Process for producing more succulent plant-based meat substitutes

Abstract

The present disclosure describes process for producing plant-based meat products using two emulsions. This process can reduce oil and moisture losses associated with cooking of the plant-based meat substitute. Furthermore, use of such emulsions in meat substitutes results in desirable textures and juiciness when they are cooked, resulting in a more meat-like organoleptic experience.

Description

PT-1895-WO-PCTPROCESS FOR PRODUCING MORE SUCCULENT PLANT-BASED MEAT SUBSTITUTESCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 699,886, filed September 27, 2025, which is incorporated by reference herein in its entirety.FIELD OF THE INVENTION

[0002] The present invention relates to meat substitutes, e.g., plant-based burgers patties, and their method of manufacture.BACKGROUND OF THE INVENTION

[0003] Consumers increasingly desire protein choices that are alternatives to animal meat protein for a variety of reasons. At the same time, many consumers enjoy the flavors and textures that are uniquely provided by meats obtained from animals. For this reason, a number of companies have striven to provide plant-based meat substitutes that replicate the experience of cooking and eating meat.

[0004] Examples of plant-based meat substitute products include the Impossible Burger from Impossible Foods, The Beyond Burger from Beyond Meat, and Ultimate Beefless Burger from Gardein. These and other products are discussed, for example, on the World Wide Web at the address healthline. com / nutrition / vegan-meat-substitutes#section4, which states that the Beyond Burger is made from pea protein, canola oil, coconut oil, potato starch and other ingredients.

[0005] Plant based meat substitutes have not been widely adopted by consumers. In order to produce an ideal meat substitute, it is important that the final product has an attractive taste, texture, and mouthfeel. Meat substitute burgers, meatloaf, and other meat substitutes based on ground meat tend to dry out when they are cooked.

[0006] Consumers want meat substitutes to be succulent like their animal-derived counterparts, but they fail to deliver juiciness. “Succulent,” “succulence,” or “juiciness,” as used herein, reflects both the presence of “juice,” i.e., water and fat, and a sustained release of the juice over time. Both meats and meat substitutes lose some of their moisture and fat when they are cooked, but many meat substitutes lose an inordinate amount of moisture and fat. As a result, meat substitutes often have less juice when one initially takes a bite than do their meat counterparts and can feel drier in the mouth from the outset.PT-1895-WO-PCT

[0007] Even if a meat substitute retains sufficient amounts of both moisture and fat during cooking, sustaining release of the moisture and fat over time has proven a challenge. As one chews the meat substitute, it becomes too dry before it is fully chewed and swallowed. That can lead to a broader perception that it is not very succulent.

[0008] A ground meat patty tends to lose some of its moisture and some of its fat when cooked by baking, grilling or pan frying, leading to substantial weight loss and obvious shrinkage of the cooked patty. The total moisture loss in any meat due to the cooking out of the natural juices is an inevitable consequence of the cooking process and largely depends upon the degree of cooking.

[0009] Such loss of fat and moisture upon cooking meat substitutes can be more pronounced. As a consequence, many commercially available meat substitute burger patties are drier and less succulent than burger patties made with meat.

[0010] Thus, current meat substitute products often fall short of the desired, meat-like organoleptic experience because they lack one or more of the visual and textural characteristics of the animal meat it is intended to mimic. Moreover, it is particularly challenging to achieve the desired consistency, juiciness and texture of the meat substitute while using only non-animal- sourced components.SUMMARY OF THE INVENTION

[0011] It has now been found that using two emulsions to make a meat substitute reduces the oil and moisture losses associated with cooking of the meat substitute. Furthermore, it has surprisingly been found that the presence of such emulsions in meat substitute results in desirable textures and juiciness when they are cooked.

[0012] The present disclosure provides improved methods and compositions that more accurately replicate the characteristics that consumers value in the preparation and consumption of meat. The methods and compositions also overcome some of the shortcomings and drawbacks of current meat substitutes.

[0013] One aspect of this disclosure sets forth a method for making a meat substitute in which water, a first fat, and a first emulsifier are mixed to form a first emulsion that will form a thermally reversible gel when heated to a temperature of at least 90° F, at least 100° F, at least 110° F, or at least 120° F. Water, a second fat, and a second emulsifier are mixed to form an oil-in-water second emulsion. The second emulsion is contacted with a textured plant protein to hydrate the textured plant protein, thereby forming a hydrated protein composition. The first emulsion and the hydrated protein composition are mixed. In some implementations of the method, the first emulsifier comprises methylcellulose.PT-1895-WO-PCT

[0014] Another aspect of this disclosure sets forth a method for making a meat substitute that includes mixing a first fat with a first emulsifier comprising methylcellulose to form a first mixture. The water and the first mixture are mixed under shear to form a first emulsion. An oil-in-water brine emulsion is formed. The oil-in-water brine emulsion includes a second emulsifier, a second fat, water, and an edible salt (preferably one or both of sodium chloride and potassium chloride), and optionally includes one or more of a coloring agent, a flavor, an antioxidant, and an antimicrobial. A hydrated protein composition is formed by combining textured plant protein and the brine emulsion. The hydrated protein composition, the first emulsion, and a non-textured protein ingredient (and, optionally, a third fat) are mixed to form a meat substitute composition. The meat substitute composition may be shaped to form the meat substitute.DETAILED DESCRIPTION

[0015] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one skilled in the art to which this invention belongs. As used herein, each of the following terms has the meaning associated with it as defined below.

[0016] As used herein, the terms “meat substitute” and “meat substitute product” are used interchangeably and refer to compositions that mimic the general appearance, flavor, texture, mouthfeel, and / or nutritional content of natural animal meat or natural animal meat compositions but containing less than 50 percent by weight (wt%) of tissues or cells from a whole vertebrate animal. Such tissues or cells may be naturally occurring animal muscle, adipose, or satellite cells from muscle tissues harvested from a vertebrate animal, e.g., a cow, a sheep, a pig, a chicken, or a turkey, or from an in vitro culture. Meat substitutes that include such animal tissues or cells are referred to herein as “hybrid meat substitutes.” A “meat substitute composition” refers to a composition that is suitable for forming into a meat substitute, e.g., by mechanically shaping it into a shape or form that better mimics the appearance of the intended natural animal meat or natural animal meat composition. Such shaping may, for example, comprise extruding the meat substitute composition into strands that mimic the appearance of ground beef.

[0017] The meat substitutes and meat substitute compositions described herein include nonmeat proteins such as plant-based proteins (e.g., pea protein, soy protein) and fungal-based proteins (e.g., mycoproteins); in vitro cultured animal cells, insect proteins, or combinations thereof. The meat substitute can comprise plant-based proteins including, but not limited to, pea protein, soy protein, wheat protein, chickpea protein, and corn protein. The meat substitute canPT-1895-WO-PCT comprise fungal based proteins including, but not limited to, mycoproteins from Fusarium venenatum.

[0018] The meat substitute can comprise in vitro cultured animal cells including, but not limited to, muscle cells, satellite cells, and adipose cells grown, differentiated, and propagated using, for example, fermentation, a bioreactor, scaffold-seeded cell culture, or other artificial methods.

