Method for producing alternative textured products

Abstract

The present invention relates to a method for producing a textured alternative protein-based food product, comprising the steps of: providing a porous textured protein-based scaffold structure; combining the scaffold structure with a nutrient solution in a mould to form a moist composition, and processing the moist composition under positive pressure to form the solid textured alternative food product. The present invention further relates to a textured alternative protein-based food product obtainable in this manner.

Description

[0001] Methods for the production of alternative textured products

[0002] The present invention relates to a method for producing a textured protein-based alternative food product, and the textured alternative food product obtained therein, in particular an alternative meat product.

[0003] Innovative foods, such as products that imitate the properties of meat, poultry, fish, seafood, dairy products like cheese or yogurt or products made from them, and are based on plant proteins, are becoming increasingly important in the context of the sustainability trend.

[0004] Creating anisotropic textures from alternative proteins to mimic meat is a challenge. Products manufactured using known and commercially available methods often differ significantly from real meat in texture, nutritional quality, color, and bite. This applies to fibrousness as well as tenderness and juiciness. Generally, every innovative food product faces the same challenges regarding texture, nutritional quality, color, and bite to ensure consumer acceptance.

[0005] In some alternative meat products based on plant proteins, the protein is textured into fibers in an extruder and then mixed with fat and texturizing agents (e.g., alginates and methylcellulose) to make the product appealing to humans. Preferably, the product obtained in this way is passed from the extruder through a cooling die and cut.

[0006] In WO 2021 / 032866 Al, a process was described that leads to the production of a foamed product which has improved properties compared to known foods that imitate the properties of meat and fish. With the aforementioned production methods, it is not possible to obtain a product that imitates the properties of meat, poultry, fish, seafood, dairy products such as cheese or yogurt, or products derived from them in all desired textures.

[0007] The object of the present invention was to provide a textured alternative food product that imitates the properties of meat, poultry, fish, seafood, dairy products such as cheese or yogurt or products derived therefrom and overcomes the problems mentioned above.

[0008] This problem has been solved by the present invention.

[0009] Specifically, the present invention relates to a method for producing a textured protein-based alternative food product, comprising the steps of: a) providing a porous textured protein-based scaffold structure; b) combining the scaffold structure from step a) with a nutrient solution in a mold to form a moist composition; c) processing the moist composition under overpressure, preferably a pressure of > 1 bar to 10 bar, particularly preferably 2 to 6 bar, to form the solid textured alternative food product.

[0010] Surprisingly, it has been found that by producing a defined porous textured scaffold structure with controlled porosity, which is then formed under pressure, products can be obtained that are closer in texture and taste to the original foodstuff, such as meat, than previous alternative products, without the need for texturizing ingredients. The present invention provides a novel approach for producing textured, protein-based alternative food products, preferably using plant proteins as the starting material for an edible scaffold structure, which is suitable for the production of alternative food products and, in particular, alternative meat products.

[0011] Starting materials derived from plant proteins are preferably subjected to overpressure and elevated temperatures in an extruder and subsequently expanded to create a porous, lightweight structure. This porous structure provides an ideal three-dimensional scaffold for texturizing alternative food products, particularly alternative meat products, and can also serve as a scaffold for cell adhesion, growth, and nutrient penetration.

[0012] In a first step of the inventive process, a porous, textured, protein-based scaffold structure is provided. This step is preferably carried out in an extruder.

[0013] The extrusion of protein-containing compositions is known. Reference is made, for example, to WO 2021 / 032866 A1. In summary, a suitable raw material is dosed into an extruder, mixed in the extruder to create a mixture, extruded from the extruder to produce an extrudate, and preferably discharged through a cooling die while the extrudate is cooled to a temperature of less than 100°C.

[0014] As described in WO 2021 / 032866 Al, the pores in the extrudate can be controlled by supplying a gas to the extruder, resulting in a foamed product. The gas can be supplied by introducing it, preferably selected from the group consisting of COp, N₂, N₂O, or SO₂, into the extruder, or alternatively by a gas-forming reaction from suitable starting materials. The gas can be introduced into the extruder in an amount of, for example, 0.01 to 5 wt%, preferably 0.05 to 2.5 wt%, based on the total weight of the raw materials fed into the extruder.

