Meat Substitute Texture via Vegetable Protein Extrusion

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Solution Overview

Problem

The existing food industry faces challenges in developing meat substitutes that mimic the texture, flavor, appearance, and nutritional characteristics of meat, while also ensuring a long shelf-life and affordability, particularly in developing countries where protein-rich food is scarce and difficult to acquire.

Innovation Solution

A process involving the preparation of a dough using hydrated vegetable protein mixed with meat, followed by extrusion and frying/cooking, which includes the addition of preservatives to extend shelf-life and achieve a meat-like texture and flavor, with the ability to form various meat-like products such as ground meat, sirloin tips, and beef strips.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If meat substitutes are made with vegetable protein to reduce cost and improve nutrition, then affordability and nutritional value are improved, but texture, flavor, appearance, and odor characteristics deteriorate

Engineering Contradiction:

Improveprotein contentVSAvoidtexture and flavor characteristics

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent combines vegetable protein with animal fat and other ingredients to create a composite material that mimics the sensory characteristics of meat. The formulation includes vegetable protein, animal fat, water, and seasonings in specific proportions to achieve both nutritional goals and sensory similarity to natural meat.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies physical and chemical parameters during processing, including hydration levels, extrusion temperature and pressure, and frying conditions. These parameter changes transform the vegetable protein matrix to develop meat-like texture, color, and flavor characteristics while maintaining nutritional benefits.

Inventive Principle:

Principle #35Parameter changes

2Stability of the object's composition

If meat products are prepared without preservatives to maintain natural characteristics, then natural flavor and composition are preserved, but shelf-life deteriorates

Engineering Contradiction:

Improvenatural compositionVSAvoidshelf-life

Core Design Contradiction:

Stability of the object's compositionVSDuration of action of stationary object

Solution Approach 1:

The patent uses minimal amounts of preservatives at controlled levels to extend shelf-life without significantly altering the natural characteristics of the product. The preservative system is designed to provide adequate protection while maintaining the natural flavor and composition as much as possible.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If meat substitutes are developed to appeal to health-conscious consumers, then dietary benefits are improved, but market acceptance by general consumers deteriorates

Engineering Contradiction:

Improvedietary benefitsVSAvoidmarket acceptance

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent creates different product formulations tailored to specific market segments while maintaining core nutritional benefits. Different protein sources, fat contents, and flavor profiles are used to create variants that appeal to both health-conscious consumers and general consumers, allowing the product to adapt to different market needs.

Inventive Principle:

Principle #3Local quality

4Manufacturing precision

If complex processing steps are used to achieve meat-like texture and flavor, then sensory characteristics are improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvetexture and flavor similarityVSAvoidprocessing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts and isolates key functional components from natural meat (such as fat content and protein structure) and replicates them using vegetable-based ingredients. This allows the achievement of meat-like sensory characteristics through targeted ingredient selection and processing rather than complex multi-step procedures.

Inventive Principle:

Principle #2Taking out (Extraction)

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 substitute products with sensory characteristics similar to natural meat, longer shelf-life, and improved nutritional value, making them a competitive alternative that is affordable and accessible to a broader population, while being free from pathogens.

Implementation Method 1

preparing an initial dough where the source of vegetable protein, which may be hydrated

Methodology Applied

Scientific EffectHydration: Absorption (physical)

Implementation Method 2

which is extruded and then fried/cooked to subsequently give it the relevant form

Methodology Applied

Scientific EffectExtrusion: Extrusion

Implementation Method 3

which is extruded and then fried/cooked to subsequently give it the relevant form

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS8293316B2Method for the preparation of meat and vegetable protein based substitute food products

Publication Date: 2012.10.23 SIGMA ALIMENTOS S A DE

AI summary

The methodology shown in this invention is suitable for the preparation of meat substitute food products of animal origin (e.g., beef, pork, poultry, deer, or fish), with nutritional characteristics, texture, flavor, and odor very similar to the meat subject matter of the substitution, containing at least one of the following meats: beef, pork, poultry, or fish, or a combination thereof, and added with vegetable protein.