Plant-Based Meat Analogue Grainy Texture via Rate Differential
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Solution Overview
Problem
Current plant-based meat alternatives fail to closely mimic the visual appearance, taste, and texture of sliced deli meat, whole cut meat, and steak, which are essential for consumer acceptance.
Innovation Solution
A method involving the extrusion of a plant-based meat analogue using a composition that includes a textured vegetable protein mixture, a soy protein emulsion system, and a non-emulsified soy protein isolate, processed through a heating and transport system with a specific rate differential to achieve a grainy texture resembling sliced deli meat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional plant-based meat alternatives are produced using standard extrusion methods, then production efficiency is maintained, but the visual appearance, texture, and taste do not closely resemble sliced deli meat
Solution Approach 1:
The patent applies parameter changes by precisely controlling the feed rate and transport rate differential, heating temperature profile, and emulsion composition ratios to achieve the desired grainy texture and visual appearance resembling sliced deli meat while maintaining production efficiency
Solution Approach 2:
The patent uses composite materials by combining textured vegetable protein mixture with a soy protein emulsion system containing multiple components (emulsified soy protein isolate, non-emulsified soy protein isolate, water, and oil) to create a complex formulation that achieves meat-like properties
2Manufacturing precision
If the transport rate is increased relative to the feed rate to achieve grainy texture, then visual appearance resembling sliced deli meat is improved, but the processing complexity increases
Solution Approach 1:
The patent applies dynamics by implementing a dynamic rate differential between feed rate and transport rate, where the transport rate is intentionally set higher than the feed rate to create controlled material movement and shear conditions that produce the grainy texture characteristic of sliced deli meat
3Manufacturing precision
If a complex emulsion system with multiple protein components is used to achieve meat-like texture, then taste and texture similarity is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the protein components into distinct functional groups: textured vegetable protein mixture for structure, emulsified soy protein isolate for binding, and non-emulsified soy protein isolate for texture development. Each component is prepared and hydrated separately before combination, allowing precise control of each ingredient's contribution to the final product
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 method successfully produces a plant-based meat analogue with a grainy texture and appearance that closely resembles sliced deli meat, addressing the gap in consumer expectations regarding taste, texture, and visual similarity.
Implementation Method 1
the temperature of the inner and the outer surfaces of the transport channel are both heated to about 85° C. to about 100° C.
Implementation Method 2
both the inner surface and the outer surface are heated to create a temperature gradient of the emulsion therebetween while being transported through the system
Implementation Method 3
the emulsion is transported through the heating and transport system using a single screw having a pitch of less than 8 mm
Data Source
AI summary
A sliced deli-style, meat-based plant proteins that mimics its meat-based counterpart are described herein are prepared through a composition and method that associate protein components in a manner that can be uniquely processed effective to produce a meat analogue from plant proteins that closely resembles sliced deli-style meats in appearance, taste, texture, and quality. When both the select compositional features and the select processing system parameters are combined, the resulting product achieves thin and elongated slices that have a grainy texture resembling, for instance, sliced roast beef or sliced turkey.