Method for producing meat alternative

Abstract

The present invention provides a production method suitable for producing a high-moisture meat alternative material using a vegetable protein as a main raw material, wherein a protein amount equivalent to that of real beef or real pork can be ingested with the meat alternative material, and the meat alternative material can be considered as beef-like or pork-like in terms of a fiber state or the like. The method for producing a meat alternative according to the present invention involves a process in which a raw material kneaded product that has been subjected to a pressure heating treatment and that contains a vegetable protein and water is passed through a breaker plate and then subjected to extrusion molding with a tapered cooling die.

Description

Method for producing meat substitute

[0001] The present invention relates to a method for producing meat substitutes, more specifically, beef-like or pork-like meat substitutes (texturized food materials) in which fibers are intertwined.

[0002] Research and development is underway to produce high-moisture meat analogues (HMMAs) from powdery raw materials such as vegetable proteins and water using an extruder (extrusion molding machine).

[0003] In order to obtain foods having a fibrous structure such as meat substitute materials, production methods using an extruder equipped with a cooling die or a breaker plate (a perforated plate for promoting crushing and mixing of raw materials) are known. For example, the following prior art documents can be cited.

[0004] Patent Document 1 describes a method for producing a protein food, which comprises heating a kneaded product containing soy protein and a heat-sensitive protein (such as egg white) with an extruder and extruding it through a breaker plate. In the production method described in Patent Document 1, simply extruding soy protein through an extruder does not result in a meat-like texture and structure due to aligned fiber orientation. Even when a breaker plate is attached to create fiber directionality, it is difficult to achieve meat-like structuring of soy protein. As a solution to these problems, a heat-sensitive protein is used in combination with soy protein as a raw material protein. In the examples of Patent Document 1, Samples 1 and 2 obtained by such a production method are evaluated as having "a meat-like texture because fiber orientation has occurred in the tissue". Note that Patent Document 1 does not describe the use of a "cooling die" as the die provided in the extruder, nor does it describe obtaining foods having complex fibers such as beef and pork.

[0005] Patent Document 2 describes a method for producing processed fish products, characterized by supplying a raw material consisting of fish meat with a moisture content of 70% or more and 10-50% starch added to it to a twin-screw extruder equipped with a breaker plate and a long die for cooling and forming; heating the raw material to a product temperature of 120-160°C in the extruder barrel; then breaking it into fibers on the breaker plate; and finally forming this fibrous material into a high-moisture to medium-moisture fiber aggregate in the long die for cooling and forming. In the manufacturing method described in Patent Document 2, it is stated that in previous food processing using extruders, when high-moisture raw materials such as fish meat were used, the moisture would turn into water vapor, causing intermittent blowouts from the extruder outlet and making stable operation impossible. Therefore, powdered raw materials such as grain flour, starch, and plant protein were added and supplied to the extruder with a moisture content equivalent to that of low-moisture raw materials. However, the resulting products were mainly low-moisture snack foods, which was considered a problem. By processing the above-mentioned specific raw materials under the above-mentioned specific conditions using a twin-screw extruder with the above-mentioned specific structure (equipped with a breaker plate and a long die for cooling and forming), the operating conditions of the extruder can be stabilized, and high-moisture to intermediate-moisture fiber aggregates can be produced, thereby solving the above problem. The example in Reference Document 2 states that the product obtained by such a manufacturing method (a sheet with 70% moisture content, 6 mm thickness, and 50 mm width) "tends to tear in a direction perpendicular to the extruder outlet, and it was confirmed that it was a fiber aggregate." Furthermore, Patent Document 2 does not describe the use of a "tapered cooling die" as the cooling die (long die for cooling and forming) for the extruder, nor does it describe the possibility of obtaining foods with complex fibers, such as beef or pork.

[0006] JP-A No. 62-111641 JP-A No. 61-274664

[0007] In conventional manufacturing methods for high-moisture meat substitutes (HMMA) using extruders, fibrous formation occurs through cooling after high-temperature, high-pressure treatment in the barrel. However, this results in dense, uniformly oriented fibers, ultimately producing a chicken-like meat substitute from the die. With such conventional manufacturing methods, it is difficult to produce beef-like or pork-like meat substitutes with intricately interwoven fibers.

[0008] The present invention aims to provide a suitable manufacturing method for producing a high-moisture alternative meat material that utilizes plant protein as the main raw material, allows for the intake of an amount of protein equivalent to that of real beef or pork, and is also beef-like or pork-like in terms of fiber structure and other aspects.

[0009] The inventors have discovered that a beef-like or pork-like alternative meat material that solves the above-mentioned problems can be produced by passing a raw material mixture containing plant protein and water, which has been subjected to pressurized and heat treatment, through a breaker plate and then extruding it with a tapered cooling die, thereby completing the present invention.