[0015] According to a further embodiment of the present invention, the raw materials can contain at least one gas-forming compound and at least one gas-releasing compound. During extrusion, a gas is formed by a chemical reaction between the gas-forming compound and the gas-releasing compound.

[0016] According to the invention, a gas-forming compound is understood to be a substance which, under the conditions prevailing in the extruder, reacts with a suitable gas-releasing compound, releasing a gas. Typical examples of a gas-forming compound are physiologically acceptable salts such as carbonates or hydrogen carbonates, e.g., sodium carbonate (NaPCO₃), potassium carbonate (K₂CO₃), or sodium bicarbonate (NaHCO₃), from which CO₂ can be released.

[0017] From these gas-forming compounds, a gas (especially preferably CO2) can be released by reaction with a gas-releasing compound. This can be any chemical compound that reacts with the corresponding gas-forming compound to produce gas. The gas-releasing compound is generally a physiologically tolerable acid. The acid can be, for example, citric acid, a phosphoric acid compound such as disodium dihydrogen diphosphate or monocalcium orthophosphate, tartaric acid or one of its salts (e.g., potassium sodium tartrate (Rochelle salt)), malic acid, fumaric acid, adipic acid, or glucono-delta-lactone. The acids can be used as free acids or in the form of their anhydrides or salts. Extruders are generally known in the prior art. Reference is made, for example, to WO 2012 / 158023 Al or to the extruders, in particular twin-screw extruders, from Bühler.Such extruders preferably have an L / D ratio (total length to screw diameter) in the range of 20 to 60, preferably 25 to 50, and particularly preferably 25 to 40. According to the invention, the extruders are preferably operated at 100 to 1000 rpm, particularly preferably at 300 to 500 rpm, and particularly preferably at 350 to 400 rpm.

[0018] A suitable extruder comprises at least one unit for feeding raw materials into a first section of the extruder. If different raw materials are to be fed into the extruder, several such units can be provided. The extruder can also have a water supply and, optionally, a steam supply.

[0019] According to a further preferred embodiment of the present invention, the extruder can be provided with a feed opening for introducing gas into the extruder. Such an extruder is described in WO 2021 / 032866 A1. Preferably, the feed opening is connected to a gas container (e.g., a pressure cylinder) and enables controlled introduction of gas into the extruder (e.g., via a control valve).

[0020] The extruder consists of several sections, called barrels, in which the material is processed and conveyed with the help of at least one rotating screw. The screw elements in the different barrels can be the same, but are preferably different to create different processing conditions in the barrels.

[0021] The extruder housing is preferably temperature-controlled.

[0022] The composition is kneaded under pressure (usually 1 to 60 bar, preferably 8 to 20 bar, particularly preferably 10 to 15 bar) to form a homogeneous mixture. An energy input of 10 to 120 Wh / kg, preferably 15 to 30 Wh / kg, is typically used.

[0023] A cooling nozzle is preferably provided at the extruder outlet to cool the extrudate below the boiling point of water, i.e., to a temperature below 100 °C under normal conditions. Cooling nozzles for extruders are well known. However, it is also possible to discharge the extrudate directly from the extruder (without passing through a cooling nozzle). In this case, the extrudate typically has a temperature above 100 °C upon exiting the extruder, for example, 110–180 °C, and water evaporates as it exits. This results in the formation of a porous, foamed structure.

[0024] According to the invention, the extruder or cooling die preferably has a slot opening to provide the porous textured material in the form of elongated strips. The porous textured material produced in the extruder is guided through a slot opening at the extruder exit and expands slightly in the process. The slot opening of the extruder or cooling die preferably has a width of 10–600 mm and a height of 0.5–5 mm. In this way, elongated strips of the extrudate with comparable dimensions can be produced.