[0019] The meat substitute can comprise a combination of two or more of plant-based protein, fungal-based proteins, insect proteins and in vitro cultured animal cells. For example, a meat substitute may include a pea protein and a fungal my coprotein, a soy protein and a cultured bovine muscle cell, a cultured avian adipocyte and a fungal mycoprotein, or any other combination of plant-based protein, fungal-based protein, insect proteins, and in vitro cultured animal cells.

[0020] For purposes of this disclosure, “animal-free meat substitute” and “animal-free meat substitute product” are interchangeable and refer to meat substitutes or meat substitute products that are free of animal cells or fats, i.e., animal-derived cells or fats or in vitro cultured animal cells. Animal-free meat substitutes may include ingredients derived from one or more of plants, fungi, and algae. “Plant-based meat substitute” and “plant-based meat substitute product” are interchangeable and refer to an animal-free meat substitute that is also free of fungus- or algae- derived ingredients.

[0021] As used herein, "fat" is an edible triglyceride composition that may also include diglycerides, monoglycerides, and free fatty acids. This includes solid or “hard” fats, which have a Mettler drop point above 25° C and are generally solid at room temperature, and oils, which have a Mettler drop point of 25° C or less and are generally liquid or semi-solid at room temperature. “Animal-free fat” refers to a fat that is free of animal-derived fats such as tallow or lard. Animal-free fats may be derived from plants, algae, or microbial fermentation, or any other non-animal source. A plant-derived fat is a plant derived only from plants, such as conventional seed oils.

[0022] The term “protein ingredient,” as used herein, refers to a food ingredient that contains at least 40%, desirably at least 50% by weight (wt%) protein on a dry-weight basis (dwb). “Plant protein ingredient,” for purposes of this disclosure, is a protein ingredient derived from plants and is free of animal-derived cells. Plant protein ingredients include plant protein concentrates, which contain at least 55 wt% (dwb) protein, and plant protein isolates, which contain at least 85 wt% (dwb) protein. Plant protein ingredients often include other non-protein components, which may include starch and / or other carbohydrates, fat, and fiber. “Animal-free protein ingredient,” as usedPT-1895-WO-PCT herein, refers to a protein ingredient that is free of animal-derived cells, including plant protein ingredients and other proteins that come from a source other than plants or animals, such as fungus (e.g., Fusarium venenatum) or non-plant algae (e.g., Euglena gracilis).

[0023] “TPP,” “texturized plant protein,” or “texturized plant protein ingredient” (TPP), as used herein, refer to edible food ingredients that have a protein content of at least 40 wt% (dwb), preferably at least 50 wt% (dwb), are made from one or more plant protein ingredients, and are processed to provide an structural integrity and identifiable structure such that individual units (which may appear as fibers, shreds, chunks, bits, granules, slices, and the like) will withstand hydration and cooking or other procedures used in the production of meat substitutes. In general, textured plant-based proteins are used to mimic the texture of meat and bind water in the meat substitute compositions. Edible protein sources from which textured proteins are produced may include, but are not limited to, legumes (e.g., pulse protein), pea, soy, corn, wheat, chickpea, potato, and the like. Textured proteins may include, but are not limited to, textured pulse protein, textured pea protein, textured soy flour, textured soy protein concentrate, textured wheat protein, textured potato protein, or combinations thereof. Methods for protein texturization are known and described in the art, and may include, for example, high temperature and pressure extrusion, spinning, freeze texturization, chemical or enzymatic texturization, and the like.

[0024] An “emulsion” is a colloidal dispersion of one immiscible liquid phase in another. If the two liquids are water and oil (liquid fat), such emulsions are typically either an oil-in-water emulsion or a water-in-oil emulsion. In an oil-in-water (or “O / W”) emulsion, water is the continuous or “external” phase and oil is the dispersed or “internal” phase. In a water-in-oil (“W / O”) emulsion, oil is the continuous or “external” phase and water is the dispersed or “internal” phase.

[0025] As used herein, an “emulsifier” is an edible amphiphilic substance that is safe for human consumption, can form a colloid with water, and stabilizes an emulsion. A “hydrocolloid emulsifier” is, for purposes of this disclosure, an emulsifier that includes a carbohydrate and may have one or more functional groups, e.g., in certain modified starches. These hydrocolloid emulsifiers may be polysaccharides extracted from plants (including marine plants such as seaweeds) or algae, or can be produced by microbial synthesis.

[0026] For purposes of this disclosure, a “gel” is a colloidal system in which a liquid is dispersed in a solid. The solid is the continuous or external phase and the liquid is the dispersed or internal phase.PT-1895-WO-PCT

[0027] A “thermally reversing hydrocolloid emulsifier” is a hydrocolloid emulsifier that forms a gel if heated above a given gelation temperature. That gel may or may not remain a gel when cooled below that gelation temperature. As used herein, a “thermally reversible gel” is a colloidal system that will change from an emulsion to a gel in response to a change in temperature but revert to an emulsion when the temperature change is reversed. Many thermally reversible gels, such as those formed by carrageenan or gelatin, convert from emulsions to gels in response to lowering their temperature, i.e., they are gels below the gelation temperature but the solid phase melts, forming an emulsion, above that temperature. Such gels may be referred to herein as “low- temperature-stable thermally reversible gels.” A “high-temperature-stable thermally reversible gel” is, for purposes of this disclosure, a colloidal system that is an emulsion below its gelation temperature but forms a gel when heated above that temperature. Note that the “low temperature” referred to in “low-temperature-stable” and the “high temperature” referred to in “high- temperature-stable” is the gelation temperature of the system, not an externally objective scale of hot or cold.

[0028] All percentages used herein, unless stated otherwise, are percentages by weight.Protein Ingredients

[0029] The present meat substitutes include textured plant protein and, optionally, non-textured plant protein. The texturized plant protein can be formed from a variety of plant-derived proteins, including pea protein, chickpea protein, soy protein, cotton seed protein, sunflower seed protein, lupin protein, oat protein, lentil protein, sesame seed protein, canola protein, broad been protein, horse bean protein, alfalfa protein, clover protein, rice protein, tapioca protein, potato protein, carob protein, wheat protein, com protein and a combination of two or more thereof. The protein in the TPP is selected from the group consisting of soy protein, pea protein, corn protein, cottonseed protein, wheat protein, sunflower seed protein, oat protein, or combinations of two or more thereof. More preferably, the protein in the TPP is soy protein, pea protein, wheat protein, sunflower protein, or mixtures of two or more thereof. More preferably, the TPP is texturized soy protein and / or texturized pea protein.

[0030] In one aspect of the invention, the texturized plant protein is present in the meat substitute in an amount of from 7 to 25%, from 12 to 22%, or from 15 to 20%, of the total weight of the meat substitute on a dry weight basis (dwb).

