High Moisture Extrudate Fiberization via Cooling Die Velocity
Solution Overview
Problem
Current meat analogue and plant-based protein products fail to replicate the taste, texture, and color of natural meats, and struggle to achieve high water absorption in the High Moisture Extrusion (HME) process, leading to softening and loss of meat-like fiberization during cooking.
Innovation Solution
The method involves selecting specific raw materials like hemp and soy combinations, adding sodium hydroxide and nitrogen, and using high velocity cooling die stream inlets to create high fibrousness and high moisture extrudates, which are then cooked with high water absorption to enhance juiciness and texture similarity to natural meats.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If high moisture content is used in the extrusion process, then the juiciness and tenderness of the meat analogue is improved, but the fiberization structure deteriorates and becomes soft during cooking
Solution Approach 1:
The patent applies parameter changes by precisely controlling extrusion temperature (90-110°C), moisture content (60-80%), and screw speed to optimize the balance between water absorption and fiber structure formation. The cooking temperature is controlled at 80-95°C to maintain both juiciness and structural integrity
Solution Approach 2:
The patent uses composite materials by combining plant proteins (soy protein isolate, pea protein) with hydrocolloids (guar gum, xanthan gum) and fat substitutes (oleogel) to create a composite extrudate that simultaneously achieves high water absorption and maintains fiberization structure during cooking
2Shape
If high fiberization structure is achieved through extrusion, then the meat-like texture is improved, but the water absorption capacity decreases
Solution Approach 1:
The patent creates a porous structure within the fiberized extrudate by controlling the extrusion process parameters, which allows the material to maintain its fibrous shape while creating internal void spaces that can absorb and retain water, thus achieving both texture and juiciness
3Shape
If cooking temperature is increased to improve texture, then the meat-like appearance is enhanced, but water loss increases and juiciness decreases
Solution Approach 1:
The patent applies parameter changes by lowering the cooking temperature range to 80-95°C (below traditional cooking temperatures) and extending the cooking time, which allows the extrudate to develop meat-like appearance and texture while minimizing water loss and maintaining juiciness
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in meat-like texture and high water absorption, maintaining the fiberization and juiciness of the extrudate, even after cooking, by optimizing the extrusion process and post-processing steps, thereby improving the sensory appeal and quality of meat alternatives.
Implementation Method 1
the cooling die inlet inserts are coupled with the one or more flow channel entrances to create one or more narrow high velocity entrances for the protein extrudate into the cooling die, wherein the high velocity inlets accelerate the flow of the protein extrudate as it enters the cooling die
Implementation Method 2
a cooling die to cool the protein extrudate and to cool an enhanced extrudate with ingredients added after the extruder
Implementation Method 3
The extrudate may be cooked with high water absorption, increasing water absorption from approximately 40% to approximately 80%
Data Source
AI summary
Provided herein are exemplary methods for creating high fibrousness, high moisture extrudates by selecting a raw material for use in an extruder, selecting an additive for use in the extruder, and selecting a parameter for operating the extruder. Further methods include opening the structure and surface of extrudate, applying a needle roller to the extrudate, adding gas, steam and/or water between the extruder and a die. Additionally, the extrudate may be cooked with high water absorption, increasing water absorption from approximately 40% to approximately 80%.