[0025] To produce the porous, textured, protein-based framework structure, suitable raw materials are combined and preferably dosed into an extruder. At least one raw material is a protein, preferably a plant protein, insect protein, cellular protein such as from yeast, bacteria, microalgae, molds, and the like, or a mixture of different proteins.

[0026] Plants are preferred as protein sources, e.g., legumes (such as peas, lupins, or beans, e.g., fava beans), cereals (such as wheat, soybeans, rapeseed, or sunflowers), or algae. Insect proteins, cellular proteins, especially from yeast, bacteria, microalgae, fungi such as molds, and the like can also be used.

[0027] According to the invention, the porous, textured, protein-based framework preferably comprises at least one additional component selected from the group consisting of starch, fiber material, and water. This additional component is added in the form of a suitable raw material and processed with the protein component, preferably in an extruder.

[0028] Preferably, the raw materials contain at least one component with a fiber content. Pea fibers, which have a fiber content of at least 50% of their dry weight, can be cited as an example. Preferably, an amount of 0-10% by weight, based on the dry weight of all raw materials, is added.

[0029] The protein-containing raw materials are preferably dosed together with a liquid, the liquid preferably being water.

[0030] According to the invention, the protein-containing raw materials are used in such a quantity that the protein content in the dry raw material is greater than 50% and particularly preferably in the range of 60% to 90%. Accordingly, any starch content (carbohydrate content) in the dry raw material does not exceed 50%, preferably in the range of 5% to 30%.

[0031] Furthermore, additives commonly used in the production of alternative food products may be added. These include, for example, salts such as sodium chloride or nitrates or phosphates, spices, flavorings and aromas, emulsifiers, pH regulators, fats, starch, alginates, pectins, colorings (such as beetroot extract), oils or other lipids, animal blood, vegetables, fruits or extracts of fruits or vegetables, or whey components, preferably in an amount of 0.1 to 10% by weight, based on the total weight of all dry raw materials.

[0032] In the first step of the process according to the invention, both wet textures and dry textures can be produced.

[0033] According to the invention, a wet texture is preferably produced in the present first step. A wet texture is understood to be a material in which the solids content is in the range of 20 to 60 wt.%, preferably in the range of 30 to 50 wt.%. The remaining 80 to 20 wt.%, preferably 70 to 45 wt.%, particularly preferably 65 to 55 wt.%, is liquid, preferably water.

[0034] Alternatively, and preferably, a dry textured product is produced in the present first step according to the invention. A dry textured product is understood to be a textured product in which the solids content of the extrudate is in the range of 60% to 90%, preferably in the range of 65% to 75%. The remaining 10% to 40% by weight, preferably 25% to 35% by weight, is liquid, preferably water. For dry textured products, it has proven advantageous if the protein content in the dry raw materials is in the range of 35% to 90%.

[0035] Prior to step b) of the inventive method, the porous textured framework structure is preferably pretreated.

[0036] Preferably, the elongated strips of extrudate obtained in step a) are cut to the desired length. This can be done with a conventional cutting tool.

[0037] Preferably, the porous textured framework structure is dried to a moisture content of less than 10 wt% water before step b). This is particularly relevant if the porous textured framework structure, preferably in the form of strips of suitable dimensions, is to be stored for a longer period of time before being processed in the subsequent steps of the inventive method. However, drying of the porous textured framework structure is not necessary if it is processed immediately.

[0038] In a second step (step b) of the inventive process, the framework structure from the first step (step a) is combined with a nutrient solution in a mold to form a moist composition.

[0039] According to the invention, any mold can be used that gives the product a desired three-dimensional shape and withstands the process conditions applied in the subsequent third step (step c) of the inventive method, i.e., overpressure and optionally heating and / or cooling. Preferably, a conventional tofu press can be used.

[0040] It is preferred according to the invention that the nutrient solution in step b) contains at least one component selected from the group consisting of a colour, a flavouring, an enzyme, a vitamin, a mineral, a nutrient, a growth factor, a pH regulator, an emulsifier, a suspension with meat cells, fat, starch, and combinations thereof.