[0031] In another aspect of the invention, the meat substitute product also includes a protein ingredient that is not texturized. This protein ingredient may be present in the meat substitutePT-1895-WO-PCT product for a variety of reasons, such as to enrich the protein content, or improve emulsification, elasticity, gelation and / or water binding effect. This protein ingredient may be from plants, fungi, algae, insects, animals, or a mixture of two or more thereof. Examples of animal protein ingredients are egg protein, dairy products such as whey or casein, or combinations of two or more thereof. Desirably, however, the protein ingredient is a plant protein ingredient. Examples of plant proteins include, amongst others, proteins selected from the group consisting of soy protein, pea protein, com protein, cottonseed protein, wheat protein, sunflower seed protein, oat protein, or combinations of two or more thereof. More preferably, the protein in the TPP is soy protein, pea protein, wheat protein, sunflower protein, or mixtures of two or more thereof. More preferably, the TPP is texturized soy protein and / or texturized pea protein. Preferably, the nontexturized plant protein ingredient comprises at least one of pea protein and soy protein.

[0032] In one more aspect of the invention, the protein ingredient that is not texturized is present in an amount of from 1.0 to 10.0 wt%, from 2.0 to 8.0 wt%, or from 3.0 to 5.0 wt% on the total weight of meat substitute product.Fats

[0033] A variety of fats can be used in the present meat substitutes. Some useful meat substitutes will contain only fats that are oils, i.e., fats that are liquid at room temperature (70° F or 21.1° C). Other desirable meat substitutes may contain a fat or fats that is (or are) a solid fat, i.e., a fat that is not an oil. Solid fats desirably have a plastic consistency at room temperature but become soft or liquid at a temperature of 100° F (34.8° C) for an improved mouthfeel when eating the cooked meat substitute. The fat might also be a combination or interesterification of a solid fat and an oil, which can better mimic the mouthfeel of animal fats. The solid fat is desirably an animal-free fat, preferably a plant-derived fat selected from the group consisting of coconut oil, palm oil, palm kernel oil, cacao butter, shea butter, and combinations or interesterifications of two or more thereof. (Note: coconut oil, palm oil, and palm kernel oil are the common names of these fats even though they might be solid fats, not oils, as those terms are used herein.)

[0034] In either type of fat composition, the oil is desirably a plant-derived oil selected from the group consisting of cottonseed oil, com oil, olive oil, peanut oil, canola oil, rice bran oil, sesame oil, safflower oil, soybean oil, sunflower oil, grapeseed oil, flaxseed oil, linseed oil, and combinations or interesterifications of two or more thereof. Oils well-suited for meat substitute burger and sausage patties, for example, may be selected from the group consisting of corn oil, canola oil, cottonseed oil, soybean oil, sunflower oil (including their corresponding high-oleicPT-1895-WO-PCT varieties), and combinations or interesterifications of two or more thereof. Some commercially useful meat substitutes include corn oil, canola oil, sunflower oil (including their corresponding high-oleic varieties), and combinations thereof.

[0035] In a more specific aspect of the invention, the fat is an animal-free fat and comprises coconut oil and an oil selected from the group consisting of canola oil, soybean oil, cottonseed oil and combinations or interesterifications of two or more thereof.Emulsifiers

[0036] Meat substitute products in accordance with this disclosure include a first emulsifier to form a first emulsion and a second emulsifier to form a second emulsion, as discussed in more detail below.

[0037] The amount of emulsifier in the meat substitute composition is preferably in an amount of from 0.1 to 10.0 wt%, from 0.2 to 5 wt%, from 0.3 to 3.0 wt%, from 0.5 to 2.0 wt%, or from 1.0 to 2.0 wt% on the total weight of the meat substitute product. The relative amounts of the first emulsifier and the second emulsifier can be varied to optimize the desired texture and succulence of the meat substitute composition. In one aspect, though, the meat substitute composition includes more first emulsifier than second emulsifier by weight. This can help promote a more stable emulsion in the first emulsion; such stability is generally not required in the second emulsion after the TPP is hydrated. The weight ratio of the first emulsifier to the second emulsifier may be between 1 and 6, between 2 and 4, or between 2.5 and 3.5.

[0038] In one further aspect of the invention, at least one of the first and second emulsifiers is a hydrocolloid emulsifier. Both the first and second emulsifiers desirably are hydrocolloid emulsifiers. Examples of hydrocolloid emulsifiers are methylcellulose, xanthan gum, guar gum, locust bean gum, konjac gum, cellulose derivatives, alginate, pectin, carrageenan, gellan gum, agar, or combinations of two or more thereof. If one is making an animal-free meat substitute, both hydrocolloid emulsifiers may also be free of animal cells or fats, i.e., animal-derived cells or fats or in vitro cultured animal cells.

[0039] The first and second emulsifiers can be the same. Preferably, though, they’re different given the different functional roles the two emulsions fulfill.

[0040] The first emulsifier should be capable of forming a thermally reversible gel with the first fat and water. Desirably, the first emulsifier is a thermally reversing hydrocolloid emulsifier that forms a first emulsion that can create a high-temperature-stable thermally reversible gel when heated. This gelation helps promote structural integrity of the meat substitute as it is cooked. SuchPT-1895-WO-PCT hydrocolloid emulsifiers have superior performance to other emulsifiers, such as proteins, which do not ordinarily form high-temperature-stable thermally reversible gels.

[0041] The first emulsifier may comprise methylcellulose as the sole emulsifier or blends of methylcellulose and another emulsifier. Methylcellulose is a thermally reversing hydrocolloid emulsifier that can form high-temperature-stable thermally reversible gels. The methylcellulose may have a degree of substitution of about 1.7-2.5, e.g., 1.75-2.2 or about 1.75-2.1.

[0042] The second emulsifier should form an emulsion that can maintain the second emulsion until it is combined with TPP. As explained below, most or all of the water in the second emulsion may be absorbed by the TPP. The second emulsifier and its usage levels should be selected to form a low-viscosity emulsion, as noted below. The second emulsifier is desirably a hydrocolloid emulsifier. The second emulsifier desirably does not promote gel formation on heating or cooling. Suitable second emulsifiers include gum Arabic, lecithin, and xanthan gum. Gum Arabic has been found to work quite well as the second emulsifier. Hence, the second emulsifier preferably comprises gum Arabic as the sole emulsifier or blends of gum Arabic and another emulsifier. Such other emulsifier, however, should be selected to help form a low-viscosity second emulsion and avoid forming a gel under the usage conditions of the second emulsion, described below.

[0043] In another aspect of the invention, the meat substitute product comprises salt. The amount of an edible salt is present in a range of from 0.1 to 3.0 wt%, from 0.2 to 2.5 wt%, from 0.5 to 2.0 wt%, or from 0.8 to 1.5 wt% based on the total weight of meat substitute product. The salt can be sodium chloride, potassium chloride, or a combination thereof.

[0044] In yet one more aspect of the invention, the meat substitute product comprises one or more ingredients selected from sodium ascorbates, citrates, sodium carbonates, sweeteners, flavors, flavor enhancers, spices / seasonings, and preservatives. The amount of each of these ingredients, if present, is preferably in a range of from 0.01 to 10.0 wt%, from 0.02 to 5.0 wt%, or from 0.05 to 3% on the total weight of the meat substitute product.

