Two-Stage Meat Analogue Heating for Fibrous Uniformity
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Solution Overview
Problem
Existing processes for producing meat analogues fail to provide sufficient meat-like fibrous structure and uniformity, and the exposure to very high temperatures compromises palatability.
Innovation Solution
A two-stage heating process involving a first heating unit to denature proteins below their melting point and a second heating unit to melt them, followed by cooling and division, using scraped surface heat exchangers to produce a stable meat analogue with improved uniformity and palatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If heating is performed in a one-step operation to achieve high temperature (180-154°C), then the meat emulsion is efficiently cooked, but the meat analogue lacks sufficient fibrous structure and uniformity
Solution Approach 1:
The heating process is divided into two distinct stages: a first heating stage to denature proteins and a second heating stage to melt proteins and form fibrous structure. This segmentation allows each stage to optimize for its specific function, preventing the trade-off between heating efficiency and structural uniformity.
Solution Approach 2:
The first heating stage performs preliminary protein denaturation before the second heating stage. This preliminary action prepares the protein structure for subsequent melting and fibrous formation, ensuring uniformity is achieved before final cooking.
2Loss of time
If meat batter is exposed to very high temperatures, then cooking is achieved quickly, but palatability is compromised
Solution Approach 1:
The process uses controlled temperature parameter changes through two distinct heating stages with different temperature profiles. The first stage operates at moderate temperatures for denaturation, while the second stage reaches higher temperatures for melting, optimizing both cooking efficiency and palatability preservation.
3Device complexity
If a single heating unit is used, then the process is simple, but uniform heat distribution and protein treatment are difficult to achieve
Solution Approach 1:
The heating system is segmented into two separate heating units, each optimized for a specific protein transformation stage. This physical segmentation enables independent control of heating parameters for denaturation and melting, achieving uniform protein treatment that cannot be obtained with a single unit.
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 process results in meat analogues with enhanced palatability and uniformity by reducing exposure to high temperatures and forming a fibrous structure, suitable for pet and human foods.
Implementation Method 1
heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter but below the melting point of the protein to produce a first heat-treated product
Implementation Method 2
heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product
Implementation Method 3
cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit
Data Source
AI summary
Processes for the production of a meat analogue, comprising: a) introducing a meat batter which comprises protein into a first heating unit and heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, and b) transferring the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, c) cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces; as well as an apparatus for the production of a meat analogue.