total content of the vegetable and / or fruit puree, and the total moisture content of the extruded plant-based extrudate is 50 to 80 wt%.

[0015] In some embodiments, the content of the at least one plant protein ingredient is between 12 and 30 wt%, preferably between 15 and 27.5 wt%, more preferably between 20 and 25 wt%.

[0016] In some embodiments, the content of the at least one plant protein ingredient is between 30 and 45 wt%, preferably 32.5 and 45 wt%, more preferably 32.5 and 42.5 wt%.

[0017] In some embodiments, the dry mixture further comprises 0 to 5 wt% of a dietary fiber powder, the dietary fiber powder containing at least 70% of an insoluble fiber and / or a soluble fiber. In some embodiments, the dietary fiber powder is from a source different from a source of the vegetable and / or fruit powder.

[0018] In some embodiments, the at least one plant protein ingredient is derived from Fabaceae botanical family such as soy, pea, mung bean, faba, chickpea and lentil; from Poaceae botanical family such as wheat gluten, rice, barley and corn; from Brassicaceae botanical family such as canola and rapeseed; or combinations thereof.

[0019] In some embodiments, the vegetable powder and / or vegetable puree is made from Solanaceae botanical family such as eggplant, tomato, pepper, paprika, bell pepper and potato; from Brassicaceae botanical family such as broccoli, cauliflower, cabbage and radish; from Apiaceae botanical family such as carrot, celery and parsnip; from Amaranthaceae botanical family such as beet and spinach; from Cucurbitaceae botanical family such as zucchini, cucumber and pumpkin; or combinations thereof.

[0020] In some embodiments, the fruit powder and / or fruit puree is made from Bromeliaceae botanical family such as pineapple; from Rosaceae botanical family such as cherry, raspberry, blackberry, plum, apricot, peach, strawberry, pear, apple and almond; from Ericaceae botanical family such as blueberry and cranberry; from Ribes botanical family such as currant and gooseberry; from Rutaceae botanical family such as orange, lemon, lime, mandarin and grapefruit; from Anacardiaceae botanical family such as mango, pistachio and cashew; from Caricaceae botanical family such as papaya; from Musaceae botanical family such as banana; from Actinidiaceae botanical family such as kiwifruit; from Passifloraceae botanical family such as passionfruit; from Cucurbitaceae botanical family such as watermelon and melon; or combinations thereof.

[0021] In some embodiments, the dry mixture further comprises 0 to 5 wt% of one or more flavouring.

[0022] In some embodiments, the liquid oil and / or fat of the component vi) is rapeseed oil, sunflower oil or a blend thereof.

[0023] In some embodiments, the vegetable puree of the component iii) is prepared from one or more of spinach, carrot, broccoli, bell pepper, tomato and pumpkin, and the at least one plant protein ingredient is prepared from soy and / or wheat. In some embodiments, the temperature in step a) is maintained at 80°C or lower.

[0024] In some embodiments, the extruder barrel is heated to a temperature between 80 and 180°C, preferably between 80 and 160°C.

[0025] In some embodiments, the extruded plant-based extrudate has an exit temperature at the end of the cooling die between 40 and 100°C, preferably between 50 and 100°C, preferably between 50 and 95°C, preferably between 50 and 90°C.

[0026] In some embodiments, the liquid oil, fat or a combination thereof of the component vi) is injected at a location downstream of the injecting location of at least one of the components iii) to v).

[0027] There is also provided a plant-based extrudate obtained by the method as described above.

[0028] There is also provided a food product comprising the plant-based extrudate as described above.

[0029] There is also provided a method for making a food product comprising the plant-based extrudate as described above, the method comprising one or more of steps of: grinding the plant-based extrudate; cutting the plant-based extrudate; marinating the plant-based extrudate; frying the plant-based extrudate; grilling the plant-based extrudate; boiling the plant-based extrudate; steaming the plant-based extrudate; and breading the plant-based extrudate.

[0030] There is also provided a method for preparing a plant-based extrudate, the method comprising steps of: a) feeding an extruder barrel with a dry mixture comprising: i) 12 to 30 wt% of at least one plant protein ingredient selected form the group consisting of plant protein flour, plant protein powder, plant protein isolate, plant protein concentrate and a mixture thereof; and ii) 0 to 15 wt% of a vegetable and / or fruit powder which is different from the at least one plant protein ingredient, b) injecting the following components into the extruder barrel at a location downstream of the feeding location of step a): iii) 20 to 80 wt% of vegetable and / or fruit puree; iv) O to 55 wt% of water; v) 0 to 3 wt% of vinegar; vi) 0 to 10 wt%, preferably 1.5 to 5 wt% of liquid oil, fat or a combination thereof, and c) extruding the mixture after steps a) and b) through a cooling die, wherein the moisture content of the vegetable and / or fruit puree is 80 to 95 wt% of the total content of the vegetable and / or fruit puree, and the total moisture content of the plant-based extrudate is 50 to 80 wt%.

[0031] In some embodiments, the plant-based extrudate is prepared as a protein gel.

[0032] There is also provided a method for preparing a plant-based extrudate, the method comprising steps of: a) feeding an extruder barrel with a dry mixture comprising: i) more than 30 wt% of at least one plant protein ingredient selected from the group consisting of plant protein flour, plant protein powder, plant protein isolate, plant protein concentrate and a mixture thereof; and ii) 0 to 15 wt% of a vegetable and / or fruit powder which is different from the at least one plant protein ingredient, b) injecting the following components into the extruder barrel at a location downstream of the feeding location of step a): iii) 15 to 60 wt% of vegetable and / or fruit puree; iv) O to 55 wt% of water; v) 0 to 3 wt% of vinegar; vi) 0 to 10 wt% of liquid oil, fat or a combination thereof, and c) extruding the mixture after steps a) and b) through a cooling die, wherein the moisture content of the vegetable and / or fruit puree is 80 to 95 wt% of the total content of the vegetable and / or fruit puree, and the total moisture content of the plant-based extrudate is 50 to 60 wt%.