[0045] The present meat substitute products further comprise water. The total amount of water is in an amount of from 30 to 80 wt%, from 35 to 75 wt%, or from 40 to 70 wt% on the total weight of meat substitute product. The total amount of water refers to the added amount of water that is used to disperse ingredients of the meat substitute composition (additional water), as well as the amount of water that is used to hydrate the texturized protein ingredient and disperse flavors and coloring agents (hydration water).PT-1895-WO-PCTMethod of manufacture

[0046] This disclosure includes methods to manufacture meat substitutes and meat substitute compositions. In one such method, water, a first fat, and a first emulsifier are mixed to form a first emulsion that is an oil-in-water emulsion. Water, a second fat, and a second emulsifier are mixed to form an oil-in-water second emulsion. The second emulsion and a texturized plant protein are combined to form a hydrated protein composition. The first emulsion and the hydrated protein are mixed to form a meat substitute.

[0047] The first emulsion may be an emulsion instead of a gel when formed and when it is mixed with the hydrated protein composition, as outlined below, but form a gel when heated above its gelation temperature. Preferably, the first emulsion forms a gel while the meat substitute is cooked but tends to revert back to an emulsion as it cools and when a consumer eats it. If so desired, the gel formed by the first emulsion may be an “emulsion gel,” i.e., a gel in which some or all of the liquid phase is an emulsion. Forming a gel at cooking temperatures allows the first emulsion to improve structural integrity of the meat substitute as it is cooked, avoiding a tendency for meat substitutes such as plant-based burgers to break apart or crumble when they’re cooked. The gel also tends to hold water and oil more tightly, reducing water and oil loss, and thus loss of succulence or “juiciness,” when the meat substitute is cooked.

[0048] The first emulsion may form a thermally reversible gel when heated to a temperature that is at least 110° F, or at least 120° F, but is less than 190° F, less than 180°F, or less than 170° F. Thus, the gelation temperature may be 110-190° F, 120-180° F, or 120-170° F.

[0049] The first emulsifier may comprise methylcellulose and a supplemental emulsifier that may complement the functionality of the methylcellulose. The supplemental emulsifier may be selected from the group consisting of native starches such as tapioca starch and waxy com starch; modified food starches such as com, wheat, tapioca, potato, or sago starches that have been chemically treated, e.g., monostarch phosphate (E1410), distarch phosphate (E1412), phosphated distarch phosphate (E1413), acetylated distarch phosphate (E1414), acetylated starch (E1420), acetylated distarch adipate (E1422), hydroxypropyl starch (E1440), hydroxy propyl distarch phosphate (E1442), and n-octenyl succinic anhydride-treated (nOSA) starches (E1450); or hydrocolloids or emulsifiers derived from sources other than grains or cereals, e.g., pectin, carrageenan, seaweed powder, xanthan gum, alginates such as sodium alginate, or lecithin.

[0050] Some consumers do not have a positive impression of methylcellulose as an ingredient and food manufacturers are replacing methylcellulose with other hydrocolloids or emulsification systems. Such alternative emulsifiers can be employed as the first emulsifier so long as they canPT-1895-WO-PCT form a first emulsion that can be heated to produce a high-temperature-stable thermally reversible gel. Desirably, such an alternative emulsifier forms an emulsion that effectively binds the other ingredients in the meat substitute during cooking.

[0051] The amount of the first emulsifier in the first emulsion will depend in part on the emulsifier chosen. In one aspect that will work when the first emulsifier is methylcellulose, the first emulsion includes 0.1-7 wt% or 0.15-5 wt%, desirably 0.15-2 wt% or 0.15-0.5 wt%, preferably 0.15-0.4 wt% or 0.2-0.25 wt% of the first emulsifier, all based on total weight of the first emulsion.

[0052] The first fat used in the first emulsion comprises a fat that is liquid at room temperature. The first fat is desirably a plant-derived oil selected from the group consisting of cottonseed oil, corn oil, olive oil, peanut oil, canola oil, rice bran oil, sesame oil, safflower oil, soybean oil, sunflower oil, grapeseed oil, flaxseed oil, linseed oil, and combinations or interesterifications of two or more thereof. Oils well-suited for meat substitute burger and sausage patties, for example, may be selected from the group consisting of com oil, canola oil, cottonseed oil, soybean oil, sunflower oil (including their corresponding high-oleic varieties), and combinations or interesterifications of two or more thereof. Some commercially useful meat substitutes include corn oil, canola oil, sunflower oil (including their corresponding high-oleic varieties), and combinations thereof.

[0053] The first emulsion is an oil-in-water (o / w) emulsion, so there should be sufficient water to allow it to form the continuous phase with a lower amount of oil. The first emulsion desirably includes about 70-95 wt% water and 5-30 wt% oil, all based on total weight of the first emulsion.

[0054] The first emulsion may also include a range of optional ingredients such as functionalized starches, flavors, flavor enhancers, spices / seasonings, colors, and preservatives. The amount of each of these optional ingredients, if present, is preferably in a range of from 0.01 to 10.0 wt%, from 0.02 to 5.0 wt%, or from 0.05 to 3 wt% based on the total weight of the meat substitute composition. If a plant protein ingredient is included in the first emulsion, it is desirably a powdered, non-texturized plant protein ingredient.

[0055] The first emulsifier, the first fat, and the water are mixed in a first mixing step to form the first emulsion. If any optional ingredients are included, they may be mixed in the first mixing step, too. In one instance, one or more optional ingredients may first be dissolved in or blended with the first fat or the water before the emulsifier, fat, and water are mixed. They may also be added near the end of the first mixing step. In most circumstances, the first emulsion is uniform,PT-1895-WO-PCT i.e., the ingredients are spread fairly evenly across the mass of the emulsion, recognizing that any emulsion has separate phases and is inherently non-homogenous.

[0056] The first emulsion can be made using a variety of techniques generally known in the field. A shear rate should be selected to adequately disperse the oil phase in the water phase to promote a stable emulsion. The mixing can be done using various types of equipment. A bowl chopper has been found to work well. Once formed, the first emulsion can be immediately mixed with the hydrated protein composition or stored for a period of time before mixing. If the first emulsion is stored before mixing, it is maintained at a temperature low enough to avoid the emulsion breaking down significantly during storage. Refrigerated storage at a temperature of 32- 40°F should suffice or a period of at least one day for most first emulsion formulations.

[0057] At the end of the first mixing step, or at least prior to combination with the hydrated protein composition, the first emulsion may have a viscosity of at least 3,000 mPa»s or at least 4,000 mPa*s. The viscosity may be 3,000-15,000 mPa*s, e.g., 3,000-10,000 mPa*s, 4,000-7,000 mPa»s or 4,000-6,000 mPa»s using a Haake rheometer at 25 °C with a parallel-plate geometries (diameter 25 mm, gap 1 mm). The shear flow test was performed by increasing the shear rate from 0.1 to 100 / s and viscosity value was recorded at 25 / s.

