Method for producing a meat substitute product

Abstract

The invention relates to a method for producing a meat substitute product, comprising edible fungus, cereal bran, vegetable oil, cereal meal, water, methylcellulose, sunflower protein and optionally vinegar, spices and salt, wherein - in a first step water and oil are emulsified in a cutter, wherein the water is preferably added first, - in the second step comminuted fruit bodies of the fungi and optional ingredients in the form of vinegar, spices and / or salt are added and mixed, - in the third step, the remaining ingredients are added and mixed, - in the fourth step, the mass is blended, wherein a blunt stirring tool is present in the cutter, and wherein the comminuted fruit bodies of the fungi are added deep-frozen and wherein the added water is at most 10 degrees warm, and wherein the ingredients are mixed at negative pressure or in a vacuum.

Description

[0001] Method for producing a meat substitute product

[0002] The invention relates to a method for producing a meat substitute product based on edible mushrooms and their fruiting bodies, as well as on cereal bran and cereal meal. The invention further relates to the products produced by the method.

[0003] A meat substitute is understood to be a product that replaces a component of a dish that usually includes meat, such as the patty of a burger. The use of edible mushrooms and their fruiting bodies for the production of food is known, for example from the applicant's granted patent EP3292769B1.

[0004] Meat alternatives, used as replacements for conventional animal protein sources, are also referred to as "meat analogues," "meat substitutes," or "meat imitations." These protein foods attempt to mimic the texture, taste, and, where applicable, nutritional profile of meat from farm animals by drawing on a virtually endless selection of diverse ingredients, including legumes, grains (e.g., gluten), oils, plants, mushrooms, algae, insects, and laboratory-grown, artificially produced tissue cells.

[0005] The production and composition of meat alternatives with regard to taste, texture, mouthfeel, and nutritional value is a technical challenge. In particular, the fatty mouthfeel, juiciness, firmness, and bite of a meat product are difficult to replicate.

[0006] To achieve the characteristic consistency and texture of a plant-based meat substitute, different processing methods are required, depending on the raw materials. For example, plant-based alternatives to minced meat are often produced as dry granules. The production of tender fillet strips requires different technical adjustments and more water in the production process. Substitutes for a firm schnitzel, on the other hand, require higher processing temperatures. If mushrooms are used as the main ingredient, a certain firmness and structure can be achieved depending on the form in which they are added and the type of processing. Even here, there are a wide variety of options, such as powder form, fine or coarse pieces; dried or undried; frozen, raw, or cooked; heating, cooking, or cooling during the process.

[0007] Addition at the beginning, in between, or at the end; type and quantity of the fungus; mycelium or fruiting body, ... The challenges in the production of meat alternatives are therefore very complex.

[0008] The object of the present invention is to provide a meat substitute product that can be manufactured from tried and tested raw materials available in large quantities, namely cereal products and edible mushrooms. While food products containing, for example, wheat gluten and mushrooms are already known, their production is challenging because every ingredient, its mixing ratio, its order of addition, and every process step affects the texture of the resulting product. In retrospect, a process may appear simple, but obtaining a product of the desired and, above all, reproducible quality requires countless hours of consideration, trials, and quality control, comparable to products in the chemical or construction industries.

[0009] The object of the invention is to find a method to make a meat substitute product comprising mushrooms and cereal products producible in a reproducible process with reproducible quality, in particular with regard to consistency and texture.

[0010] To solve the problem, a method for producing a

[0011] Meat substitute product according to claim 1 proposed, which is produced using the fruiting bodies of edible mushrooms and cereal products.