[0033] In some embodiments, the at least one plant protein ingredient is prepared from soy and / or wheat.

[0034] These and other aspects, features and advantages of the invention will become more apparent to those skilled in the art from the detailed description of embodiments of the invention, in connection with the attached drawings.

[0035] BRIEF DESCRIPTION OF THE DRWAINGS

[0036] Figure lAto 1C show example configurations of an extrusion system for the invention.

[0037] Figures 2A and 2B show hardness (g) and chewiness (g) of plant-based extrudates according to the invention in Example 1, of a protein extrudate without vegetable and of a plant-based chicken extrudate in Example 2.

[0038] Figures 3A to 3E show microstructures of the plant-based extrudates according to the invention in Example 1, and Figure 3F and Figure 3G show microstructures of the protein extrudate without vegetable and the plant-based chicken extrudate in Example 2.

[0039] Figure 4 shows sensory attributes such as firm, moist, compact, chewy, rubbery and fibrous for plant-based extrudates according to the invention, for a protein extrudate without vegetable and for a plant-based chicken extrudate. DETAILED DESCRIPTION OF THE INVENTION

[0040] "Extrusion" is a process used to create objects of a fixed cross-sectional profile. A material is pushed or pulled through a die of the desired cross-section. The two main advantages of this process over other manufacturing processes are its ability to create very complex cross-sections, and to prepare products that are brittle, because the material only encounters compressive and shear stresses. High-moisture extrusion (HME) is known as wet extrusion. Extruders typically comprise an extruder barrel within which rotates a close fitting screw. The screw is made up of screw elements, some of which are helical screw threads to move material through the extruder barrel. Material is introduced into the extruder barrel toward one end, moved along the extruder barrel by the action of the screw and is forced out of the extruder barrel through a nozzle or die at the other end. The rotating screw mixes and works the material in the barrel and compresses it to force it through the die or nozzle. The degree of mixing and work to which the material is subjected, the speed of movement of the material through the extruder barrel and thus the residence time in the extruder barrel and the pressure developed in the extruder barrel can be controlled by the pitch of the screw thread elements, the speed of rotation of the screw and the rate of introduction of material into the extruder barrel. The extruder barrel comprises multiple extruder barrel sections which are joined end to end. Multiple extruder barrel sections are required to carry out different processes involved in extrusion such as conveying, kneading, mixing, devolatilizing, metering and the like. Each extruder barrel section comprises a liner which is press fit into an extruder barrel casing, and heating and cooling elements are provided to regulate temperature of extruder barrel section within permissible range. The total length of an extrusion process can be defined by its modular extrusion barrel length. An extruder barrel is described by its unit of diameter. A "cooling die" is for cooling the extruded product to a desired temperature.

[0041] Figures 1A to 1C illustrate an example configuration of an extruder. The extruder consists of an extruder barrel (2) equipped with one or more screws driven by a motor (1) and a cooling die (3). As generally illustrated in Figure 1A, the present disclosure provides a process for producing a plant-based extrudate. The process may comprise a) feeding an extruder barrel (2) with a dry mixture (4), b) injecting a wet mixture (5) into the extruder barrel (2) at a location down-stream of the feeding location of step a), and c) extruding the mixture after steps a) and b) through a cooling die (3). The dry mixture (4) may comprise i) 12 to 45 wt% of at least one plant protein ingredient selected from the group consisting of plant protein flour, plant protein powder, plant protein isolate, plant protein concentrate and a mixture thereof, and ii) 0 to 15 wt% of a vegetable and / or fruit powder which is different from the at least one plant protein ingredient. The wet mixture (5) may comprise iii) 15 to 80 wt% of vegetable and / or fruit puree, iv) 0 to 55 wt% of water, v) 0 to 3 wt% of vinegar, and vi) 0 to 10 wt%, preferably 1.5 to 5 wt% of liquid oil, fat or a combination thereof.

[0042] One or more of the components iii) to vi) may be injected separately at different locations of the extruder barrel (2) or together at the same location of the extruder barrel (2).

[0043] A hopper may be used to feed the dry mixture (4) to the extruder barrel (2).

[0044] According to the present invention, the at least one plant protein ingredient in the form of a dry powder is added to the extruder barrel (2) and water is injected separately, downstream of the dry protein feeding location. The mixing of the dry plant protein and water is done within the extruder barrel through the mechanical energy forced. Therefore, it is not necessary to form a dough of the plant protein and water before feeding the extruder barrel.

[0045] In FIG. 1A, all components iii) to vi) of the wet mixture are injected at the same injecting location of the wet mixture (5).

[0046] FIG. IB illustrates another example in which the liquid oil, fat or a combination thereof is injected at a location (6) downstream of the injecting location for other components of the wet mixture (5').

