Plant-Based Meat Fibre Alignment via Texturization and Separation
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Solution Overview
Problem
Existing methods for producing plant-based meat alternatives struggle to replicate the taste, appearance, and texture of animal meat, particularly in creating whole cut meat analogues that match the experience of eating animal tissue.
Innovation Solution
A method involving high-temperature texturization of non-animal derived proteins to form fibrous muscle tissue analogues, followed by partial separation of fibers to improve texture and marinating, combined with the use of binders and fat analogues to enhance flavor and moisture retention, allowing for the creation of whole cut meat analogues with aligned or varied fiber orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If high-temperature texturisation is applied to form fibrous muscle tissue analogue, then fibre alignment and texture are improved, but fibre separation is insufficient to achieve meat-like texture
Solution Approach 1:
The patent applies segmentation by mechanically separating the fibrous muscle tissue analogue into individual or small bundles of fibres after texturisation. This is achieved through processes such as rolling, cutting, or pulling the fibres apart, which divides the initially unified fibrous structure into more discrete elements that better mimic the natural separation found in animal muscle tissue.
Solution Approach 2:
The patent employs partial separation of fibres rather than complete separation, maintaining some fibre bundling while creating sufficient separation to achieve meat-like texture. This partial action allows the product to retain the benefits of aligned fibres for structure while introducing enough separation for realistic texture and marinating properties.
2Strength
If fibres are tightly bound in fibrous structure, then structural integrity is maintained, but marinating efficiency and flavour penetration are reduced
Solution Approach 1:
By separating the fibres after texturisation, the patent increases the surface area and creates pathways for marinade penetration while maintaining structural integrity through controlled bundling. The fibres remain connected enough to hold together during cooking but are separated enough to allow flavour absorption.
Solution Approach 2:
The partial fibre separation creates a porous or semi-porous structure within the meat analogue that allows marinade to penetrate deeper into the product. This porous structure is achieved by creating voids and channels between the separated fibre bundles, enabling better flavour distribution throughout the product.
3Manufacturing precision
If complete fibre separation is achieved, then texture resembles animal meat, but product falls apart and loses structural integrity
Solution Approach 1:
The patent applies partial fibre separation rather than complete separation, achieving the optimal balance between texture realism and structural integrity. The fibres are separated enough to create meat-like texture and marinating properties but remain sufficiently connected to maintain product coherence during handling and cooking.
Solution Approach 2:
The patent combines separated fibres back into bundled structures through controlled aggregation, creating a hybrid structure that maintains both fibre separation for texture and fibre connection for strength. This merging process allows the product to exhibit meat-like characteristics while retaining structural integrity.
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 produces meat analogues with a texture and marinating efficiency similar to animal meat, enabling improved flavor penetration and retention, and the ability to mimic the appearance and taste of various animal meats.
Implementation Method 1
forming a fibrous muscle tissue analogue by high-temperature texturisation of a base material comprising a non-animal derived protein, the high-temperature texturisation configured to cause denaturing of the non-animal derived protein and formation of substantially parallel fibres
Implementation Method 2
forming a fibrous muscle tissue analogue by high-temperature texturisation comprises applying shear stresses to the base material
Implementation Method 3
partially separating at least some of the fibres of the fibrous muscle tissue analogue comprises compressing the fibrous muscle tissue analogue
Data Source
AI summary
The present application provides a method of producing a meat analogue, for example a meat analogue produced from a vegetable protein. The method comprises forming a fibrous muscle tissue analogue by high-temperature texturisation of a base material comprising a non-animal derived protein. The high-temperature texturisation is configured to cause denaturing of the non-animal derived protein and formation of substantially parallel fibres in the fibrous muscle tissue analogue. The method further includes partially separating at least some of the fibres of the fibrous muscle tissue analogue. Also disclosed is apparatus for producing a meat analogue, a meat analogue, and a method of producing a meat analogue by binding together two or more fibrous muscle tissue analogues.