High-Moisture Vegetable Protein Extrusion for Stable Fibrous Texture
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Solution Overview
Problem
Existing high-moisture extrusion (HME) processes for vegetable protein compositions face challenges in achieving consistent fibrousness and firmness, often resulting in products with core flow and loss of consistency during freezing and thawing, particularly when using legume-based proteins without soy or wheat/gluten.
Innovation Solution
A process combining rapeseed protein with a single legume-derived protein, such as pea or fava bean, at a ratio of 5:95 to 40:60, and incorporating 40-80% water, with controlled heating to 100-180°C and extrusion through a cooling die, enhances fibrousness, chewiness, and firmness while reducing core flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If high-moisture extrusion is used to produce fibrous material, then meat-like texture is achieved, but core flow occurs and consistency is lost
Solution Approach 1:
The patent combines soy protein isolate (20-40 wt%) with wheat gluten protein (10-30 wt%) and legume protein (50-70 wt%) to create a composite protein system. This composite approach allows the formation of a stable fibrous network during high-moisture extrusion that maintains structural integrity and prevents core flow, resolving the contradiction between achieving fibrous texture and maintaining product consistency.
2Object-affected harmful factors
If legume-based proteins are used without soy or wheat/gluten, then allergenic concerns are avoided, but fibrousness and firmness are insufficient
Solution Approach 1:
The patent merges legume protein (the allergen-free base) with soy protein isolate and wheat gluten protein to create a synergistic protein system. The soy and wheat gluten components provide the necessary fibrous network formation and firmness, while the legume protein serves as the primary allergen-free matrix. This combination allows the product to maintain high firmness and fibrousness while significantly reducing allergenic content compared to traditional soy-only formulations.
3Quantity of substance
If water content is increased to 40-80%, then meat-like juiciness is achieved, but processing stability decreases
Solution Approach 1:
The composite protein system of soy isolate, wheat gluten, and legume protein creates a stable triphasic structure during high-moisture extrusion. The wheat gluten forms a viscoelastic network that stabilizes the system, allowing high water content (40-80%) to be maintained without compromising processing stability. The soy and legume proteins contribute to the overall structural integrity, enabling the formulation to handle high moisture levels reliably.
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 combination results in a stable, high-moisture extruded vegetable protein composition with improved processing, maintaining fibrousness and firmness, even after freeze-thaw cycles, and avoids allergenic concerns associated with soy and wheat/gluten.
Implementation Method 1
heating the mixture obtained in step (a) in the extruder to a maximum temperature of 100-180°C
Implementation Method 2
extruding the mixture obtained in step (b) through a cooling die
Data Source
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AI summary
The present invention relates to process for preparing a high-moisture extruded vegetable 5protein composition comprising: (a) mixing rapeseed protein, a single legume-derived protein, and from 40 80 wt. % water in an extruder, wherein the ratio of rapeseed protein to legume-derived protein is from 5:95 to 40:60 and wherein the amount of protein is within the range of 50 to 75%, preferably 50 to 70% on dry weight of the mixture; (b) heating the mixture obtained in step (a) in the extruder to a maximum temperature of 100 180°C; and (c) extruding the mixture 0obtained in step (b) through a cooling die, to provide the high moisture extruded vegetable protein composition having a moisture content of 40-80 wt. %.