[0047] FIG. 1C illustrates another example with two injecting locations (5a, 5b) for components iii) to v) of the wet mixture, and an injecting location (6) for the component vi) of the wet mixture. For example, water and vinegar may be injected at the location (5a) and the vegetable and / or fruit puree may be injected at the location (5b), or the vegetable and / or fruit puree may be injected at the location (5a) and water and vinegar may be injected at the location (5b). For example, the vegetable and / or fruit puree and vinegar may be injected at the location (5a) and water may be injected at the location (5b), or water may be injected at the location (5a) and the vegetable and / or fruit puree and vinegar may be injected at the location (5b). The injecting location (6) for the liquid oil, fat or a combination thereof may be the same as the injecting location (5a) or (5b), or between the injecting locations (5a) and (5b).

[0048] Although FIG. 1A to 1C show only one or two injecting locations, there may be three or more injecting locations for one or more of the components iii) to vi) of the wet mixture provided that such injecting location(s) are downstream of the feeding location of the dry mixture (4), and that the liquid oil, fat or a combination thereof may not be injected alone as the first component immediately after the feeding of the dry mixture (4).

[0049] For example, the liquid oil, fat or a combination thereof is injected within the second half part of the total length of the extruder barrel (2), or within the last third part of the total length of the extruder barrel, or within the last quarter part of the total length of the extruder barrel, or within the last sixth part of the total length of the extruder barrel, or within the last screw element of the extruder barrel. "The second half part" is a half part of the total length of the extruder barrel (2) which is remote from the location of dry mixture feeding.

[0050] The extruder barrels may be heated to a temperature of between 80 to 180°C, preferably 80 to 160°C. The pressure on a front plate of the extruder barrels may be between 2 to 10 bar, preferably 5 bar. The screw speed may be around 200-500 rpm.

[0051] During the cooling within the cooling die (3), both the temperature and the pressure may be gradually reduced as the heated dough travels through the cooling device (3). The dough has moisture and is under elevated temperature, so preferably moisture flashing is controlled to avoid rapid expansion of the food product. Product expansion that is too rapid may disrupt the structure of the texturized food product. The extruded plant-based extrudate may have an exit temperature at the end of the cooling die (3) between 40 and 100°C, preferably between 50 and 100°C, preferably between 50 and 95°C, preferably between 50 and 90°C.

[0052] The terms "plant protein flour" and "plant protein powder" as used herein are used interchangeably and refer to a flour or (dry or dehydrated) powder obtained from plant(s) with high protein content. The plant protein flour or plant protein powder may typically contain 10-50 wt%, 15-50 wt%, or 20-50 wt% of plant proteins on a moisture-free basis.

[0053] The term "plant protein concentrate" as used herein refers to proteins extracted from plant(s) but without additional processing steps of reducing fat and carbohydrate contents carried out to obtain a protein isolate. The plant protein concentrate may typically be a plant material having a protein content of from about 65% to less than about 80-90% plant protein on a moisture-free basis. Plant protein concentrate may also contain plant fiber, typically from about 3.5% up to about 20% by weight on a moisture-free basis.

[0054] The term "plant protein isolate" as used herein refers to proteins extracted from plant(s) by various methods such as isoelectric precipitation separation and ultrafiltration to obtain a highly concentrated protein fraction. The plant protein isolate may typically be a plant material having a protein content of at least about 80-90% plant protein on a moisture- free basis.

[0055] In some embodiments, the at least one plant protein ingredient is plant protein concentrate and / or plant protein isolate.

[0056] The at least one plant protein ingredient may be derived from any one or more of legumes, grains, cereals, seeds, pulses and nuts.

[0057] The at least one plant protein ingredient may be derived from a plant of Fabaceae botanical family, Poaceae botanical family, Brassicaceae botanical family or combinations thereof.

[0058] The at least one plant protein ingredient may be derived from pea protein, chickpea protein, mung bean protein, faba protein, lentil protein, corn protein (e.g., ground corn or corn gluten), wheat protein (e.g., ground wheat or wheat gluten such as vital wheat gluten), potato protein, legume protein such as soy protein (e.g., soybean meal, soy concentrate, or soy isolate), rice protein (e.g., ground rice or rice gluten), barley protein, algae protein, canola or rapeseed protein, or combinations thereof.

[0059] Preferably, the at least one plant protein ingredient is soy protein concentrate and / or isolate, or wheat gluten, more preferably the at least one plant protein ingredient is a mix from soy protein concentrate and / or isolate and wheat gluten, more preferably the at least one plant protein ingredient is soy protein concentrate and / or isolate.

[0060] The plant-based extrudate may comprise the at least one plant protein ingredient in an amount of 12-30 wt%, or 15-30 wt%, or 17-30 wt%, or 20-30 wt%, or 15-27.5 wt%, or 20-

[0061] 27.5 wt%, or 20-25 wt%.

[0062] The plant-based extrudate may comprise plant protein isolate and / or plant protein concentrate, preferably soy protein isolate and / or soy protein concentrate in an amount of 12-30 wt%, or 15-30 wt%, or 17-30 wt%, or 20-30 wt%, or 15-27.5 wt%, or 20-27.5 wt%, or 20-25 wt%.

[0063] The plant-based extrudate may comprise the at least one plant protein ingredient in an amount of 30-45 wt%, or 30-42.5 wt%, or 30-40 wt%, or 32.5-45 wt%, or 32.5-42.5 wt%, or 32.5-40 wt%, or 35-45 wt%, or 35-42.5 wt%, or 35-40 wt%.

[0064] The plant-based extrudate may comprise the protein isolate and / or protein concentrate, preferably prepared from soy and / or wheat in an amount of 30-45 wt%, or 30-

[0065] 42.5 wt%, or 30-40 wt%, or 32.5-45 wt%, or 32.5-42.5 wt%, or 32.5-40 wt%, or 35-45 wt%, or 35-42.5 wt%, or 35-40 wt%.