[0041] The nutrient solution may preferably be a culture medium known in the prior art. Non-restrictive examples of cell culture media that can be purchased from commercial suppliers (e.g., Gibco, Sartorius, etc.) or synthesized include SAFC Excell media, BME (Basal Eagle Medium), MEM (Minimum Eagle Medium), Medium 199, DMEM (Dulbecco's modified Eagle Medium), GMEM (Glasgow modified Eagle Medium), DMEM-HamF12, Ham-F12 (Gibco) and Ham-F10 (Gibco), and IMDM (Iscove's Modified Dulbecco's

[0042] Medium), MacCoy's 5A Medium, RPMI 1640 and GTM3.

[0043] If desired or necessary, such culture media can be supplemented with additional components such as amino acids, proteins like growth factors, fats, vitamins, minerals, flavorings or flavorings, edible surfactants, antibiotics, buffers, platelet-rich plasma (PRP), platelet-poor plasma (plasma), platelet concentrate, red blood cell lysate, platelet lysate (PL), cytokines, fibers, pectin, alginate, agarose, elastin, chitin, chitosan, fibrin, fibrinogen, polysaccharides, sugars, alginates, collagen, gelatin, polymers, or any combination thereof.

[0044] The combination of the framework structure from the first step (step a) with a nutrient solution in a mold to form a moist composition can be carried out in any conceivable way. Preferably, the ratio of framework structure to nutrient solution is in the range of 1:1 to 1:3.

[0045] According to a first preferred embodiment, animal cells are added to the moist composition thus obtained. The term "animal cells" used here includes not only cells from terrestrial animals but also cells from fish, shellfish, and other marine animals. Preferably, animal cells are added in an amount of 1-10% by weight, based on the moist composition.

[0046] In this first formulation, at least one additional fat component may preferably be added to improve the taste and texture. Preferably, the at least one fat component is added in an amount of 0-10% by weight, based on the moist composition. In this first formulation, the nutrient solution preferably contains an enzyme such as transglutaminase.

[0047] The composition thus prepared is then subjected to the third step (step c) of the process according to the invention.

[0048] According to a second preferred embodiment, fungal cells are added to the moist composition thus obtained, instead of animal cells. Preferably, cells from mold fungi, for example of the genus *Rhizopus*, are used. Such mold fungi are conventionally used for fermentation. Preferably, fungal cells are added in an amount of 1-10 wt%, based on the moist composition.

[0049] The composition thus prepared is then subjected to the third step (step c) of the process according to the invention, wherein in this executing cell a fermentation takes place in step c).

[0050] According to a third preferred embodiment, the scaffold structure from the first step (step a) is used as a scaffold for the growth of mammalian cells.

[0051] In this invention, it is preferred that the scaffold structure from step a) is subjected to sterilization before step b), a suspension containing mammalian cells is applied to the surface of the sterilized scaffold structure in step b), and the moist composition is cultured for several days before being subjected to step c).

[0052] The mammalian cells are predominantly muscle cells.

[0053] According to this embodiment of the present invention, the framework structure from step a) is sterilized. Typical sterilization methods such as heat treatment, filtration, or irradiation can be used. However, sterilization can also be carried out in the first and second embodiments described above, if desired.

[0054] In the third embodiment, the structure is also combined with a nutrient solution as described above. According to a preferred embodiment, the nutrient solution can be provided in the pores of the framework structure (by targeted introduction into the pores) and then slowly released.

[0055] The mammalian cells are preferably applied to the surface of the sterilized scaffold structure.

[0056] In this formulation, the moist composition is cultured for several days before being subjected to step c). Cultivation for 2 to 5 days under standard mammalian cell culture conditions is preferred.

[0057] In the third step (step c) of the inventive process, the moist composition described above is processed under overpressure, preferably a pressure of > 1 bar to 10 bar, particularly preferably 2 to 6 bar, to form the solid textured alternative food product.