[0010] In other words, the present invention encompasses at least the following in one aspect: [Clause 1] A method for producing a substitute meat, comprising the process of passing a pressurized and heated raw material mixture containing plant protein and water through a breaker plate and then extruding it with a tapered cooling die. [Clause 2] The method for producing the substitute meat according to Claim 1, wherein the pressure of the raw material mixture immediately before passing through the breaker plate is 0.1 to 10 MPa. [Clause 3] The method for producing the substitute meat according to Claim 1 or 2, wherein the temperature of the raw material mixture immediately before passing through the breaker plate is 10 to 200°C. [Clause 4] The method for producing the substitute meat according to any one of Claims 1 to 3, further comprising the process of extruding the raw material mixture with a cooling die before passing through the breaker plate. [Clause 5] The method for producing the substitute meat according to any one of Claims 1 to 4, further comprising the process of adding a pseudo-fat composition to the raw material mixture. [Clause 6] The method for producing the substitute meat according to any one of Claims 1 to 5, wherein the temperature of the extruded product at the outlet of the tapered cooling die is 10 to 100°C. [Clause 7] The manufacturing method according to any one of Clauses 1 to 6, wherein the moisture content of the raw material mixture is 40 to 75% by mass. [Clause 8] The manufacturing method according to any one of Clauses 1 to 7, wherein the opening of the tapered cooling die has a shape in which the vertical width decreases from the inlet side to the outlet side. [Clause 9] A tapered cooling die comprising a breaker plate on the upstream side with respect to the extrusion direction. [Clause 10] The cooling die according to Clause 9, further comprising a cooling die on the upstream side of the breaker plate. [Clause 11] The cooling die according to Clause 9 or 10, wherein the opening of the tapered cooling die has a shape in which the vertical width decreases from the inlet side to the outlet side.

[0011] In other aspects, the present invention also includes alternative meats obtained by the manufacturing method described in any one of claims 1 to 8 and / or the manufacturing method using the cooling die described in any one of claims 9 to 11, as well as processed cooked products containing these alternative meats.

[0012] Furthermore, the numerical values ​​described herein are in accordance with the common technical understanding that measurement inevitably involves errors, and can be interpreted as follows: (A) values ​​with the most significant digit not indicated as a significant figure rounded to the nearest whole number; (B) values ​​rounded up or down according to the smallest unit appropriate to the measuring device or instrument; or (C) values ​​that allow for an increase or decrease of ±1%, ±2%, ±5%, or ±10%. For example, pressure, temperature, mass, etc., in this specification can be interpreted as described in (A) above. As an example, the provision "in the range of 0.1 to 10 MPa" is a provision that encompasses embodiments where the measured pressure is in the range of 0.05 MPa (0.1 MPa when rounded to two decimal places) or more and 10.5 MPa (10 MPa when rounded to one decimal place). In accordance with any of the interpretations (A) to (C) above, the numerical values ​​described herein may be given the prefix "approximately" as needed.

[0013] The manufacturing method of the present invention makes it possible to produce a high-moisture alternative meat material that is beef-like or pork-like in terms of protein content, fiber state (surface and internal disorder), and binding properties. By using such an alternative meat material of the present invention, the variations of processed and cooked products, which were previously substantially limited to chicken-like products, can be expanded to include beef-like or pork-like products with superior fiber texture, mouthfeel, and appearance.

[0014] Figure 1 is a photograph illustrating the beef-like meat substitute according to the present invention (Example 1) and the chicken-like meat substitute according to the prior art (Comparative Example 1).

[0015] —Method for producing alternative meat— The method for producing alternative meat according to the present invention (hereinafter also simply referred to as "the method for producing the present invention") includes a process (hereinafter also referred to as "BP post-processing") in which a raw material mixture containing plant protein and water, which has been subjected to pressurized and heat treatment, is passed through a breaker plate and then extruded using a tapered cooling die.

[0016] The manufacturing method of the present invention may further include, if necessary, a process of extruding the raw material mixture with a cooling die before passing it through a breaker plate (also referred to herein as "BP pretreatment").

[0017] • Extruder The pressurized heating treatment in this invention can be carried out, for example, using an extruder. The "extruder" itself can be an embodiment similar to those commonly used in the food industry. An extruder is generally a device equipped with a screw, barrel, hopper, feeder, and die. Raw materials are fed from the hopper through the feeder into the barrel, heated by a heater, and then pressurized and sheared by the screw to knead them in a high-temperature, high-pressure environment. After kneading, the mixture is extruded through the die to obtain a molded raw material mixture. The extruder may be a single-screw or twin-screw type.

[0018] The conditions and structure (e.g., screw pattern) related to the extruder for obtaining the raw material mixture are not limited to a specific embodiment and can be appropriately adjusted while considering the effects and advantages of the present invention. For example, the heating temperature of the extruder barrel is usually 80 to 300°C, preferably 130 to 170°C. The rotational speed of the screw is usually 50 to 1000 rpm, preferably 100 to 500 rpm.