[0066] The term "vegetable and / or fruit puree" refers to a paste or liquid suspension made by grinding, pressing, blending and / or sieving a whole vegetable and / or fruit.

[0067] The term "vegetable and / or fruit powder" refers to a powder made by drying or dehydrating a whole vegetable and / or fruit.

[0068] A source of the vegetable and / or fruit puree may differ from a source of the at least one plant protein ingredient. A source of the vegetable and / or fruit powder differs from a source of the at least one plant protein ingredient.

[0069] The plant-based extrudate may comprise the vegetable puree and / or fruit puree in an amount of 15-80 wt%, or 15-70 wt%, or 15-60 wt%, or 20-80 wt%, or 20-70 wt%, or 20-60 wt%. The vegetable and / or fruit puree may be obtained by re-hydrating vegetable / fruit powder with water. In some embodiments, 0 to 15 wt% of vegetable and / or fruit powder may be added to the dry mixture. The vegetable and / or fruit powder may constitute some part or all of 15 to 80 wt% of vegetable puree and / or fruit puree of the final plant-based extrudate. The vegetable powder and / or puree may be obtained from one vegetable, or may be obtained from two or more different vegetables.

[0070] The fruit powder and / or puree may be obtained from one fruit, or may be obtained from two or more different fruits.

[0071] The term "vegetable" refers to any part of an edible herbaceous plant.

[0072] For example, the vegetable powder and / or puree may be obtained from a leaf vegetable, a stem vegetable, an edible tuber, a root vegetable, a flower vegetable, a bulb vegetable or combinations thereof.

[0073] The vegetable powder and / or puree may be obtained from a vegetable of Solanaceae botanical family, Brassicaceae botanical family, Apiaceae botanical family, Amaranthaceae botanical family, Cucurbitaceae botanical family, or combinations thereof.

[0074] The vegetable powder and / or puree may be obtained from spinach, carrot, bell pepper, pumpkin, butternut, broccoli, cauliflower, eggplant, radish, avocado, papaya, onion, leek, beet, green pea, sweet potato, potato, tomato, zucchini, cucumber, cabbage, endive, asparagus, celery, rhubarb, watermelon, melon or combination thereof.

[0075] The term "fruit" refers to any part of a culinary fruit.

[0076] For example, the fruit powder and / or puree may be obtained from a drupe or a stone fruit, a pome, a berry, a citrus fruit, a tropical fruit or combinations thereof.

[0077] The fruit powder and / or puree may be obtained from a fruit of Bromeliaceae botanical family, Rosaceae botanical family, Ericaceae botanical family, Ribes botanical family, Rutaceae botanical family, Anacardiaceae botanical family, Caricaceae botanical family, Musaceae botanical family, Actinidiaceae botanical family, Passifloraceae botanical family, Cucurbitaceae botanical family, or combinations thereof.

[0078] The fruit powder and / or puree may be obtained from lemon, orange, lime, mandarin, grapefruit, pomelo, blueberry, raspberry, strawberry, mango, banana, apple, pear, peach, grape, kiwifruit, pineapple, apricot, plum, passion fruit or combination thereof.

[0079] Alternatively or additionally to the vegetable and / or fruit powder, the dry mixture (4) may further comprise a dietary fiber powder. For example, the dietary fiber powder may be or comprise a citrus fiber powder, a pectin powder, a konjac powder, an agar powder, a seaweed powder, a psyllium powder, a cellulose powder, a resistant starch fiber powder, a wheat bran powder.

[0080] In some embodiments, the dry mixture (4) comprises 0 to 5 wt%, or 0.5 to 4 wt%, or 1 to 3 wt%, or 1.5 to 2.5 wt% of the dietary fiber powder.

[0081] The dietary fiber powder may contain at least 70% of an insoluble fiber and / or a soluble fiber.

[0082] When the dry mixture comprises the vegetable and / or fruit powder, some part or all of the vegetable and / or fruit powder may also serve as a source of dietary fiber powder.

[0083] In some embodiments, the dry mixture (4) may comprise 0 to 5 wt% of a dietary fiber powder, for example a citrus fiber powder, and 0 to 15 wt% of a vegetable and / or fruit powder, for example derived from a vegetable and / or fruit other than a citrus fruit.

[0084] Preferably, a source of the dietary fiber powder differs from a source of the vegetable and / or fruit powder and / or puree.

[0085] The plant-based extrudate may further comprise vegetable pieces and / or grains. For example, the plant-based extrudate may contain cut pieces of spinach, carrot, bell pepper, pumpkin, butternut, broccoli, cauliflower, eggplant, radish, avocado, papaya, onion, leek, beet, green pea, sweet potato, potato, parsnip, tomato, zucchini, cucumber, cabbage, endive, asparagus, celery, rhubarb, watermelon, melon or combination thereof. Examples of the grains are cereal or pseudocereal grains such as millet, barley, wheat, spelt, chia, buckwheat, sesame, oat, rye, sorghum, amaranth and quinoa.

[0086] The term liquid oil, fat or combination thereof may include soybean oil, corn oil, sunflower oil, high oleic sunflower oil, olive oil, canola or rapeseed oil, safflower oil, peanut oil, palm oil, cottonseed oil, coconut oil, almond oil, hazelnut oil, fractionated palm fat, fully or partially hydrogenated or inter-esterified palm oil and combinations thereof. Preferably the liquid oil is sunflower oil.