[0058] As noted above, the second emulsion is formed by mixing a second emulsifier, a second fat, and water. The second emulsion should be a water-in-oil emulsion and remain an emulsion until it is combined with TPP. Preferably, it does not form a gel under conditions of use, e.g., at temperatures of 30-50°F. To promote hydration of the TPP, the second emulsifier desirably has a low viscosity. This will allow water to flow to the TPP so it can be absorbed. The viscosity may be less than 200 mPa»s, less than 100 mPa»s, less than 50 mPa»s, or less than 25 mPa»s. Suitable viscosities for the second emulsion may be 2-100 mPa»s, e.g., 2-50 mPa»s or 1-15 mPa»s at 25 °C. Gum Arabic will work well as the second emulsifier and provide the second emulsion with a suitable viscosity.

[0059] The oil-holding capacity of the second emulsifier need not be very high, though. In certain implementations, a relatively low oil-holding capacity, e.g., 0.9-3 g oil / g (dwb) of emulsifier, can form a sufficiently stable O / W emulsion. In one method of manufacture, the second emulsion is used to hydrate the TPP shortly after it is made. In such a method, the longterm stability of the emulsion is less important than it is if the second emulsion will be stored for some time before it is used to hydrate the TPP.

[0060] The amount of the second emulsifier in the second emulsion will depend in part on the emulsifier chosen. In one aspect that will work when the second emulsifier is gum Arabic, thePT-1895-WO-PCT first emulsion includes .1-3 wt%, 1-2.5 wt%, 1.25-2.5 wt%, 1.25-2 wt%, or 1.5-2 wt% of the first emulsifier, all based on total weight of the first emulsion.

[0061] The second fat used in the second emulsion comprises a fat that is liquid at room temperature. The first and second fats may be the same, or they may differ from one another. The second fat is desirably a plant-derived oil selected from the group consisting of cottonseed oil, corn oil, olive oil, peanut oil, canola oil, rice bran oil, sesame oil, safflower oil, soybean oil, sunflower oil, grapeseed oil, flaxseed oil, linseed oil, and combinations or interesterifications of two or more thereof. Oils well-suited for meat substitute burger and sausage patties, for example, may be selected from the group consisting of com oil, canola oil, cottonseed oil, soybean oil, sunflower oil, their corresponding high oleic varieties, and combinations or interesterifications of two or more thereof. Some commercially useful meat substitutes include corn oil, canola oil, sunflower oil (including their corresponding high-oleic varieties), and combinations thereof.

[0062] The second emulsion is an oil-in-water (o / w) emulsion, so there should be sufficient water to allow it to form the continuous phase with a lower amount of oil. The second emulsion desirably includes 60-98 wt% water and2-40 wt% oil, all based on total weight of the second emulsion.

[0063] The second emulsion may also include a range of optional ingredients such as functionalized starches, flavors, flavor enhancers, spices / seasonings, colors, and preservatives such as antioxidants and antimicrobials. It has proven beneficial to include a water-soluble food color in the water phase of the second emulsion. The TPP will absorb this colored water as it hydrates, thereby imparting a color to the TPP that approximates the color of the meat the meat substitute mimics. For beef substitutes, the color is desirably red to brown. Suitable colors may derived from fruit and vegetable extracts, e.g., beet juice and beet extracts. Preferably, this food color is thermolabile so that it goes from a red color to a darker, preferably browner, color upon cooking, much like beef does. This food color can include heme, if so desired. Heme-free thermolabile colors are also available, such as those described in US Patent Application Publication Nos. US 2024 / 0032569 and US 2023 / 0320390, and in PCT International Publication Nos. WO 2022 / 197586 and WO 2023 / 278968.

[0064] The second emulsion may also include an edible salt, as noted above, to form an oil-in- water brine emulsion to season the meat substitute. Although salt can be added to the meat substitute in other ways, the salt is preferably dissolved in the water phase of the second emulsion. This simplifies processing vs adding and mixing in salt in later stages. When it is hydrated, the TPP will absorb water from the second emulsion, including the salt dissolved in that water. ThisPT-1895-WO-PCT seasons each piece of hydrated TPP with salt. It also evenly distributes the salt throughout the meat substitute without as much additional mixing as would be required to uniformly distribute the salt if dry salt were added elsewhere in the process.

[0065] One or both of the water soluble food color and the salt can be added to the water before it is combined with the oil and the second emulsifier to form the second emulsion. If the food color used in the second emulsion, or a component thereof, is oil-soluble but has limited water solubility, it may be mixed with the oil before the oil and water are combined in the second emulsion. This would be less desirable, though, because the color would not readily penetrate individual pieces of TPP. That could lead to an uneven appearance when someone cuts or bites into the meat substitute.

[0066] The second emulsion can be formed by a variety of techniques generally known in the field. The second emulsion should be mixed with enough shear to dissolve the second emulsifier (if it is water-soluble) and to get the oil emulsified. High shear generally is neither necessary nor preferred. The mixing can be done using various types of equipment. A Fatosa, S. A. mixer, model number AVI 50 VV N.235 sold by UltraSource, has been found to suffice.

[0067] The second emulsion is contacted with a textured plant protein in a hydration step in which at least a portion of the water in the second emulsion hydrates the TPP, forming a hydrated protein composition. Although passive contact may be acceptable, the second emulsion and the TPP are desirably mixed together, combined under vacuum, or, preferably, mixed under vacuum. A bowl chopper with vacuum capability, e.g., a GEA CutMaster commercially available from GEA Group Aktiengesellschaft, works well because it allows one to mix the second emulsion and the TPP with or without applying a vacuum.

[0068] As noted above, texturized plant protein can be formed from a variety of plant-derived proteins. Desirably, the protein in the TPP is selected from the group consisting of soy protein, pea protein, corn protein, cottonseed protein, wheat protein, sunflower seed protein, oat protein, or combinations of two or more thereof. Preferably, the protein in the TPP is soy protein, pea protein, wheat protein, sunflower protein, or mixtures of two or more thereof. More preferably, the TPP is texturized soy protein and / or texturized pea protein.

[0069] The TPP may have any particle size distribution suitable for the intended meat substitute. For meat substitutes that mimic ground meat of the type commonly used in burger patties or meat loaf, for example, the TPP may have a relatively small particle size. In one implementation, at least 70% of the TPP is between 0.8 mm and 6.4 mm. The particle size chosenPT-1895-WO-PCT for a specific application will depend on the desired mouthfeel and chew characteristics desired for the intended meat substitute product. .

[0070] The TPP is desirably hydrated to a moisture content of 60 wt% to 80 wt%, desirably from 60 wt% to 75 wt%. Preferably, the hydration is continued until the moisture has penetrated to at least 80%, at least 90% or at least 95% of the volume of a majority - preferably greater than 75%, greater than 80%, greater than 90%, or greater than 95% - of the TPP particles. Penetration can be measured by breaking a representative sample of 50 TPP particles and relying on a visible difference between the dry material and the (likely darker) hydrated material to visually estimate what percentage of the visible surface area is hydrated.