[0019] The conditions relating to the raw material mixture are not limited to a specific embodiment and can be appropriately adjusted while considering the effects and advantages of the present invention. For example, the pressure of the raw material mixture immediately before passing through the breaker plate (i.e., on or near the surface of the barrel side or optionally the cooling die side of the breaker plate) is usually 0.1 to 10 MPa, preferably 0.3 to 7 MPa. The temperature of the raw material mixture immediately before passing through the breaker plate is usually 10 to 200°C, preferably 40 to 120°C. Under the above-mentioned pressure, temperature, and other conditions, the raw material mixture can pass through the breaker plate in a well-organized state, and subsequent binding can be good. The pressure and temperature of the raw material mixture immediately before passing through the breaker plate can be measured by a pressure gauge and a thermometer provided at that location.

[0020] The pressure, temperature, and other conditions of the raw material mixture described above can be adjusted by the conditions and structure related to the extruder as described above, for example, by setting the pressure and temperature at the barrel outlet side (distal end side in the extruder, downstream side with respect to the extrusion direction, near the breaker plate) within the range of the pressure and temperature of the raw material mixture. However, it is preferable to adjust these conditions by BP pretreatment performed by a cooling die installed upstream of the breaker plate, if necessary.

[0021] The pressurized heat treatment in the present invention can also be performed using means other than an extruder, for example, by using a 3D printer or a Joule heating device. When using means other than an extruder, the pressurized heat treatment, BP post-treatment, and BP pre-treatment as needed do not necessarily have to be performed continuously. The raw material mixture can be prepared in advance by pressurized heat treatment using a 3D printer, Joule heating device, etc., and then the BP post-treatment can be performed by supplying it to a tapered cooling die equipped with a breaker plate and extruding it, or, as needed, supplying it to a cooling die further upstream of the breaker plate and extruding it to perform BP pre-treatment and BP post-treatment. On the other hand, the equipment for pressurized heat treatment, such as a 3D printer or Joule heating device, the breaker plate and tapered cooling die for BP post-treatment, and the cooling die for BP pre-treatment as needed can be appropriately connected to perform the pressurized heat treatment, BP post-treatment, and BP pre-treatment as needed continuously. When using a 3D printer, Joule heating device, etc., their structure and the conditions related to the pressurized heating process can be appropriately adjusted while considering the effects and advantages of the present invention. For example, the structure and processing conditions of the 3D printer, Joule heating device, etc. can be adjusted so that a material similar to the raw material mixture obtained by the extruder structure and processing conditions described above can be obtained.

[0022] • Breaker Plate: In this invention, the "breaker plate" is an important component for forming a complex fibrous structure similar to that of beef or pork. The breaker plate itself can be an embodiment similar to those commonly used in the food industry.

[0023] The conditions related to the processing using the breaker plate (also referred to as "BP processing" in this specification) and the structure of the breaker plate used in said processing are not limited to a specific embodiment and can be appropriately adjusted while considering the effects and advantages of the present invention. The holes provided in the breaker plate may be circular, elliptical, triangular, quadrilateral or other polygonal shapes, or they may be slits, and their shape, size, number, arrangement, etc., are arbitrary. The number of breaker plates is also arbitrary, and when multiple breaker plates are used, the hole configurations may be the same or different for each plate.

[0024] • Cooling die: In this invention, the "cooling die" is an important component for obtaining an extruded product with a complex fibrous structure without swelling, by gradually releasing the pressure of the raw material mixture while cooling it. The cooling die itself can be an embodiment similar to those commonly used in the food industry.

[0025] Cooling dies include straight-type dies with a constant opening size, and tapered-type dies which have a structure in which the cross-sectional area decreases and narrows from the inlet side (upstream side with respect to the extrusion direction, for example, the proximal end side with respect to the extruder barrel) to the outlet side (downstream side with respect to the extrusion direction, for example, the distal end side with respect to the barrel), and / or at least some of the elements (sides, diameter, etc.) constituting the opening become smaller. In the present invention, a tapered-type cooling die is used in BP post-processing. On the other hand, in BP pre-processing, which is performed as needed, either a straight-type cooling die or a tapered-type cooling die may be used.

