Meat Replacement Product Starch Solubility Control

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Solution Overview

Problem

Meat replacement products manufactured with high moisture protein texturization extrusion have an unacceptable mouthfeel that deteriorates quickly, failing to mimic the tenderness and compressibility of cooked chicken thigh meat, and struggle with starch solubility and texture retention during storage.

Innovation Solution

Incorporating a manufacturing method that uses a twin-screw extruder to create a continuous proteinaceous fibrous matrix structure with gelatinized starch, where at least 5.1% of the starch is soluble, located in disruptions of the matrix structure, and controlling starch solubility to maintain a desirable mouthfeel and texture for an extended period.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If high moisture protein texturization extrusion is used to manufacture meat replacement products, then the products resemble muscle food more closely, but the mouthfeel becomes unacceptable after a short time when the product cools

Engineering Contradiction:

Improvemuscle-like textureVSAvoidmouthfeel sustainability

Core Design Contradiction:

ShapeVSDuration of action of stationary object

Solution Approach 1:

The patent applies parameter changes by controlling starch solubility (at least 5.1% soluble starch) and moisture content (40-80% during extrusion) to prevent protein matrix hardening during cooling, thereby sustaining acceptable mouthfeel for extended periods while maintaining muscle-like texture

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite materials by combining protein fractions with starch-containing particles to create a mixed matrix structure where starch granules disrupt protein-protein interactions and prevent excessive firming during cooling, resolving the contradiction between muscle-like texture and mouthfeel sustainability

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If starch is incorporated into the protein matrix, then mouthfeel is improved, but starch solubility control becomes challenging affecting texture retention

Engineering Contradiction:

Improvemouthfeel qualityVSAvoidstarch solubility control

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The patent specifies precise parameter ranges: at least 5.1% soluble starch and 40-80% moisture content during extrusion, which optimizes both mouthfeel quality and texture retention by controlling the balance between starch solubility and protein matrix structure

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs feedback control by measuring and adjusting starch solubility and moisture content parameters during manufacturing to achieve the target range, ensuring consistent mouthfeel and texture retention across production batches

Inventive Principle:

Principle #23Feedback

3Duration of action of stationary object

If the product is sold deep frozen to maintain mouthfeel, then texture is preserved, but convenience and storage requirements increase

Engineering Contradiction:

Improvemouthfeel sustainabilityVSAvoidstorage convenience

Core Design Contradiction:

Duration of action of stationary objectVSEase of operation

Solution Approach 1:

The patent changes the critical parameter of starch solubility (at least 5.1%) and moisture content (40-80%) to stabilize the protein matrix structure at refrigerated temperatures, allowing the product to maintain acceptable mouthfeel for extended periods without freezing, thereby improving storage convenience

Inventive Principle:

Principle #35Parameter changes

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 results in a meat replacement product with improved mouthfeel and starch solubility, sustaining a texture comparable to cooked chicken thigh meat for up to 24 hours without the need for freezing, and prevents hardening by using washable starch clusters that act as disruptive compounds within the protein matrix.

Implementation Method 1

a twin-screw extruder to create a continuous proteinaceous fibrous matrix structure with gelatinized starch

Methodology Applied

Scientific EffectGelatinization:

Implementation Method 2

The extrusion enables controlling the functional properties such as density, rate and time of rehydration, shape, product appearance and mouthfeel

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS20220248713A1A meat replacement product, a method of manufacturing the same, the use of insoluble washable starch in food products, and a twin-screw extruder

Publication Date: 2022.08.11 VALIO OY

AI summary

A meat replacement product, a method of manufacturing the same, and the use of insoluble washable starch in food products to improve the mouthfeel of a meat replacement product. Improvements to meat replacement products and high moisture protein texturization extrusion are disclosed. By selecting the extrusion parameters and starting materials containing mechanically processed starch-containing grains suitably, the formation of an emulsion between the starch and proteinaceous matrix forming protein melt can be prevented or reduced to such an extent that there exists a substantial amount of starch that is not bound in the protein matrix. The presence of starch not bound in the protein matrix improves mouthfeel and sustains an acceptable mouthfeel for a prolonged period.