Flaked Fish Analogs With Controlled Emulsion Structure
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Solution Overview
Problem
Existing methods for producing fish analogs fail to achieve a realistic fish-like appearance and texture, resulting in products that do not adequately mimic real fish.
Innovation Solution
Creating flaked fish analogs with a specific composition of 18-25% protein, 3-9% fat, and 60-85% moisture, achieved by forming a homogeneous dough mixture of proteins, fats, and water, then emulsifying and cooling it under controlled temperature and pressure conditions, and optionally adding fish skin to mimic the appearance of real fish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion-expansion techniques or meat emulsion processing are used to produce analogs, then the products have a uniform homogeneous mass or layered structure, but they lack the flaked appearance and texture characteristic of real fish
Solution Approach 1:
The patent applies parameter changes by carefully controlling temperature, pressure, and composition ratios during the emulsion process. Specifically, the protein content is maintained at 10-20%, fat at 5-15%, and moisture at 60-80%, with temperature controlled at 4-10°C during mixing and -10 to 10°C during freezing. These precise parameter controls enable the formation of flaked structure without requiring complex equipment modifications.
Solution Approach 2:
The patent uses composite materials by combining multiple protein sources (fish protein 30-70%, plant protein 30-70%), various fats (fish oil, vegetable oils), and functional ingredients (starches, gums, emulsifiers) to create an analog that replicates the complex structure of real fish. This composite approach allows achievement of flaked appearance through composition rather than complex processing.
2Manufacturing precision
If fibrous plant protein is used to create texture in fish analogs, then the product has structure, but the fibrous texture is not characteristic of fish and fails to mimic real fish meat
Solution Approach 1:
The patent extracts the fibrous component from the formulation by eliminating traditional textured vegetable protein ingredients. Instead, it relies on the natural protein matrix formed from fish and plant proteins combined with fats and moisture, which spontaneously forms flaked structure during controlled freezing without requiring fibrous additives.
Solution Approach 2:
The patent changes the physical parameters of the emulsion system by controlling temperature progression (mixing at 4-10°C, freezing at -10 to 10°C) and composition ratios (protein 10-20%, fat 5-15%, moisture 60-80%). These parameter changes enable the formation of non-fibrous flaked structure that accurately resembles real fish texture.
3Manufacturing precision
If meat emulsion is processed to produce layered chunks, then the product has meat-like appearance, but it cannot provide acceptable appearance and texture that mimics real fish
Solution Approach 1:
The patent inverts the traditional approach by not trying to create fish-like structure from meat-emulsion processing, but rather forming a fish-like emulsion system from the beginning using a combination of fish and plant proteins with specific fat and moisture content. The flaked structure emerges naturally from this inverted formulation approach during controlled freezing, avoiding complex meat-emulsion processing steps.
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
The resulting flaked fish analogs have a realistic fish-like appearance and texture, distinct from fibrous meat analogs, and can be packaged to showcase their appearance, providing a suitable substitute for real fish in food products.
Implementation Method 1
emulsifying and cooling it under controlled temperature and pressure conditions
Implementation Method 2
emulsifying and cooling it under controlled temperature and pressure conditions
Data Source
AI summary
The invention provides flaked fish analogs comprising from about from about 18 to about 25% protein, from about 3 to about 9% fat, and from about 60 to about 85% moisture. The compositions have a realistic fish-like appearance and texture, mostly due to the presence of “flakes” that mimic the flakes of real fish.