[0026] The structure and processing conditions related to the tapered cooling die for BP post-processing are not limited to a specific embodiment and can be appropriately adjusted while considering the effects and advantages of the present invention. The length of the tapered cooling die for BP post-processing is preferably 0.01 to 2, more preferably 0.1 to 1, relative to the screw length of 1, for example, 100 to 1000 mm. The opening (cross-sectional shape perpendicular to the extrusion direction) of the tapered cooling die for BP post-processing is, for example, a square or rectangle with a width (horizontal direction) of 1 to 10 mm and a height (vertical direction) of 1 to 10 mm, or a circle or ellipse with a diameter (major axis, minor axis) of 1 to 10 mm on the inlet side, and for example, a square or rectangle with a width (horizontal direction) of 1 to 10 mm and a height of 1 to 10 mm, or a circle or ellipse with a diameter of 1 to 10 mm on the outlet side. If the opening on the entrance side is square or rectangular, it is preferable that the vertical width decreases and the horizontal width increases towards the exit side (the resulting cross-sectional area may decrease, remain the same, or increase). If the opening on the entrance side is circular or elliptical, it is preferable that the vertical width (minor axis) decreases and the horizontal width (major axis) increases towards the exit side (the resulting cross-sectional area may decrease, remain the same, or increase). This is preferable because it results in a more disordered texture of the substitute meat fibers.

[0027] The temperature of the cooling water used to cool the tapered cooling die for BP post-treatment can be set as appropriate, but it is appropriate to set it so that the temperature of the extruded product obtained by BP post-treatment is usually between 0 and 100°C, preferably between 30 and 100°C. The temperature of the extruded product obtained by BP post-treatment can be measured by a thermometer installed at the outlet of the tapered cooling die for BP post-treatment.

[0028] The conditions and structure related to the straight or tapered cooling die for BP pretreatment, which is performed as needed, are not limited to a specific embodiment and can be appropriately adjusted while considering the effects and advantages of the present invention. The length of the BP pretreatment cooling die is preferably 0.1 to 2, more preferably 0.5 to 1.3, relative to the screw length of 1, for example, 100 to 1000 mm. The opening of the BP pretreatment cooling die is, for example, a square or rectangle with a width of 1 to 10 mm and a height of 1 to 10 mm, or a circle or ellipse with a diameter of 1 to 10 mm, on the inlet side and outlet side, respectively.

[0029] - Simulated fat addition treatment The manufacturing method of the present invention may further include, if necessary, a treatment in which a simulated fat composition is added to the raw material mixture (also referred to as "simulated fat addition treatment" in this specification). By performing the simulated fat addition treatment, the substitute meat obtained by the present invention can be given a marbling-like appearance and its juiciness can be increased.

[0030] The pseudo-fat addition treatment can be carried out by adding it to the raw material mixture subjected to post-BP treatment, for example, to the raw material mixture immediately after passing through the breaker plate. Such embodiments are preferred because the pseudo-fat composition can penetrate into the gaps between the fibers. Alternatively, the pseudo-fat addition treatment may be carried out by adding it to the raw material mixture that has undergone pre-BP treatment (immediately before passing through the breaker plate) or to the raw material mixture that has undergone post-BP treatment (finally extruded), for example by dripping it onto the surface. Alternatively, adding the pseudo-fat composition, for example in the form of an aqueous solution, to the raw material mixture fed into the extruder and feeding it in together can also be considered an embodiment of the pseudo-fat addition treatment.

[0031] The tapered cooling die for BP post-treatment or the cooling die for BP pre-treatment may be equipped with means for adding a pseudo-fat composition, such as an inlet for injecting or a device for dripping, depending on the embodiment of the pseudo-fat addition treatment that is performed as needed. The pseudo-fat composition may be added at one location or at two or more locations.

[0032] ・Raw material mixture The "raw material mixture" in the manufacturing method of the present invention is obtained by introducing raw materials containing at least plant protein and water into an extruder or the like and subjecting them to pressurized heat treatment. The raw materials introduced into the extruder or the like may, if necessary, be mixed (cut) in advance using a stirrer (cutter) under appropriate conditions (rotation speed, time, etc.) with, for example, plant protein and other raw materials used as necessary (especially in powder form). Raw materials can be introduced into the extruder or the like by introducing plant protein and other powdered raw materials (solid materials) used as necessary from one inlet, and water and other liquid raw materials (liquid materials) used as necessary from another inlet.

[0033] ・Plant-based protein In the present invention, plant-based proteins similar to those commonly used in the production of food products can be used. Examples of plant-based proteins include soy protein (a protein-containing component extracted from soybeans and purified as necessary), pea protein, broad bean protein, chickpea protein, wheat protein, potato protein, rice protein, canola protein, oat protein, peanut protein, and proteins derived from other legumes, seeds, grains, etc., but soy protein is preferred. Examples of soy protein include whole-fat soy protein (containing protein, oils and fats, fiber, sugars, ash (inorganic salts), fiber, etc.), defatted soy protein (whole-fat soy protein from which oils and fats have been removed), concentrated soy protein (defatted soy protein from which sugars, ash, etc. have been removed, with a purity of generally around 70%), and isolated soy protein (defatted soy protein from which fiber, sugars, ash, etc. have been removed, with a purity of generally around 90%), but concentrated soy protein is preferred. Plant proteins may be used individually or in combination of two or more in any ratio.

