Extruded Plant-Based Food Process for Fibrous Texture and Juiciness
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Solution Overview
Problem
Conventional extruded plant-based food products often compromise on taste, texture, and nutritional balance, particularly when increasing protein content, leading to unappealing chalky and bland flavors and loss of desirable texture, while also being low in dietary fiber and high in fat, contributing to health issues like obesity and chronic diseases.
Innovation Solution
A process involving extrusion and injection technology, where a composition of 40-70wt% water and 15-35wt% plant protein is fed into an extruder barrel, extruded above the denaturation temperature, and then subjected to a constriction followed by cooling and injection of an aqueous solution, which enhances the fibrous appearance, juiciness, and tenderness of the product, while maintaining a reduced flavor profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the protein content is increased to improve nutritional value, then the protein level increases, but the product texture becomes chalky and bland
Solution Approach 1:
The patent applies parameter changes by controlling the moisture content (40-70wt%) and protein content (15-35wt%) within specific ranges, and by controlling the extrusion temperature above the denaturation temperature of plant protein. These parameter optimizations allow high protein content to be achieved while maintaining desirable texture properties, resolving the contradiction between nutritional value and sensory quality.
2Ease of manufacture
If conventional extrusion process is used to simplify manufacturing, then the process is simple, but the product lacks fibrous appearance and juiciness
Solution Approach 1:
The patent segments the extrusion process into distinct stages: feeding the composition into the extruder barrel, extruding above denaturation temperature, passing through a constriction, cooling through a cooling die, and injecting aqueous solution. This segmentation allows each stage to be optimized for its specific function, achieving fibrous appearance and juiciness while maintaining overall process simplicity through modular design.
3Stability of the object's composition
If heat treatment is applied during extrusion to improve protein denaturation, then protein structure is improved, but heat-sensitive ingredients like vitamins and minerals are degraded
Solution Approach 1:
The patent applies preliminary action by injecting the aqueous solution containing heat-sensitive ingredients (vitamins, minerals, colorants, flavors) after the extrusion and cooling steps are complete. This timing ensures that these sensitive ingredients are added before any further heat treatment, preserving their nutritional value and functional properties while still achieving proper protein denaturation during the extrusion phase.
4Quantity of substance
If starch is reduced to improve health profile, then dietary fiber content improves, but product juiciness and tenderness deteriorate
Solution Approach 1:
The patent uses the injected aqueous solution as an intermediary to compensate for reduced starch. The aqueous solution, which can contain water, oils, flavors, colors, and other ingredients, is injected into the extruded product to provide the necessary juiciness and tenderness that would otherwise be supplied by starch. This allows the formulation to be low in starch while maintaining desirable sensory properties.
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 process allows for the production of extruded plant-based food products with a high protein content, fibrous appearance, and improved juiciness and tenderness, while preserving flavor and nutritional balance, using a reduced amount of flavors and starch, and enabling the incorporation of heat-sensitive ingredients like vitamins and minerals.
Implementation Method 1
extruding the composition from step a) in extruder barrels above the denaturation temperature of the plant protein
Implementation Method 2
cooling the composition from step c) through a cooling die
Data Source
AI summary
The invention generally relates to a process for preparing an extruded plant-based food product. More specifically the invention relates to a process for preparing an extruded plant-based food product with a fibrous appearance and good juiciness and tenderness properties.