[0071] The hydration step may include a step of checking the degree of penetration of the water from the second emulsion into the TPP particles. As noted above, the second emulsion may include a color that is similar to, and behaves similarly to, the color of the meat that the meat substitute is intended to mimic. If the color is water-soluble, it will be absorbed into the TPP, making it easier to see how far the water has penetrated into a given TPP particle. This allows one to select a relatively small, generally representative sample of TPP particles, or preferably some of the larger TPP particles, and determine the degree of penetration by breaking them apart to see how far the color extends into the TPP.

[0072] The relative amounts of the second emulsion and the TPP should provide at least enough water to hydrate the TPP to the desired degree. Although the second emulsion can contain an excess of water beyond that required for such hydration, it desirable contains less than 120%, less than 110%, or less than 105% of the amount of water required to fully hydrate the TPP.

[0073] As noted above, most or all of the water in the second emulsion may be absorbed by the TPP in this hydration step. This likely will break the second emulsion. Because the water was in an emulsion as it was absorbed, though, the remaining oil from the emulsion will be evenly distributed in the hydrated protein composition. Desirably, much of the oil that isn’t absorbed by the TPP is carried in a thin layer toward the outer surface of the TPP particles. If one were to mix water and oil separately with the TPP, i.e., without first forming the second emulsion, it may be harder to get such a desirable oil distribution without excessive mixing that may damage the hydrated TPP. The remaining second emulsifier in contact with the TPP can also contribute to retaining water that is released from the TPP in the meat substitute, helping promote the succulence of the cooked product.

[0074] The hydrated protein composition can include a variety of other optional ingredients in addition to TPP and what is in the second emulsion. The hydrated protein composition mayPT-1895-WO-PCT include a non-textured protein ingredient. Non-textured protein ingredients may be dried powders or the like, such as a flowable plant protein concentrate or a plant protein isolate. The hydrated protein composition can also include a fat, e.g., a solid fat, in addition to the fat in the second emulsion. Such optional additional ingredients may be added at the same time as the second emulsion contacts the TPP. Preferably, though, such optional ingredients are added to the hydrated protein composition after the TPP has been hydrated or toward the end of the hydration step.

[0075] The hydrated protein composition (with or without optional additional ingredients) is mixed with the first emulsion to distribute the hydrated protein composition and the first emulsion fairly evenly among one another to form a meat substitute composition. The mixing can be accomplished in a variety of known ways. As noted above, the first emulsion may be capable of forming a thermally reversible gel. During mixing, the first emulsion is desirably in the form of an emulsion rather than a gel. For a high-temperature-stable thermally reversible emulsion, this would entail mixing the first emulsion and the hydrated textured vegetable protein at a temperature below the gelation temperature of the emulsion. The degree of shear in mixing should be sufficient to ensure adequate mixing, but it should not be high enough to materially degrade the stability of the first emulsion or the integrity of the TPP particles.

[0076] The relative amounts of the first emulsion and the hydrated protein composition can vary depending on the type of meat substitute being formed and the desired nutritional and organoleptic properties. In some commercially useful formulations, the weight ratio of the first emulsion and the hydrated protein composition is between 0.1 and 1 (i.e., between 1 : 10 and 1 : 1), e.g., 0.1-0.5.

[0077] Secondary ingredients can be added when the first emulsion and the hydrated protein composition are mixed. Such secondary ingredients may be non-texturized protein ingredients, fats (the same as or different from one or both of the first and second fats), functionalized starches, flavors, flavor enhancers, spices / seasonings, colors, and preservatives.

[0078] In one preferred process, no non-textured protein ingredient is added to the hydrated protein composition. Adding the non-texturized protein ingredient to the hydrated protein composition may adversely impact hydration of the TPP, for example. Instead, it is preferred that any such non-textured protein ingredient be added as a secondary ingredient when the first emulsion and the hydrated protein composition are mixed. This can increase the protein content of the meat composition for nutritional purposes and may improve the organoleptic properties of the meat substitute. This non-textured protein ingredient may be a plant protein ingredient. Non- textured protein ingredients may be dried powders or the like, such as a flowable plant proteinPT-1895-WO-PCT concentrate or plant protein isolate. The powdered plant protein ingredient may comprise one or both of pea protein and soy protein. In one implementation, the protein powder may be capable of passing through a 200-mesh screen or a 325-mesh screen (Tyler series), meaning the TPP particles have a nominal particle size less than 75 microns or less than 45 microns, respectively.

[0079] In one suitable process, a solid fat is mixed with the first emulsion and the hydrated protein composition. The hard fats will produce meat substitutes that better approximate the organoleptic qualities of the animal-derived meat it is intended to mimic. Adding the solid fat as a secondary ingredient at this stage avoids having the solid fat adversely impact the first or second emulsion’s functional properties. Such solid fats may comprise animal fats such as lard or tallow. If an animal-free meat substitute is desired, the solid fat may comprise a fat selected from the group consisting of coconut oil, palm oil, palm kernel oil, and combinations or interesterifications of two or more thereof. The solid fat may be added as fat flakes that are solid or semisolid when they are added and, preferably, during the mixing with the first emulsion and the hydrated protein composition.

[0080] If the meat substitute is to be a hybrid meat substitute, the secondary ingredients mixed with the first emulsion and the hydrated protein composition may include animal cells. The animal cells may be animal muscle or adipose cells, either derived from a whole vertebrate animal or from an in vitro culture.

[0081] The meat substitute composition may be shaped into a desired form to make a meat substitute product. The meat substitute product can be stored at 4°C, can be frozen at -18°C or can be heat treated (like steam cooking, pan frying or oven baking) prior to storing at 4°C or freezing at -18°C.

[0082] Meat substitute products in accordance with this disclosure can take a variety of forms, including hot dogs, fish sticks and the like. The advantages of the present meat substitutes are particularly beneficial for meat substitutes that mimic meat products that are formed from ground or minced meat and grilled or cooked in a pan or on a griddle, such as burger patties, sausage patties, meatballs, and “crumbles.”

[0083] In some aspects, the meat substitute product can mimic a beef product, e.g., ground beef, steak, beef jerky, beef ribs, beef patties, beef sausages, and the like. In some aspects, the meat substitute product can mimic a pork product, e.g., ground pork, pork chops, ham, smoked pork, bacon, pork sausage, pork patties, pork ribs, and the like. In some aspects, the meat substitute product can mimic a chicken product, e.g., ground chicken, chicken breast, check legs, chicken thighs, chicken wings, chicken patties, chicken tenders, chicken nuggets, chicken sausage, and thePT-1895-WO-PCT like. In some aspects, the meat substitute product can mimic a turkey product, e.g., ground turkey, turkey sausage, turkey patties, and the like. In some aspects, the meat substitute product can mimic a fish product, e.g., filets or steaks of salmon, halibut, tuna or other fish species; or processed fish products such as fish sticks, fish balls, surimi and the like. In some aspects, the meat substitute product can mimic a shellfish product, e.g., crab, lobster, shrimp, crayfish, clams, scallops, oysters, mussels, and the like. In some aspects, the meat substitute product can mimic a cured, salted, or processed meat product, e.g., charcuterie, salami, summer sausage, prosciutto, bologna, kielbasa, and the like.