[0034] The amount of plant protein added to the total amount of raw material mixture can be appropriately adjusted while considering the effects and benefits of the present invention, depending on the type of plant protein used (for example, the content (purity) of soy protein in concentrated soy protein, or conversely, the content of dietary fiber other than soy protein and the moisture content), but is preferably 25 to 60% by mass, and more preferably 30 to 50% by mass.

[0035] The moisture content of the raw material mixture can be adjusted as appropriate, taking into consideration the effects and other aspects of the present invention, but is preferably 40 to 75% by mass, and more preferably 50 to 65% by mass. The moisture content of the raw material mixture can be adjusted by adding an appropriate amount of water to an extruder or the like, taking into consideration the moisture content derived from raw materials other than plant protein used as needed.

[0036] The moisture content of the raw material mixture can be measured using general methods and measuring devices for food products, for example, by atmospheric pressure heating and drying, or by using a commercially available near-infrared moisture meter.

[0037] The optional raw material mixture may further contain raw materials other than plant protein and water, as needed. Examples of such optional raw materials include proteins other than plant protein, seasonings, flavorings, colorings, and masking agents. Examples of proteins other than plant protein include livestock meat such as beef, pork, and lamb, chicken, fish, insect protein, algae protein, fungal protein, cultured meat, egg white, and milk protein. Masking agents are components that make it difficult to perceive off-flavors and odors of plant protein (such as concentrated soy protein), and examples include stevia and yeast extract. The types of optional raw materials and their amounts relative to the total amount of the raw material mixture can be appropriately adjusted according to the intended use of the final extruded product (alternative meat material) and while referring to the amounts used in conventional foods in general. For example, since the raw material mixture of the present invention is ultimately obtained as a beef-like or pork-like extruded product, it is preferable to blend optional components to exhibit a taste, aroma, color, etc., similar to beef or pork.

[0038] • Pseudo-fat composition In the present invention, the composition of the pseudo-fat composition used as needed (components and their amounts) can be appropriately adjusted depending on the embodiment of the pseudo-fat addition treatment, taking into consideration the effects of the present invention, and especially depending on the state of the raw material mixture to which the pseudo-fat composition is added.

[0039] The pseudo-fat composition may include, for example, one or more components selected from the group consisting of (a) oils and fats, (b) starch, (c) modified starch, (d) protein, (e) gelling agent, and (f) thickening polysaccharides.

[0040] (a) The oils and fats may be vegetable oils or animal oils as long as they are edible. Examples of vegetable oils include solid vegetable oils at room temperature such as cocoa butter, palm oil, peanut butter, and hydrogenated oils (margarine, etc.), and liquid vegetable oils at room temperature such as linseed oil, olive oil, sesame oil, rice bran oil, safflower oil, soybean oil, corn oil, rapeseed oil, palm kernel oil, sunflower oil, cottonseed oil, coconut oil, peanut oil, and salad oil (standard products that meet specific conditions such as ingredients and other requirements, manufactured using specific raw materials, including blended salads). Examples of animal oils include solid animal oils at room temperature such as beef tallow, lard, horse fat, and milk fat (butter, etc.), and liquid animal oils at room temperature such as fish oil, whale oil, chicken oil, and liver oil.

[0041] (b) Examples of starches include corn starch, waxy corn starch, tapioca starch, potato starch, rice starch, wheat starch, sweet potato starch, cassava starch, sago starch, kudzu starch, and pea starch.

[0042] (c) Modified starch is starch that has been subjected to enzymatic, physical, or chemical processing, and examples thereof include acetylated adipic acid crosslinked starch, acetylated phosphate crosslinked starch, acetylated oxidized starch, sodium octenyl succinate starch, acetic acid starch, oxidized starch, hydroxypropyl starch, hydroxypropyl phosphate crosslinked starch, monoesterified phosphate crosslinked starch, phosphorylated starch, and phosphate crosslinked starch. For example, acetic acid starch, hydroxypropyl starch, phosphate crosslinked starch, etc. are generally used as thickeners.

[0043] (d) As the protein for the pseudo-fat composition, proteins other than the vegetable proteins for the raw material kneaded product described in this specification and the vegetable proteins listed as optional raw materials that can be blended into the raw material kneaded product as necessary can be used, but vegetable proteins and sodium caseinate are preferred.