[0087] In some embodiments, the plant-based extrudate comprises the liquid oil and / or fat in an amount of 0-10 wt%, or 0.5-10 wt%, or 1-10 wt%, or 1.5-10 wt%, or 1-8 wt%, or 1.5-8 wt%, or 1-5 wt%, or 1.5-5 wt%. In some embodiments, the plant-based extrudate comprises sunflower oil in an amount of 0-10 wt%, or 0.5-10 wt%, or 1-10 wt%, or 1.5-10 wt%, or 1-8 wt%, or 1.5-8 wt%, or 1-5 wt%, or 1.5-5 wt%.

[0088] In some embodiments, the plant-based extrudate is made by mixing 12 to 30 wt% of soy plant protein isolate and / or soy plant protein concentrate; 0 to 5 wt% of a citrus fiber powder; 20 to 80 wt% of a vegetable puree made of any one or more of carrot, spinach, bell pepper, broccoli, tomato and pumpkin; 0 to 55 wt% of water; 0 to 3 wt% of vinegar; and 0 to 10 wt%, preferably 1.5 to 5 wt% of liquid oil, fat or a combination thereof.

[0089] In some embodiments, the plant-based extrudate is made by mixing 30 to 45 wt% of a plant protein isolate and / or plant protein concentrate prepared from soy and / or wheat; 0 to 15 wt% of a vegetable powder made of any one or more of carrot, spinach, bell pepper, broccoli, tomato and pumpkin; 15 to 60 wt% of a vegetable puree made of any one or more of carrot, spinach, bell pepper, broccoli, tomato and pumpkin; 0 to 55 wt% of water; 0 to 3 wt% of vinegar; and 0 to 10 wt% of liquid oil, fat or a combination thereof.

[0090] In some embodiments, pH of the vegetable and / or fruit puree is between 4.3 to 7.0. In some embodiments, pH of the vegetable and / or fruit puree is between 4.3 to 4.9. In some embodiments, pH of the vegetable and / or fruit puree is about 4.7. In some embodiments, pH of the vegetable and / or fruit puree is between 5.9 to 7.0. In some embodiments, pH of the vegetable and / orfruit puree is between 6.3 to 6.5. In some embodiments, pH of the vegetable and / or fruit puree is between 4.9 to 5.5. In some embodiments, pH of the vegetable and / or fruit puree is about 7.0.

[0091] Further ingredients selected from flavoring, filler and / or optionally fortification compounds may be added to the dry mixture (4) when feeding the extruder barrel (2) in step a).

[0092] The term "flavouring" in the context of the present application includes salt, flavouring agents, taste enhancing ingredients, herbs, spices or mixtures thereof, which are suitable for being used in a food product. Taste enhancing ingredients may be provided by monosodium glutamate (MSG) and / or yeast extract etc. Salt refers to any suitable alkali metal salt or mixture thereof. The salt used in the composition of this invention is typically, but not limited to, sodium chloride. For example, potassium chloride may be used or any low-sodium product having a taste impression of sodium chloride may be used, as long as the taste in the end formulation is acceptable.

[0093] The plant-based extrudate may comprise flavouring in an amount of 0-5 wt%, or 0.25-

[0094] 5 wt%, or 0.5-4 wt%, or 0.5-3 wt%, or 0.5-2.5 wt%.

[0095] The term "filler" in the content of this invention may include carbohydrates. Carbohydrates may be provided by starches, flours, sugars, maltodextrins, glucose syrups etc., preferably maltodextrin. Starches and / or flours include those from rice, wheat, corn, barley, and sorghum, potato, cassava, sweet potato, arrowroot, yam, pea, chickpea, mung beans or lentil or any combination thereof.

[0096] The plant-based extrudate may comprise fillers in the range of 0.5 to 10 wt%, or 0.5-8 wt%, or 0.5-7 wt%, or 1-10 wt%, or 1-8 wt%, or 1-7 wt%, or 2-7 wt%, or 0.5-6 wt%, or 0.5-5 wt%, or 0.5-4 wt%, or 0.5-3 wt%.

[0097] The plant-based extrudate may comprise starch and / or flour in the range 0-4 wt%, or 0-3 wt%, or 0.5-4 wt%, or 0.5-3 wt%.

[0098] The dry mixture may also comprise one or more fortification compounds as vitamins, minerals and iron salts. The term vitamins include Vitamins A, B-complex (such as B-l, B-2, B-

[0099] 6 and B-12), C, D, E and K, niacin, and acid vitamins such as pantothenic acid, folic acid and biotin, preferably vitamin B-12. The term minerals include calcium, iron, zinc, magnesium, iodine, copper, phosphorus, manganese, potassium, chromium, molybdenum, selenium, nickel, tin, silicon or vanadium. The term iron salts include ferric sodium EDTA, reduced iron, ferrous lactate, ferric citrate, ferric pyrophosphate, ferrous sulphate monohydrate or ferric ammonium citrate brown, preferably ferric pyrophosphate.

[0100] Specific amounts of fortification compounds will depend on a variety of factors such as the identity of the ingredient; the species of animal; the animal's age, body weight, general health, sex, and diet; the animal's consumption rate; the purpose for which the food product is administered to the animal; and the like. Therefore, the components and their amounts may vary widely.

[0101] The dry mixture may also comprise one or more colours. The term colours may include FD&C colors, such as blue no. 1, blue no. 2, green no. 3, red no. 3, red no. 40, yellow no. 5, yellow no. 6, and the like; natural colors, such as caramel coloring, annatto, chlorophyllin, cochineal, betanin, turmeric, saffron, paprika, lycopene, elderberry juice, pandan, butterfly pea and the like; titanium dioxide; and any suitable food colorant known to the skilled artisan.

