Heat Stable Extruded Protein Composition for Thermal Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing extruded protein products made from animal and non-animal sources lack the ability to maintain texture and structure during thermal processing, limiting their use in commercially available products.
Innovation Solution
A thermally processed protein composition with a protein content of 65% to 90% by dry weight, featuring protein fibers oriented in a generally parallel orientation, hardness greater than 3 kg, chewiness greater than 10 kg*mm, and springiness of at least 0.90, which can be commercially sterile or pasteurized, and packaged in hermetically sealed containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extruded protein products are subjected to thermal processing to achieve commercial sterility or pasteurization, then consumer safety and shelf stability are improved, but the texture and structure of the product deteriorate
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the protein matrix through controlled thermal processing parameters (temperature, time, atmosphere) to achieve commercial sterility while preserving the fibrous texture. The extrusion process parameters are also optimized to create a protein structure that is inherently more resistant to thermal degradation.
Solution Approach 2:
The patent uses composite materials by combining protein sources with specific functional ingredients and additives that enhance thermal stability. The composite protein matrix is designed to maintain structural integrity during thermal processing while achieving the desired safety and shelf stability.
2Reliability
If extruded protein products are subjected to thermal processing, then commercial sterility is achieved, but the meat-like texture is lost
Solution Approach 1:
The patent applies preliminary action by pre-forming the protein fibers through extrusion to create the desired meat-like texture before thermal processing. The extrusion process aligns protein molecules into fibrous structures that are then protected during subsequent thermal treatment to maintain the texture through the product's shelf life.
Solution Approach 2:
The patent utilizes parameter changes by controlling the thermal processing conditions (temperature, time, heating rate) to selectively achieve microbial destruction while minimizing damage to the protein fiber structure. The extrusion parameters are also adjusted to create a matrix that undergoes minimal structural change during thermal processing.
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 thermally processed protein composition retains a meat-like texture and structure, making it suitable for various food products, including soups and shredded forms, while ensuring commercial sterility and consumer safety.
Implementation Method 1
heating the stream to a temperature of from about 240° F. to about 330° F.
Implementation Method 2
applying to a heat stable extruded protein composition heat in an amount sufficient to render the heat stable extruded protein composition pasteurized or commercially sterile
Implementation Method 3
applying to a heat stable extruded protein composition heat in an amount sufficient to render the heat stable extruded protein composition pasteurized or commercially sterile
Data Source
AI summary
The present disclosure relates to extruded protein compositions suitable for thermal processing and thermally processed protein compositions made from extruded protein compositions. In particular, a thermally processed protein composition has a particular protein content with protein fibers in a generally parallel orientation, and a particular hardness, chewiness and springiness.