[0012] In one embodiment, a process for producing a meat substitute is proposed, comprising fruiting bodies of at least one type of edible mushroom with a content of 30-70 wt.%, cereal bran, in particular wheat bran, with a content of 0.5-5 wt.%, vegetable oil with a content of 10-40 wt.%, cereal meal, in particular wheat meal and / or spelt meal, with a content of 5-10 wt.%, water with a content of 10-40 wt.%, methylcellulose with a content of 1-4 wt.%, sunflower protein with a content of 2-8 wt.%, vinegar with a content of 0-4 wt.%, spices with a content of 0-4 wt.%, and salt with a content of 0-4 wt.%.% each based on the weight of all the aforementioned ingredients, wherein in a first step water and oil are emulsified in a cutter, the water preferably being added first, in a second step crushed mushroom fruiting bodies and optional ingredients in the form of vinegar, spices and / or salt are added and mixed, in a third step the remaining ingredients are added and mixed, in a fourth step the mass is blended, wherein a blunt stirring tool is provided in the cutter, in particular by mounting the cutter blades in reverse so that their blunt side is aligned in the direction of rotation of the tool, and wherein the crushed mushroom fruiting bodies are added frozen, and wherein the added water is at most 10 degrees Celsius, and wherein the ingredients are mixed under pressure or vacuum.Due to the numerous steps to be followed, the defined sequence of additions, and the specification of essential process parameters, it becomes clear that this is a complex technical process. The edible mushroom is preferably present at a proportion of 40-60% by weight.

[0013] Preferably, the water is added in the first step, followed by the oil. Mixing is initially carried out at a lower rotational speed, for example, 2000–4000 revolutions per minute, and subsequently at a higher rotational speed, for example, 5000–7000 revolutions per minute. The first mixing step can be performed at ambient pressure, while the second mixing step is preferably performed under reduced pressure, for example, 90% vacuum. The first mixing step can preferably be performed for a duration of between 20 and 100 seconds, and the second mixing step can preferably be performed for a duration of between 30 and 120 seconds.

[0014] The mixing in the second step can initially take place at a lower rotational speed, for example 100-400 revolutions per minute, and then at a higher rotational speed, for example 500-700 revolutions per minute. The first mixing preferably takes place over a period of between 60 and 180 seconds, and the second mixing preferably takes place over a period of between 30 and 120 seconds.

[0015] The mixing in the fourth step can take place at a rotational speed in the range of 300 to 1000 revolutions per minute.

[0016] The following steps can follow the fourth step: in the fifth step a product is formed from the mass, in the sixth step the product is heated, and in the seventh step the product is cooled and / or frozen.

[0017] By following these steps, it is possible to produce a meat substitute product with the desired consistency, especially comparable to a meat patty, with good repeatability.

[0018] It is important to vacuum-seal the mixing container, which removes air from the mixture, thus increasing the product's firmness.

[0019] It is also important that the temperature of the raw material remains below freezing, which is achieved by adding frozen mushrooms and cold water. This inhibits the binding of the methylcellulose; otherwise, the mixture would set too quickly and lumps would form.

[0020] The entire process can be carried out in a standard cutter. A cutter emulsifies optimally and can also mix. However, it is essential that it is used differently, i.e., with blunt mixing tools.

[0021] By installing the knives in reverse in the system, completely different mixing forces are achieved; in particular, the methylcellulose behaves very differently than when it is simply mixed in.

[0022] Comparable products, according to the state of the art, usually include transglutaminase for supporting protein cross-linking; the product in question does not contain this. While transglutaminase does create cross-linking in combination with protein, it results in a rather brittle, dry structure.

[0023] The product in question, however, remains very juicy and / or fatty.

[0024] Preferably, in the fifth step, products are formed from the mass by a blade rotor of a vacuum cutter, which removes air during the cutting process.

[0025] Preferably, in the sixth step, heating with steam takes place over a period of 5-30 minutes. Heating is preferably carried out to a temperature above 75 °C. Alternatively, or preferably additionally, heating can be carried out by frying, roasting, or heating in an oven. In particular, the product can be precooked and then deep-fried. Preferably, the fruiting body pieces are in the form of pieces with a minimum dimension of at least 3 mm and a maximum dimension of at most 25 mm.

[0026] In one version, the fungus is a fungus of the genus Pleurotus or Agaricus.

[0027] It is preferred that the mushroom be the king oyster mushroom (Pleurotus eryngii).

[0028] In one version, the mushroom is a mushroom (Champignon).

[0029] In one version, the mushroom is intended to comprise a mixture of mushrooms, in particular button mushrooms and king oyster mushrooms.

[0030] The invention also relates to a meat substitute product that is produced according to the method in question.

[0031] A meat substitute product is preferred in which the raw fruiting body pieces have a minimum size of at least 3 mm in every spatial direction.

[0032] The mushrooms are preferably added in the form of raw, frozen pieces and remain chunky during the process.