[0044] (e) Examples of the gelling agent include agar, gelatin, curdlan, carrageenan (κ-carrageenan, ι-carrageenan), gellan gum, and pectin. Note that curdlan can be gelled by temperature adjustment (irreversible gelling by heating to 80°C or higher in the case of high-set gel, reversible gelling by reheating after cooling to 40°C or lower after heating to 60°C to 80°C in the case of low-set gel), as well as gelling by neutralization after dissolving in an alkaline solution, relatively weak gelling by adding monovalent ions such as sodium and potassium, or relatively strong gelling by adding and crosslinking divalent ions such as calcium ions and magnesium ions. When using a gelling agent that has the property of gelling by other means than temperature adjustment, it is appropriate to also blend the components necessary for gelling (neutralizing agent, crosslinking agent, pH adjuster, etc.) according to the pseudo-fat composition.

[0045] (f) Examples of the thickening polysaccharides include carrageenan (λ-carrageenan), galactomannan, xanthan gum, chitin, chitosan, guar gum, methyl celluloses (methyl cellulose (MC), hydroxypropyl methyl cellulose (HPMC), carboxymethyl cellulose (CMC), etc.), and locust bean gum.

[0046] In one embodiment of the present invention, when the pseudo-fat addition treatment is performed when the raw material kneaded product is hot (40°C or higher, for example, 40 to 150°C), the pseudo-fat composition can be prepared to contain, for example, (b) starch, (c) modified starch, (d) protein (e.g., egg white, soy protein, wheat protein), (e) gelling agent (e.g., curdlan), and (f) thickening polysaccharides (e.g., methyl celluloses).

[0047] In another embodiment of the present invention, when the pseudo-fat addition treatment is performed when the raw material kneaded product is cold (40°C or lower, for example, 0 to 40°C), the pseudo-fat composition can be prepared to contain, for example, (a) fats and oils (e.g., animal fats such as beef tallow, lard, poultry fat, fish oil, and vegetable fats such as palm oil), (c) modified starch, (e1) agar, (e2) gelatin, (e3) agar and other gelling agents (e.g., curdlan) so as to solidify within that temperature range.

[0048] The pseudo-fat composition may be prepared by dissolving or suspending it in water (as a solution or suspension) according to the components used, or by mixing and emulsifying such a solution or suspension in water and fats and oils (as an emulsion).

[0049] The addition amount of the pseudo-fat composition to the raw material kneaded product can be appropriately adjusted according to the embodiment of the pseudo-fat addition treatment, particularly according to the state of the raw material kneaded product to which the pseudo-fat composition is added, while considering the effects of the present invention. However, the blending amount of the pseudo-fat composition with respect to the total of the raw material kneaded product (corresponding to the lean meat in the alternative meat) and the pseudo-fat composition (corresponding to the fat in the alternative meat) (the whole alternative meat) is, for example, 0.1 to 50% by mass, preferably 0.1 to 20% by mass. In one embodiment of the present invention, when adding the pseudo-fat composition to the raw material kneaded product subjected to the BP post-treatment, for example, the raw material kneaded product immediately after passing through the breaker plate, 10 to 20 g / min of the pseudo-fat composition can be added to 40 kg / h of the raw material kneaded product in an appropriate form such as a solution, suspension, emulsion, etc. (introduced from one place or two or more places).

[0050] The raw materials contained in the raw material mixture and the components contained in the pseudo-fat composition used in the manufacturing method of the present invention are, in principle, not substantially lost by the BP post-treatment, BP pre-treatment, and pseudo-fat addition treatment included in the manufacturing method of the present invention, and are ultimately included in the substitute meat of the present invention. That is, the types and amounts of vegetable proteins and other optional raw materials contained in the raw material mixture, as well as the components contained in the pseudo-fat composition used as needed, in the manufacturing method of the present invention can be converted into the types and contents of raw materials and components in the substitute meat of the present invention (by reinterpreting the description in the specification), and vice versa. For example, the preferred range (25 to 60% by mass) and more preferred range (30 to 50% by mass) of the amount of vegetable protein relative to the total amount of raw material mixture, as described herein in relation to the manufacturing method of the present invention, substantially correspond to the preferred range and more preferred range of the vegetable protein content in the total amount of substitute meat when the substitute meat obtained as a product contains only the lean portion made from the raw material mixture (and does not contain the fatty portion made from the pseudo-fat composition). On the other hand, if the alternative meat includes not only lean meat but also fatty meat, the preferred range (25-60% by mass) and more preferred range (30-50% by mass) of the amount of vegetable protein relative to the total amount of raw material paste can be converted into preferred and more preferred ranges for the vegetable protein content in the total amount of alternative meat including lean and fatty meat, taking into account the amount of pseudo-fat composition used. For example, if the amount of fat (pseudo-fat composition) relative to the entire alternative meat (total of raw material paste and pseudo-fat composition) is 0.1-50% by mass, the preferred amount of vegetable protein relative to the total amount of raw material paste, which is 25-60% by mass, can be converted into a preferred range for the amount of vegetable protein in the entire alternative meat of 12.5% ​​by mass (25% by mass × (100-50) / 100) to 60% by mass (60% by mass × (100-0.1) / 100).