[0102] The compositions disclosed herein may lack any element that is not specifically disclosed herein. Thus, a disclosure of an embodiment using the term "comprising" includes a disclosure of embodiments "consisting essentially of" and "consisting of" and "containing" the components identified. Similarly, the methods disclosed herein may lack any step that is not specifically disclosed herein. Thus, a disclosure of an embodiment using the term "comprising" includes a disclosure of embodiments "consisting essentially of" and "consisting of" and "containing" the steps identified. Any embodiment disclosed herein can be combined with any other embodiment disclosed herein unless explicitly and directly stated otherwise.

[0103] Unless defined otherwise, all technical and scientific terms and any acronyms used herein have the same meanings as commonly understood by one of ordinary skill in the art in the field of the invention. Although any compositions, methods, articles of manufacture, or other means or materials similar or equivalent to those described herein can be used in the practice of the present invention, the preferred compositions, methods, articles of manufacture, or other means or materials are described herein.

[0104] The term "wt%" used herein refers to weight % of the total plant-based extrudate unless expressed otherwise.

[0105] As used herein, "about," is understood to refer to numbers in a range of numerals, for example the range of -40% to +40% of the referenced number, more preferably the range of -20% to +20% of the referenced number, more preferably the range of -10% to +10% of the referenced number, more preferably -5% to +5% of the referenced number, more preferably -1% to +1% of the referenced number, most preferably -0.1% to +0.1% of the referenced number.

[0106] All numerical ranges herein should be understood to include all integers, whole or fractions, within the range. Moreover, these numerical ranges should be construed as providing support for a claim directed to any number or subset of numbers in that range. For example, a disclosure of from 1 to 10 should be construed as supporting a range of from 1 to

[0107] 8, from 3 to 7, from 1 to 9, from 3.6 to 4.6, from 3.5 to 9.9, and so forth.

[0108] As used herein, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise.

[0109] As used in herein, the term "substantially free" means that no more than about 10 weight percent, preferably no more than about 5 weight percent, and more preferably no more than about 1 weight percent of the excluded material is present. In a preferred embodiment, "substantially free" means that no more than about 0.1 weight percent of the excluded material remains. "Entirely free" typically means that at most only trace amount of the excluded material is present, and preferably, no detectable amount is present. Conversely, "substantially all" typically means that at least about 90 weight percent, preferably at least about 95 weight percent, and more preferably at least about 99 weight percent of the material is present.

[0110] EXAMPLES

[0111] Example 1 - Preparation of plant-based extrudates according to the invention

[0112] Plant-based extrudates according to the invention were prepared as follows, according to recipes in Tables 1 to 5, respectively.

[0113] Firstly, a frozen vegetable puree was defrosted and blended to obtain a homogenous mixture. For each recipe, a dry mixture was fed in an extruder while a wet mixture was injected at a location downstream of the dry mixture feeding. A homogeneous mass was obtained in the first barrels of the extruder and the mixing raised the temperature on the extruder barrels. An extrudate was obtained at the exit of the cooling die.

[0114] Tables 1 to 3 show recipes for vegetable protein gels as the plant-based extrudate according to the invention. For recipes in Tables 1 to 3, soy protein isolate was used as a gelling agent. The vegetable protein gels according to the recipes in Table 2 and 3 were prepared by further adding a citrus fiber in the dry mixture. Table 1 - Carrot gel extrudate

[0115] Table 2 - Carrot gel extrudate with citrus fiber Table 3 - Broccoli gel extrudate with citrus fiber Tables 4 and 5 show recipes for vegetable high moisture extrudate (HME) as the plantbased extrudate according to the invention. For recipes in Tables 4 and 5, a soy protein concentrate and / or wheat gluten were used as a matrix. Table 4 - Carrot high moisture extrudate (carrot HME)

[0116] Table 5 - Broccoli high moisture extrudate (Broccoli HME)

[0117] Example 2 - Preparation of reference extrudates not according to the invention

[0118] As a reference not according to the invention, a protein extrudate without vegetable and a plant-based chicken extrudate were produced by wet extrusion as follows. A dry mixture of soy protein concentrate, wheat gluten and salt was fed in the extruder, and then vinegar and water were injected into the extruder at a location downstream of the dry mixture feeding. A homogeneous mass was obtained in the first barrels of the extruder and the mixing raised the temperature on the extruder barrels. An extrudate with a fibrous structure was obtained at the exit of the cooling die. Tables 6 and 7 show respectively the recipes for the protein extrudate without vegetable and the plant-based chicken extrudate.

[0119] For the plant-based chicken extrudate according to the recipe in Table 7, yeast extract was further added in the dry mixture.

[0120] Table 6 -Protein extrudate without vegetable

[0121] Table 7 - Plant-based chicken extrudate Example 3 - Texture analysis of the plant-based extrudates of the invention and the reference protein extrudates

[0122] The texture analysis was performed on the plant-based extrudates according to the invention (recipes in Table 1 to Table 5 in Example 1), the protein extrudate without vegetable (recipe in Table 6 in Example 2) and the plant-based chicken extrudate (recipe in Table 7 in Example 2) obtained as above.

[0123] The compression tests were performed at the room temperature with a TA-HDplus (Stable Micro Systems, UK) using as probe a compression plate P / 75. A 50 kg daily calibrated load cell was used. The samples were cut with a cookie cutter of a diameter of 25mm. The resulting pieces were place successively on the equipment platform to perform the test. The compression test was performed consisting of a double compression at a constant speed of 1 mm / s, while the force was recorded to a strain of 60% with a trigger force set at 0.020 N and a holding time of 5 seconds between the two compressions. Each variant was analyzed 10 times and the maximum force recorded during the first compression was considered as the hardness.