[0058] According to the invention, the pressure can be applied in any conventionally known way. For example, a plate can be placed on top of the moist composition in the mold, which can then be pressed down into the mold using a conventional pressing device.

[0059] Under the pressure conditions thus generated, the moist composition is incubated under suitable temperature and humidity conditions for a period of preferably 1 to 5 days, more preferably 2 to 3 days. Suitable temperature and humidity conditions for cell growth or fermentation are known and can, for example, be a temperature of 30–60 °C, preferably 30–50 °C, and a relative humidity of 50–90%, preferably 60–80%.

[0060] According to a preferred embodiment, step c) can be carried out with a defined temperature cycle (repeated heating and cooling).

[0061] The exact conditions depend on the type of cells that are to grow or ferment in step c).

[0062] Under the conditions in the third step (step c), the product solidifies.

[0063] After completion of the third step (step c) of the inventive process, the solidified product can be removed from the mold and further processed if desired.

[0064] For example, flavorings and colorings can be added to the product.

[0065] The present invention further relates to a textured alternative protein-based food product comprising a porous textured protein-based scaffold structure and a phase of solidified nutrient solution in or on the scaffold structure.

[0066] Preferably, it is an alternative meat product.

[0067] The textured, protein-based alternative food product according to the invention is preferably obtained using the inventive method described above.

[0068] The foregoing statements regarding composition apply analogously. The textured, protein-based alternative food product according to the invention can be processed in a known manner, for example by hardening, additional cutting, cooling, baking, smoking, breading, marinating, and packaging.

[0069] The inventive textured protein-based alternative food product can be fried in a pan.

[0070] The present invention is explained in more detail with reference to non-limiting examples and drawings.

[0071] It shows:

[0072] Fig. 1 shows a schematic representation of one embodiment of the inventive method.

[0073] Fig. 2 shows an illustration of the alternative food product obtained in Example 1.

[0074] Fig. 3 shows an illustration of the alternative food product obtained in Example 2.

[0075] Fig. 4 shows an illustration of the alternative food product obtained in Example 3.

[0076] Fig. 5 shows an illustration of the alternative food product obtained in Example 4.

[0077] Figure 1 shows a schematic representation of an embodiment of the inventive process. In a first step, a porous, textured protein-based scaffold structure is produced in an extruder 1. The resulting extrudate is combined in a mold with a nutrient solution 2 (shown here schematically in an Erlenmeyer flask) to form a moist composition. Subsequently, the moist composition is processed in a press 3 under overpressure, preferably a pressure of > 1 bar to 10 bar, particularly preferably 2 to 6 bar, to form the solid, textured alternative food product.

[0078] Example 1

[0079] A mixture of soybean concentrate and water (approx. 3:1) was processed in an extruder at 350 rpm to produce a textured vegetable protein (TVP) and extruded through a slot opening in a cooling die (slot dimensions: 15 mm wide and 0.5 mm high). An elongated strip with a thickness of approximately 1.7 mm, a moisture content of 17.96%, a porosity of 62%, a density of 1.2879 g / ml, and a bulk density of 153 g / l was obtained, which was then cut into suitable pieces.

[0080] The pieces were hydrogenated with water in a ratio of TVP : water = 1:2 and placed in a conventional tofu press.

[0081] The mixture contained 94.5 wt% TVP, 3 wt% lactic acid, 2 wt% rice flour and 3 wt% of the mold Rhizopus oryzae.

[0082] A press was used to apply overpressure to the resulting mixture. The apparatus was then fermented in an oven at 35°C for approximately two days (47 hours). The fermentation process was monitored by measuring changes in pH. During fermentation, lactic acid was broken down, causing a rise in pH. When the mushroom growth ceased, the pH stabilized or, in some cases, decreased.

[0083] An elongated product was obtained, as shown in Fig. 2. The product was fried in a pan. The product obtained in Example 1 was less compact than the products obtained in the other examples. Example 2

[0084] Example 1 was repeated, but with 0.1 wt% nitrogen (N2) introduced into the extruder. An elongated strip with a thickness of approximately 1.6 mm, a moisture content of 18.71%, a porosity of 65%, a density of 1.3171 g / ml, and a bulk density of 133 g / l was obtained, which was cut into suitable parts.