[0051] —Meat Alternatives— In one aspect, the present invention provides meat alternatives obtained by the manufacturing method of the present invention as described above, and processed cooked products containing them.

[0052] The meat substitute of the present invention has complex, intertwined fibers with a random orientation, similar to beef or pork, rather than uniform, unidirectional fibers like chicken. The fibrous disorder in the meat substitute of the present invention is observed not only on the surface but also internally (as shown in the examples below, in the panel evaluation test, the evaluation that the fibrous disorder is formed not only on the surface but also internally (evaluation score 5) is more prevalent than the evaluation that the fibrous disorder is formed only on the surface (evaluation score 3) (average score of 4 or higher)). The fibers or fibrous structure of the meat substitute refers to a structure in which fibers with a diameter of several tens of micrometers are accumulated, similar to those found in ordinary meat, and is an element that allows the meat substitute to reproduce a meat-like texture. The fact that the meat substitute of the present invention has complex, intertwined fibers with a random orientation, similar to beef or pork, can be observed and determined by visual inspection, and if necessary, the fibers themselves can be observed using, for example, a scanning electron microscope (SEM).

[0053] Furthermore, the meat substitute of the present invention has binding properties; that is, the fibers are not in a loose state but are bound together. The binding properties are such that at least the fibers are bound together when extruded using the tapered cooling die of the manufacturing method of the present invention, and preferably they are so firmly bound that they do not break apart even when pressed with a finger.

[0054] The shape and size of the meat substitute of the present invention are not particularly limited and can be determined according to their intended use. The meat substitute of the present invention has intricately intertwined fibers that are well bound together, making it easy to maintain the desired shape and size.

[0055] The substitute meat of the present invention can be seasoned (marinated, etc.), coated and fried, or processed in the same way as ordinary beef or pork. Examples of processed foods containing the substitute meat of the present invention include grilled meat, steak (fillet steak if a pseudo-fat composition is added), stir-fries (e.g., bulgogi in the case of beef substitute meat, twice-cooked pork in the case of pork substitute meat), curry, fried foods, and dried meat-like foods (jerky, etc.).

[0056] —Tapered Cooling Die— In one aspect, the present invention provides a tapered cooling die suitable for use in the manufacturing method of the present invention as described above. Such a tapered cooling die of the present invention includes a breaker plate on the upstream side with respect to the extrusion direction, and optionally further includes a cooling die upstream of the breaker plate. Technical matters relating to the tapered cooling die of the present invention, such as the structure of the breaker plate, the tapered cooling die, and optionally the cooling die (preferred embodiments, etc.), can be applied to the matters described above in relation to the manufacturing method of the present invention.

[0057] With regard to technical matters not specified herein, those skilled in the art can appropriately consider general or well-known and commonly used technical matters in the art to which the present invention pertains, particularly those relating to food, and thereby be able to implement the invention described herein.

[0058] [I] Manufacturing of Alternative Meat Materials Part 1: Variations of BP Pre-treatment and BP Post-treatment For each example and comparative example, concentrated soy protein as a plant protein and water were put into an extruder according to the formulations shown in Tables 1 to 3. The raw materials were kneaded and heated under conditions of barrel temperature 80 to 250°C and pressure 0.1 to 10 MPa. The resulting kneaded raw material was subjected to BP pre-treatment or control treatment, BP treatment, BP post-treatment or control treatment according to the conditions shown in Tables 1 to 3. The final extruded product (dough) was extruded so that its temperature was in the range of 0 to 100°C, cut, and cooled.

[0059] The "fiber disorder" and "binding properties" of the extruded products obtained from each example and comparative example were evaluated by six panelists according to the following criteria, and the average of the evaluation scores is shown in the table. <Fiber disorder> 1: Fibers are uniform in one direction 2: Surface fibers are somewhat disordered 3: Surface fibers are disordered 4: Surface fibers are disordered, and inner fibers are somewhat disordered 5: Surface and inner fibers are disordered <Binding properties> 1: Not bound, loose 3: Bound but can be loosened by pressing with a finger 5: Bound and cannot be loosened by pressing with a finger

[0060] The evaluation results for each example and comparative example are shown in Tables 1 to 3. Examples 1 to 7, which satisfy the constituent requirements of the present invention, all received high evaluations for "texture disorder" and "binding properties," and are excellent as beef-like or pork-like meat substitutes. On the other hand, Comparative Examples 1 and 2, which did not undergo BP treatment and BP post-treatment using a tapered cooling die, Comparative Example 3, which did not undergo BP post-treatment, Comparative Examples 4 and 7, which did not undergo BP post-treatment using a tapered cooling die but used a straight cooling die, and Comparative Examples 5 and 6, which did not undergo BP treatment (processing using a straight cooling die and a tapered cooling die was performed consecutively), had insufficient fiber disorder (it may be observed to some extent on the surface, but not sufficiently inside), and cannot be said to be sufficient as beef-like or pork-like meat substitutes.