[0084] The meat substitute may include fiber. The fiber may include, but is not limited to, pectin, apple fiber, psyllium, flax fiber, rice bran extract, Konjac flour, and the like. The meat substitute may include 0.01-5 wt%, 0.2-4 wt%, or 0.5-2 wt% fiber. The meat substitute may include less than 5 wt%, e.g., less than 3 wt%, less than 2 wt%, less than 1 wt%, or less than 0.5 wt% fiber.

[0085] The meat substitute may include starch. The starch may include a pregelatinized starch, a modified starch, or combinations thereof. The starch may include, but is not limited to, potato starch, tapioca starch, rice starch, pea starch, com starch, waxy com starch, wheat starch, or any combination thereof. The meat substitute may include 0.1-7 wt%, 0.2-4 wt%, or 0.5-2 wt% starch. The meat substitute may include less than 7 wt%, e.g., less than 5 wt%, less than 3 wt%, less than 2 wt%, less than 1 wt%, or less than 0.5 wt% starch.

[0086] The meat substitute may include a preservative. For example, the meat substitute may include a preservative such as potassium sorbate, cultured dextrose, vinegar, and the like.EXAMPLES

[0087] The invention is further described in detail by reference to the following experimental examples. These examples are provided for purposes of illustration only and are not intended to be limiting unless otherwise specified.Example 1

[0088] A plant-based hamburger meat substitute composition was made having the formula set forth in Table 1 :Table 1 : Plant-based burger compositionPT-1895-WO-PCTFirst emulsion

[0089] The formula of the first emulsion is shown in Table 2, in which “PBMS wt%” refers to the weight percentage of the identified ingredients in the overall plant-based burger composition shown in Table 1.Table 2: First emulsion formulation

[0090] The flavor paste and sunflower oil were mixed in a Seydelmann model K-64 bowl chopper at a blade speed of 400 rpm and a bowl speed of 13.4 rpm until it appears homogenous and no large clumps of fat paste are visible (3-5 min). The starch and methylcellulose were mixed together and this dry blend was added to the bowl chopper. These ingredients were initially mixed at a low speed (blade speed of 120 rpm and a bowl speed of 6.7 rpm), followed by mixing for 3 minutes at a blade speed of 1600 rpm and a bowl speed of 13.4 rpm.

[0091] The reverse-osmosis water was added to the bowl chopper at a temperature of about 40 °F and the ingredients were mixed at a blade speed of 1600 rpm and a bowl speed of 13.4 rpmPT-1895-WO-PCT for 5 minutes. The contents were then chilled to a temperature of about 35 °F with dry ice over a period of 2-3 minutes while mixing at a blade speed of 120 rpm and a bowl speed of 6.7 rpm. The resultant oil-in-water first emulsion was a smooth, almost fluffy paste. This first emulsion was stored in a cooler at a temperature of about 34-38 °F while the second emulsion was made.Second emulsion

[0092] The formula of the second emulsion is shown in Table 3, in which “PBMS wt%” refers to the weight percentage of the identified ingredients in the overall plant-based burger composition shown in Table 1.

[0093] Table 3: Second emulsion formulation

[0094] The reverse-osmosis water was added to a Fatosa S.A. vacuum mixer (model no. AVI 50) at a temperature of about 40 °F. The red and brown colors were mixed to create a color concentrate that was added to the water to form an aqueous blend. The dry ingredients (gum Arabic, potassium chloride, and antimicrobial) were mixed together to form a premix that was added to and mixed with the aqueous blend for 5-7 minutes. The flavors were then added to the mixture, which was mixed for an additional 10 minutes. Finally, the sunflower oil was added to the mixer and mixed for 10 minutes to form an oil-in-water second emulsion.PT-1895-WO-PCTTexturized plant protein hydration

[0095] The textured pea protein was added to the second emulsion in the mixer and mixed under vacuum for 20 minutes for form a hydrated protein composition. At the end of the 20 minutes, the contents of the mixer were visually inspected to confirm the color from the second emulsion is distributed evenly and the surface of the TPP particles are no longer shiny. A sample of the TPP particles was removed and broken open to visually confirm the moisture had penetrated at least 95% (preferably 100%) of the volume of the particles. The color from the second emulsion is absorbed into the TPP particles, making it easier to identify any uncolored (and hence unhydrated) areas of the broken surface of a particle. If the hydration was deemed inadequate, the material would have been mixed under vacuum for an additional 5 or 10 minutes and inspected again.Plant-based burger composition

[0096] The rice protein was added to the hydrated protein composition and mixed without vacuum for three minutes. The remaining dry ingredients (non-textured pea protein, meat flavor, and rice bran extract) were added to the mixer and mixed for 3-5 minutes in a forward direction then 3-5 minutes in a reverse direction until the dry ingredients appear to be evenly distributed. The first emulsion was then added to the mixer and mixed without vacuum until the emulsion appears to be evenly distributed and the mixture has a relatively homogeneous color, about 5 minutes.

[0097] The resultant meat substitute composition was cooled with nitrogen while mixing until the composition had a temperature of 30-40 °F. Small solid particles or flakes of the coconut oil were then added and mixed for 2 minutes on reverse, then mixed forward while chilling until the temperature was about 28.5 °F. The temperature was maintained above 28 °F to minimize or avoid ice formation.Meat substitute product

[0098] The plant-based burger composition was chilled with carbon dioxide to a target temperature of 27.5-28.5 °F. The composition was formed into circular patty shapes using a Formax mold. The patties were about 4.25 inches (10.8 cm) in diameter and weighed about 4 ounces (113 g).Example 2PT-1895-WO-PCT

[0099] A plant-based hamburger meat substitute was made having the formula set forth inTable 4:Table 4: Plant-based burger compositionFirst emulsion

[0100] The formula of the first emulsion is shown in Table 5, in which “PBMS wt%” refers to the weight percentage of the identified ingredients in the overall plant-based burger composition shown in Table 4.Table 5: First emulsion formulation

[0101] The flavor paste and sunflower oil were mixed in a Seydelmann model K-64 bowl chopper at a blade speed of 400 rpm and a bowl speed of 13.4 rpm until it appears homogenousPT-1895-WO-PCT and no large clumps of fat paste are visible (3-5 min). The starch and methylcellulose were mixed together and this dry blend was added to the bowl chopper. These ingredients were initially mixed at a low speed (blade speed of 120 rpm and a bowl speed of 6.7 rpm), followed by mixing for 3 minutes at a blade speed of 1600 rpm and a bowl speed of 13.4 rpm.