[0033] Because the mushrooms are included as pieces, the biting and / or chewing behavior is similar to a conventional meat product, especially a meat patty.

[0034] The use of fruiting bodies of edible mushrooms and cereal products as raw materials is advantageous, as these are common and proven foods and represent a resource-saving alternative to meat or other animal products.

[0035] The use of fruiting bodies of Pleurotus eryngii (Brown Oyster Mushroom) as raw material is particularly advantageous, as these mushrooms can be cultivated well in large quantities and the flesh of the fruiting body has a rather firm consistency compared to other mushrooms.

[0036] The product manufactured according to the present method

[0037] The meat substitute product is characterized by a compressive strength and texture comparable to meat or meat products, whereby different textures can be produced from one and the same raw material using the inventive method. This is achieved in particular by adjusting the proportion and / or size of the fruiting body pieces of the fungus.

[0038] The density of the finished product is preferably in the range between 0.7 and 1.8 g / cm³. 3 , especially in the range of 0.9 to 1.3 g / cm³ 3 , for example 1.2 g / cm³ 3 .

[0039] The particularly preferred method also includes the following steps:

[0040] - (if necessary) Preparation of the mushrooms (e.g. cleaning) ,

[0041] - Chop the mushrooms into pieces of 3 to 25 mm before adding them in the second step.

[0042] The invention is illustrated by a drawing:

[0043] Fig. 1: shows a process flow diagram of the method according to the invention.

[0044] Fig. 2: shows the results of a texture analysis via a pressure test.

[0045] Figure 1 illustrates the sequence of individual process steps, beginning with the addition of water and oil to a cutter and emulsification in the first step. The result is an emulsion.

[0046] In the second step, the emulsion is mixed with the crushed mushroom fruiting bodies and the optional ingredients in the form of vinegar and / or spices and / or salt. Pepper and fenugreek are preferred spices.

[0047] In the third step 3, the remaining ingredients, comprising cereal products in the form of bran and meal, sunflower protein and methylcellulose, are added.

[0048] The cereal products preferably consist of wheat bran or spelt bran and wheat meal or spelt meal or a mixture of wheat and spelt products.

[0049] In the fourth step (4), the mixture is blended. In the optional fifth step (5), the mixture is formed into a product. In the optional sixth step (6), the product is heated. In the optional seventh step (7), the product is cooled and / or partially frozen and / or deep-frozen.

[0050] In the second step, consisting of mixing the emulsion with crushed fruiting bodies, and in the third step, mixing with the other ingredients, no further crushing of the ingredients takes place, including the mushrooms.

[0051] The other solid ingredients can be added in powder form.

[0052] In steps 6 and / or 7, the product may already be in its final form, especially in the form of a patty.

[0053] The product can be sold or stored chilled or frozen.

[0054] A specific product example of a tangible meat substitute product in the form of a burger patty is given below.

[0055] The product, hereinafter referred to as the patty in question, was produced, precooked, fried and deep-frozen according to the described process steps 1 to 5.

[0056] The product's ingredient list includes mushrooms 57%, vegetable oils (rapeseed, sunflower; in varying proportions), whole grain spelt flour, sunflower protein, thickener: methylcellulose, spirit vinegar, table salt, wheat bran, spices.

[0057] The average nutritional value per 100 g is: Energy 1269 kJ / 307 kcal, Fat 28 g, of which saturates 2.8 g, Carbohydrate 7.2 g, of which sugars < 0.5 g, Protein 6.5 g, Salt 2.3 g.

[0058] With this information, a person skilled in the art is able to produce a comparable product within the scope of the present invention. In particular, a person skilled in the art can derive the selection of ingredients from the value ranges specified in the main claim from the ingredients listed in descending order of their weight percentage and the nutritional information.

[0059] The water initially added in the process evaporates to a proportion of less than 5%.

[0060] The patty was produced with a diameter of 10 cm and a thickness of 14 mm.

[0061] This patty in question and other burger patties available on the market were analyzed with regard to their density and texture.