[0124] As seen in Figure 2A, the hardness of the plant-based extrudates according to the invention was between Ilk and 21k grams, that was significantly lower than the protein extrudate without vegetable and the plant-based chicken extrudate (around 30-40k grams). The chewiness as seen in Figure 2B was also significantly lower with values around 4.3k to 10k grams for the plant-based extrudates according to the invention than 19k to 25k grams for the both reference extrudates without vegetables.

[0125] This example shows that the plant-based extrudates according to the invention provide a new texture which is remarkably different from the existing protein extrudate by wet extrusion. As seen in Figures 2A and 2B, such unique texture was maintained in the carrot gel extrudate with citrus fiber and the broccoli gel extrudate with citrus fiber. Fiber addition can add further nutritional benefits while keeping the characteristic texture which is still remarkably different from the existing protein extrudate. Example 4 - Microstructure of the plant-based extrudates of the invention and the reference protein extrudates

[0126] The difference between the structure of the plant-based extrudate according to the invention (recipes in Tables 1 to 5 in Example 1) and the protein extrudate without vegetable (recipe in Table 6 in Example 2) and the plant-based chicken extrudate (recipe in Table? in Example 2) obtained as above was observed by confocal microscopy. Specimens of 5x5x5 mm were cut from the samples. Specimens were embedded in a sample holder with a cold curing glue (TissueTek) and rapidly frozen by plunging into liquid nitrogen. Specimens were moved into the cryomicrotome chamber (Leica 3050S), warmed up to -25°C and thin sections (12 micron thickness) cut and placed on microscopy slides. Slides were then stained with Toluidine Blue (1% in water) to stain proteins (in dark blue), gluten (light blue) and carbohydrates (magenta). Color staining cannot be appreciated in the B&W images but arrows were provided to identify each phase in the images. Imaging of the slides was performed in an inverted optical microscope (Zeiss Axio Observer Zl) in bright field mode with a magnification of 200x.

[0127] Figures 3A to 3E show microscopy images of the structure of the plant-based extrudates according to the invention, respectively 3A showing the carrot gel extrudate (recipe in Table 1), 3B showing the carrot gel extrudate with citrus fiber (recipe in Table 2), 3C showing the broccoli gel extrudate with citrus fiber (recipe in Table 3), 3D showing the carrot HME (recipe in Table 4) and 3E showing the broccoli HME (recipe in Table 5).

[0128] Figures 3A to 3C show a continuous microstructure of protein rich network aligned preferentially. However, the network aligned composition is homogenous, the protein zones are much thicker (20-100 microns) and continuous along the sample. Some carbohydrate rich elongated areas with approximate dimensions of 10-20 microns thickness and 100-200 microns length are located in between the protein rich fibers. The microstructure is also less dense than the microstructure of the reference protein extrudates, appreciable by the spaces in between the protein rich fibers, which are not observed at all in Figures 3F and 3G. FIG. 3A, 3B and 3C show water trapped in large spaces between continuous protein phases. Oil droplets are also observed in FIG. 3A, FIG. 3B and FIG. 3C. As seen in Figures 3B and 3C, such unique microstructure was maintained in the carrot gel extrudate with citrus fiber and the broccoli gel extrudate with citrus fiber. Fiber addition can add further nutritional benefits while keeping the characteristic microstructure which is still remarkably different from the existing protein extrudate.

[0129] Figures 3D and 3E show a fibrous structure with some regions aligned and other regions not aligned. These latter regions which are impacted by the presence of the vegetable parts creating space between the protein rich fibers. The microstructure is also less dense than the microstructure of the protein extrudate without vegetable and the plant-based chicken extrudate, appreciable by the spaces in between the protein rich fibers, which are not observed at all in Figures 3F and 3G.

[0130] Figures 3F and 3G show microscopy images of the fibrous structure of the reference protein extrudates not according to the invention, respectively 3F showing the protein extrudate without vegetable (recipe in Table 6) and 3G showing the plant-based chicken extrudate (recipe in Table 7). Microstructure shows a combination of gluten and soy protein rich fibers aligned preferentially. The fibers present a thickness of 10-30 microns. Some carbohydrate rich ellipsoidal areas with dimensions in the 10-30 microns are located in between the protein rich fibers.

[0131] This example and Figures 3A to 3G also show the significant difference in the structure and texture between the plant-based extrudates according to the invention and the reference protein extrudates not according to the invention.

[0132] Example 5 - Impact of the vegetable composition on the sensory attributes

[0133] A descriptive sensory test of carrot HME (recipe in Table 4 in Example 1) , pumpkin HME (recipe in Table 8), broccoli HME (recipe in Table 5 in Example 1), spinach HME (recipe in Table 9) and tomato HME (recipe in Table 10) as the plant-based extrudate according to the invention was conducted with 9 panelists by comparing it to the protein extrudate without vegetable (recipe in Table 6 in Example 2) and the plant-based chicken extrudate (recipe in Table 7 in Example 2). The texture attributes firm, moist, compact, chewy, rubbery and fibrous were evaluated on a scale from 0 to 5. Table 8 - Pumpkin high moisture extrudate (pumpkin HME)

[0134] Table 9 - Spinach high moisture extrudate (spinach HME) Table 10 - Tomato High moisture extrudate (tomato HME) The sensory analysis (Fig. 4) revealed that the plant-based extrudates with vegetable according to the invention (e.g. carrot HME, pumpkin HME) were less firm, rubbery and chewy while keeping the fibrous and increased moist attributes. Moreover, the impact on the sensory attributes varies with the vegetable source. This example shows that the plant-based extrudates rich in vegetables according to the invention provide new sensory attributes.