[0085] An elongated product was obtained, which is shown in Fig. 3.

[0086] Example 3

[0087] Example 1 was repeated, but with the addition of 2 wt% baking soda (containing a COp source such as typically NaHCOa and an acidifying agent such as disodium dihydrogen diphosphate or cream of tartar) to the extruder. An elongated strip approximately 2.5 mm thick, with a moisture content of 18.83%, a porosity of 70%, a density of 1.1817 g / ml, and a bulk density of 87 g / l was obtained, which was cut into suitable pieces.

[0088] It was found that the fermentation was essentially complete after 24 hours (no further pH increase, fruity odor). This could be due to the fact that a very compact product was obtained in this example (low density and bulk density). To complete the process, the fermentation was carried out for a total of 43 hours.

[0089] An elongated product was obtained, which is shown in Fig. 4.

[0090] Example 4: Example 1 was repeated, but at 500 rpm in the extruder. An elongated strip with a thickness of approximately 2 mm, a moisture content of 16.14%, a porosity of 75%, a density of 1.3131 g / ml and a bulk density of 90 g / l was obtained, which was cut into suitable parts.

[0091] An elongated product was obtained, as shown in Fig. 5. The product according to Example 4 was more compact than the products obtained in Examples 1 to 3. After 47 hours of fermentation, a fruity odor was detectable.

Claims

Patent claims 1. A method for producing a textured protein-based alternative food product, comprising the steps of: a) providing a porous textured protein-based scaffold structure; b) combining the scaffold structure from step a) with a nutrient solution in a mold to form a moist composition; c) processing the moist composition under overpressure, preferably a pressure of > 1 bar to 10 bar, particularly preferably 2 to 6 bar, to form the solid textured alternative food product.

2. The method according to claim 1, characterized in that it is an alternative meat product.

3. Method according to claim 1 or 2, characterized in that step a) is carried out in an extruder (1).

4. Method according to claim 3, characterized in that a gas is provided in the extruder (1).

5. Method according to claim 3 or 4, characterized in that the porous textured material produced in an extruder (1) is guided through a slot opening at the extruder outlet to provide the porous textured material in the form of elongated strips.

6. Method according to any one of claims 1 to 5, characterized in that the protein forming the protein base is selected from the group consisting of a plant protein such as soy protein or pea protein, insect protein, mushroom protein, algae protein, yeast protein, and combinations thereof.

7. Method according to any one of claims 1 to 6, characterized in that the porous textured protein-based scaffold structure comprises at least one additional component selected from the group consisting of starch, fibrous material and water.

8. Method according to one of claims 1 to 7, characterized in that the porous textured framework structure is dried to a moisture content of less than 10 wt.% water before step b).

9. Method according to any one of claims 1 to 8, characterized in that the nutrient solution (2) in step b) contains at least one component selected from the group consisting of a colour, a flavouring, an enzyme, a vitamin, a mineral, a nutrient, a growth factor, a pH regulator, an emulsifier, a suspension with meat cells, fat, starch, and combinations thereof.

10. Method according to one of claims 1 to 9, characterized in that in step b) a mushroom is additionally added and during step c) fermentation takes place.

11. Method according to any one of claims 1 to 10, characterized in that the scaffold structure from step a) is subjected to sterilization before step b), in step b) a suspension containing mammalian cells is applied to the surface of the sterilized scaffold structure and the moist composition is cultured for several days before it is subjected to step c).

12. Method according to any one of claims 1 to 9, characterized in that step c) is carried out under heating.

13. Textured protein-based alternative food product, comprising a porous textured protein-based scaffold structure and a solidified nutrient solution phase in or on the scaffold structure.

14. Textured alternative food product according to claim 13 , characterized by the fact that it is an alternative meat product .

15. Textured alternative food product according to claim 13 or 14, characterized in that it is obtained by the process according to one of claims 1 to 12.

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