[0062] To determine the density, cubes with an edge length of 10 mm were precisely cut from the raw and cooked burger patties. The mass of the samples was determined gravimetrically using a precision balance (Sartorius Lab Instruments, ENTRIS2241-1S, d=0.1mg). The density (p) was approximately calculated using the following formula:

[0063] Mass (g)

[0064] Density (p) =

[0065] Volume (cm3)

[0066] The pressure resistance was measured using a texture analyzer equipped with a cylindrical plunger with a diameter of 20 mm. A modified version of the method from Texture Technologies Corp. and Stable Micro Systems, Ltd., Hamilton, USA, was used, specifically designed for characterizing meat and veggie patties.

[0067] The following parameters were set for the pressure measurements:

[0068] Penetration depth: 10 mm

[0069] Penetration speed: 0.5 mm / s

[0070] Data recording: Start upon reaching a resistance of 5g. Measurement process: Recording of the pressure both during penetration and withdrawal of the plunger. The following table shows the results of the approximate density determination.

[0071] The density of the patty in question was comparable to that of a commercially available beef patty when raw and very comparable when cooked.

[0072] Figure 2 shows the results of the texture analysis by pressure test of the patty in question in comparison to two different beef patties and four different plant-based meat substitutes available on the market.

[0073] The first and fourth plant-based meat substitutes are based on soy protein.

[0074] The second and third plant-based meat substitutes are based on textured pea protein.

[0075] It was found that the determined curve 8 of the patty in question deviated only slightly from the curves 9 of the beef patties, with the four plant-based meat substitute alternatives all being significantly softer and their pressure curves 10 lying in the lower area of ​​the figure.

[0076] The maximum gel strengths determined are shown in the following table.

[0077] In principle, the results obtained indicate that the patty in question is comparable to a commercially available beef patty in terms of density and texture and differs from the plant-based meat alternatives examined.

Claims

Patent claims 1. A process for producing a meat substitute product, comprising fruiting bodies of at least one type of edible mushroom with a content of 30-70% by weight, cereal bran, in particular wheat bran, with a content of 0.5-5% by weight, vegetable oil with a content of 10-40% by weight, cereal meal, in particular wheat meal and / or spelt meal, with a content of 5-10% by weight, water with a content of 10-40% by weight, methylcellulose with a content of 1-4% by weight, sunflower protein with a content of 2-8% by weight, vinegar with a content of 0-4% by weight, spices with a content of 0-4% by weight, and salt with a content of 0-4% by weight, each based on the weight of all the aforementioned ingredients, wherein - in a first step, water and oil are emulsified in a cutter, with the water being preferentially added, - in the second step, crushed mushroom fruiting bodies and optional ingredients in the form of vinegar, spices and / or salt are added and mixed, - in the third step the remaining ingredients are added and mixed, - in the fourth step the mass is mixed, whereby a blunt stirring tool is used in the cutter and the crushed fruiting bodies of the mushrooms are added frozen and the added water is at most 10 degrees and the mixing of the ingredients takes place under pressure or under vacuum.

2. The method according to claim 1, characterized in that - in the fifth step (5) a product is formed from the mass, - in the sixth step (6) the product is heated, - in the seventh step (7) the product is chilled, partially frozen or deep-frozen.

3. Method according to claim 1 or 2, characterized in that in the first step the emulsification of water and oil takes place over a period of 1-2 minutes, wherein this is initially done at a first rotational speed and then at a higher second rotational speed.

4. Method according to one of claims 1 to 3, characterized in that in the fifth step products are formed from the mass by a blade rotor of a vacuum cutter which removes air during the cutting process.

5. Method according to one of claims 1 to 4, characterized in that in the sixth step heating with steam takes place over a period of 5-30 min.

6. Method according to one of claims 1 to 5, characterized in that the crushed fruiting bodies of the fungi are present as fruiting body pieces in the form of pieces with a minimum extent of at least 3 mm and a maximum extent of at most 25 mm.

7. Method according to any one of claims 1 to 6, characterized in that the mushroom comprises a mushroom or a mushroom of the genus Pleurotus or Agaricus, in particular king oyster mushroom (Pleurotus eryngii), or a mixture of these mushrooms.

8. Meat substitute product produced according to a method of claims 1 to 7, wherein the crushed fruiting bodies of the fungi are present as lumpy fruiting body pieces in the meat substitute product and have a minimum size of at least 3 mm in every spatial direction.

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