[0061]

[0062]

[0063]

[0064] [II] Manufacturing of Alternative Meat Materials Part 2: Variations of BP Treatment The extruded product (dough) was discharged, cut, and cooled in the same manner as in Example 1, except that the structure of the breaker plate used for BP treatment (shape and number of holes) was changed as shown in Table 4.

[0065] The results are shown in Table 4. It can be seen that even with various changes to the structure of the breaker plate, it is possible to produce excellent beef-like or pork-like meat substitutes with relatively high ratings for "organic disorder" and "binding properties."

[0066]

[0067] [III] Production of processed meat alternatives (jerky) (Example 12) Jerky produced from high-moisture alternative meat material (HMMA) 77 parts by weight of the alternative meat material (3 mm thick) obtained in Example 1 was added to 23 parts by weight of seasoning liquid (containing soy sauce, amino acids, spices, flavorings, sweeteners, and water), vacuum-packed, heated by steaming (95°C, 50 minutes), and then left to stand in the refrigerator for 3 days. After that, it was dried in a drying chamber until the water activity was 0.8. The bulk density of the obtained dried meat-like food (jerky) was 0.6.

[0068] (Comparative Example 8) Jerky made from textured vegetable protein (TVP) 500 parts by weight of dried textured soy protein (3 mm thick) was mixed with 1000 parts by weight of seasoning liquid (containing soy sauce, amino acids, spices, flavorings, sweeteners, and water), and mixed in a vacuum mixer. The mixture was then dried in a drying chamber until the water activity reached 0.8. The bulk density of the resulting dried meat-like food (jerky) was 0.51.

[0069] Note that the "bulk density" for Example 12 and Comparative Example 8 was calculated by cutting each dried meat-like product (jerky) into pieces measuring 5 mm in length x 5 mm in width (x 3 mm in thickness), with a volume of 113 cm³. ３ The weight (g) of the dried meat-like product packed into the container / volume (cm³) of the container ３ The calculation was performed as follows. The processed food product of Example 12 using the alternative meat material (HMMA) according to the present invention has a higher bulk density and a denser structure than the processed food product of Comparative Example 8 using the conventional alternative meat material (TVP), and this is thought to be related to the results of the sensory evaluation described below.

[0070] Sensory evaluations were conducted on the "fibrous texture," "texture," and "appearance" of the dried meat-like products of Example 12 and Comparative Example 8 according to the following criteria. The results are shown in Table 5. The processed product of Example 12, which uses the alternative meat material (HMMA) according to the present invention, has superior characteristics as a dried meat-like food (jerky) in terms of fibrous texture, texture, and appearance compared to the processed product of Comparative Example 8, which uses a conventional alternative meat material (TVP). <Fiberus> A: Good (Dense and easily crumbled fibrous texture) B: Fairly good (Fiberly somewhat dense and easily crumbled) C: Poor (Fiberly with many pores like fried tofu) <Texture> A: Good (Meat-like elastic texture) B: Fairly good (A slightly soft texture remains) C: Poor (Soft texture like fried tofu) <Appearance> A: Good (Dense and irregular fibers are visible) B: Fairly good (Not dense, but irregular fibers are visible) C: Poor (No fibers are visible)

[0071]

Claims

1. A method for producing alternative meat, comprising a process of passing a pressurized and heat-treated raw material mixture containing plant protein and water through a breaker plate and then extruding it through a tapered cooling die.

2. The manufacturing method according to claim 1, wherein the pressure of the raw material mixture immediately before passing through the breaker plate is 0.1 to 10 MPa.

3. The manufacturing method according to claim 1, wherein the temperature of the raw material mixture immediately before passing through the breaker plate is 10 to 200°C.

4. The manufacturing method according to claim 1, further comprising the process of extruding the raw material mixture with a cooling die before passing it through the breaker plate.

5. The manufacturing method according to claim 1, further comprising the process of adding a pseudo-fat composition to the raw material mixture.

6. The manufacturing method according to claim 1, wherein the temperature of the extruded product at the outlet of the tapered cooling die is 10 to 100°C.

7. The manufacturing method according to claim 1, wherein the moisture content of the raw material mixture is 40 to 75% by mass.

8. The manufacturing method according to claim 1, wherein the opening of the tapered cooling die has a shape in which the vertical width decreases from the inlet side to the outlet side.

9. A tapered cooling die equipped with a breaker plate on the upstream side with respect to the extrusion direction.

10. The cooling die according to claim 9, further comprising a cooling die on the upstream side of the breaker plate.

11. The cooling die according to claim 9, wherein the opening of the tapered cooling die has a shape in which the vertical width decreases from the inlet side to the outlet side.

Images