[0135] Although the invention has been described by way of example, it should be appreciated that variations and modifications may be made without departing from the scope of the invention as defined in the claims.

Claims

Claims1. A method for preparing a plant-based extrudate, the method comprising steps of: a) feeding an extruder barrel with a dry mixture comprising: i) 12 to 45 wt% of at least one plant protein ingredient selected from the group consisting of plant protein flour, plant protein powder, plant protein isolate, plant protein concentrate and a mixture thereof; and ii) 0 to 15 wt% of a vegetable and / or fruit powder which is different from the at least one plant protein ingredient, b) injecting the following components into the extruder barrel at a location down-stream of the feeding location of step a): iii) 15 to 80 wt% of vegetable and / or fruit puree; iv) O to 55 wt% of water; v) 0 to 3 wt% of vinegar; vi) 0 to 10 wt%, preferably 1.5 to 5 wt% of liquid oil, fat or a combination thereof, and c) extruding the mixture after steps a) and b) through a cooling die, wherein the moisture content of the vegetable and / or fruit puree is 80 to 95 wt% of the total content of the vegetable and / or fruit puree, and the total moisture content of the extruded plant-based extrudate is 50 to 80 wt%.

2. The method according to claim 1, wherein the content of the at least one plant protein ingredient is between 12 and 30 wt%, preferably between 15 and 27.5 wt%, more preferably between 20 and 25 wt%.

3. The method according to claim 1, wherein the content of the at least one plant protein ingredient is between 30 and 45 wt%, preferably 32.5 and 45 wt%, more preferably 32.5 and42.5 wt%.

4. The method according to any one of claims 1 to 3, wherein the dry mixture further comprises 0 to 5 wt% of a dietary fiber powder, the dietary fiber powder containing at least 70% of an insoluble fiber and / or a soluble fiber.

5. The method according to claim 4, wherein the dietary fiber powder is from a source different from a source of the vegetable and / or fruit powder.

6. The method according to any one of claims 1 to 5, wherein the at least one plant protein ingredient is derived from Fabaceae botanical family such as soy, pea, mung bean, faba, chickpea and lentil; from Poaceae botanical family such as wheat gluten, rice, barley and corn; from Brassicaceae botanical family such as canola and rapeseed; or combinations thereof.

7. The method according to any one of claims 1 to 6, wherein the vegetable powder and / or vegetable puree is made from Solanaceae botanical family such as eggplant, tomato, pepper, paprika, bell pepper and potato; from Brassicaceae botanical family such as broccoli, cauliflower, cabbage and radish; from Apiaceae botanical family such as carrot, celery and parsnip; from Amaranthaceae botanical family such as beet and spinach; from Cucurbitaceae botanical family such as zucchini, cucumber and pumpkin; or combinations thereof.

8. The method according to any one of claims 1 to 7, wherein the fruit powder and / or fruit puree is made from Bromeliaceae botanical family such as pineapple; from Rosaceae botanical family such as cherry, raspberry, blackberry, plum, apricot, peach, strawberry, pear, apple and almond; from Ericaceae botanical family such as blueberry and cranberry; from Ribes botanical family such as currant and gooseberry; from Rutaceae botanical family such as orange, lemon, lime, mandarin and grapefruit; from Anacardiaceae botanical family such as mango, pistachio and cashew; from Caricaceae botanical family such as papaya; from Musaceae botanical family such as banana; from Actinidiaceae botanical family such as kiwifruit; from Passifloraceae botanical family such as passionfruit; from Cucurbitaceae botanical family such as watermelon and melon; or combinations thereof.

9. The method according to any one of claims 1 to 8, wherein the dry mixture further comprises 0 to 5 wt% of one or more flavouring.

10. The method according to any one of claims 1 to 9, wherein the liquid oil and / or fat of the component vi) is rapeseed oil, sunflower oil or a blend thereof.

11. The method according to any one of claims 1 to 10, wherein the vegetable puree of the component iii) is prepared from one or more of spinach, carrot, broccoli, bell pepper, tomato and pumpkin, and the at least one plant protein ingredient is prepared from soy and / or wheat.

12. The method according to any one of claims 1 to 11, wherein the temperature in step a) is maintained at 80°C or lower.

13. The method according to any one of claims 1 to 12, wherein the extruder barrel is heated to a temperature between 80 and 180°C, preferably between 80 and 160°C.

14. The method according to any one of claims 1 to 13, wherein the extruded plant-based extrudate has an exit temperature at the end of the cooling die between 40 and 100°C, preferably between 50 and 100°C, preferably between 50 and 95°C, preferably between 50 and 90°C.

15. The method according to any one of claims 1 to 14, wherein the liquid oil, fat or a combination thereof of the component vi) is injected at a location downstream of the injecting location of at least one of the components iii) to v).

16. A plant-based extrudate obtained by the method according to any one of claims 1 to 15.

17. A method for making a food product comprising the plant-based extrudate according to claim 16, the method comprising one or more of steps of: grinding the plant-based extrudate; cutting the plant-based extrudate; marinating the plant-based extrudate; frying the plant-based extrudate; grilling the plant-based extrudate; boiling the plant-based extrudate; steaming the plant-based extrudate; and breading the plant-based extrudate.

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