[0102] The reverse-osmosis water was added to the bowl chopper at a temperature of about 40 °F and the ingredients were mixed at a blade speed of 1600 rpm and a bowl speed of 13.4 rpm for 5 minutes. The contents were then chilled to a temperature of about 35 °F with dry ice over a period of 2-3 minutes while mixing at a blade speed of 120 rpm and a bowl speed of 6.7 rpm. The resultant oil-in-water first emulsion was a smooth, almost fluffy paste. This first emulsion was stored in a cooler at a temperature of about 34-38 °F while the second emulsion was made.Second emulsion

[0103] The formula of the second emulsion is shown in Table 6, in which “PBMS wt%” refers to the weight percentage of the identified ingredients in the overall plant-based burger composition shown in Table 4.Table 6: Second emulsion formulationPT-1895-WO-PCT

[0104] The reverse-osmosis water was added to a Fatosa S.A. vacuum mixer (model no. AVI 50) at a temperature of about 40 °F. The red and brown colors were mixed to create a color concentrate that was added to the water to form an aqueous blend. The dry ingredients (gum Arabic, potassium chloride, and antimicrobial) were mixed together to form a premix that was added to and mixed with the aqueous blend for 5-7 minutes. The flavors were then added to the mixture, which was mixed for an additional 10 minutes. Finally, the sunflower oil was added to the mixer and mixed for 10 minutes to form an oil-in-water second emulsion.Texturized plant protein hydration

[0105] The textured pea protein was added to the second emulsion in the mixer and mixed under vacuum for 20 minutes for form a hydrated protein composition. At the end of the 20 minutes, the contents of the mixer were visually inspected to confirm the color from the second emulsion is distributed evenly and the surface of the TPP particles are no longer shiny. A sample of the TPP particles was removed and broken open to visually confirm the moisture had penetrated at least 95% (preferably 100%) of the volume of the particles. The color from the second emulsion is absorbed into the TPP particles, making it easier to identify any uncolored (and hence unhydrated) areas of the broken surface of a particle. If the hydration was deemed inadequate, the material would have been mixed under vacuum for an additional 5 or 10 minutes and inspected again.Plant-based burger composition

[0106] The rice protein was added to the hydrated protein composition and mixed without vacuum for three minutes. The remaining dry ingredients (non-textured pea protein, meat flavor, and rice bran extract) were added to the mixer and mixed for 3-5 minutes in a forward direction then 3-5 minutes in a reverse direction until the dry ingredients appear to be evenly distributed. The first emulsion was then added to the mixer and mixed without vacuum until the emulsion appears to be evenly distributed and the mixture has a relatively homogeneous color, about 5 minutes.

[0107] The resultant meat substitute composition was cooled with nitrogen while mixing until the composition had a temperature of 30-40 °F. Small solid particles or flakes of the coconut oil were then added and mixed for 2 minutes on reverse, then mixed forward while chilling until the temperature was about 28.5 °F. The temperature was maintained above 28 °F to minimize or avoid ice formation.PT-1895-WO-PCTMeat substitute product

[0108] The plant-based burger composition was chilled with carbon dioxide to a target temperature of 27.5-28.5 °F. The composition was formed into circular patty shapes using a Formax mold. The patties were about 4.25 inches (10.8 cm) in diameter and weighed about 4 ounces (113 g).

Claims

PT-1895-WO-PCTCLAIMSWhat is claimed is:

1. A method for making a meat substitute composition comprising: a. mixing water, a first fat, and a first emulsifier to form a first emulsion that will form a thermally reversible gel when heated to a temperature of at least 90° F, at least 100° F, at least 110° F, or at least 120° F; b. mixing water, a second fat, and a second emulsifier to form an oil-in-water second emulsion; c. contacting the second emulsion with a textured plant protein to hydrate the textured plant protein, thereby forming a hydrated protein composition; and d. mixing the first emulsion and the hydrated protein composition.

2. A method for making a meat substitute comprising the steps of: a. mixing a first fat with a first emulsifier comprising methylcellulose to form a first mixture; b. mixing water and the first mixture under shear to form a first emulsion; c. forming an oil-in-water brine emulsion comprising a second emulsifier, a second fat, water, and an edible salt (preferably one or both of sodium chloride and potassium chloride), and optionally one or more of a coloring agent, a flavor, an antioxidant, and an antimicrobial; d. forming a hydrated protein composition by combining textured plant protein and the brine emulsion; e. mixing the hydrated protein composition, the first emulsion, and a non-textured protein ingredient and, optionally, a third fat to form a meat substitute composition; and f. shaping the meat substitute composition to form the meat substitute.

3. The method of claim 1 or claim 2, wherein the first emulsion is an oil-in-water emulsion.

4. The method of any preceding claim, wherein each of the first emulsion and the second emulsion is an oil-in-water emulsion.PT-1895-WO-PCT5. The method of any one of claims 1, 3 and 4, wherein the water mixed in the second emulsion comprises an edible salt, preferably at least one of sodium chloride and potassium chloride.

6. The method of any preceding claim, wherein the first emulsion has a first viscosity of at least 3,000 mPa»s or at least 4,000 mPa»s at a temperature of 25 °C.

7. The method of any one of claims 1 and 3-6, wherein mixing the first emulsion and the hydrated protein composition further comprises mixing fat flakes with the first emulsion and the hydrated protein composition.

8. The method of any preceding claim, wherein no non-texturized protein ingredient is present in the step of contacting the second emulsion with the textured plant protein.

9. The method of any preceding claim, wherein mixing the first emulsion and the hydrated protein composition further comprises mixing a second protein ingredient, preferably a non-textured protein ingredient, with the first emulsion and the hydrated protein composition.

10. The method of claim 9, wherein the second protein ingredient comprises pea protein, defatted soy flour, defatted soy isolate, soy protein concentrate, vital wheat gluten, potato protein, corn protein isolate, or combinations thereof.

11. The method of any preceding claim, wherein the first emulsifier is different from the second emulsifier.

12. The method of any preceding claim, wherein the first fat and the second fat are different.

13. The method of any preceding claim, wherein the first emulsion is present in an amount of from 10-50 wt%, preferably 15-45 wt%, 20-40 wt%, or 25-35 wt% of the weight of the meat substitute composition.

14. The method of any preceding claim, wherein the first emulsifier comprises a thermally reversing hydrocolloid emulsifier, preferably methylcellulose.PT-1895-WO-PCT15. The method of any preceding claim, wherein the first emulsifier comprises methylcellulose and another emulsifier selected from the group consisting of native starches, modified food starches, pectin, carrageenan, seaweed powder, xanthan gum, alginates, or any combination thereof.

16. The method of any one of claims 1-14, wherein the first emulsion further comprises a functional starch that increases viscosity of the first emulsion.

17. The method of any one of claims 1-14, wherein the first emulsion further comprises potato starch, tapioca starch, rice starch, pea starch, com starch, waxy com starch, wheat starch, or any combination thereof.

18. The method of any preceding claim, wherein at least one of the first fat and the second fat comprises soybean oil, olive oil, canola oil, avocado oil, palm oil, palm kernel oil, coconut oil, cocoa butter, peanut oil, com oil, flax oil, sunflower oil, safflower oil, cottonseed oil, or any combination thereof.

19. The method of any preceding claim, wherein the second emulsifier comprises gum Arabic.

20. The method of any preceding claim, wherein the hydrated protein composition includes a non-texturized second protein that is not a textured plant protein.

21. The method of any one of claims 2-20, wherein the third fat comprises coconut oil.

22. The method of any one of claims 2-20, wherein the third fat is present in amount of about 0-10 wt% of the meat substitute product.

23. A meat substitute obtained by the method according to any preceding claim.

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