Plant-Based Cold Cuts with Low-Acylated Gellan for Meat-Like Texture
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Solution Overview
Problem
Existing plant-based cold cuts do not adequately replicate the texture and bite of their meat counterparts, lacking the necessary consistency and similarity in taste and appearance.
Innovation Solution
A production process using low-acylated gellan, plant proteins, and optional additives like sodium citrate, agar, and flavorings, where the mixture is heated to at least 90°C and poured into molds to solidify, creating a firm and sliceable product.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If plant-based cold cuts are made using conventional gelling agents and plant proteins, then the product can be produced without animal ingredients, but the texture and bite do not adequately replicate meat counterparts
Solution Approach 1:
The patent applies parameter changes by using low-acylated gellan instead of conventional gelling agents, and by controlling the heating temperature to at least 90°C. These parameter changes in the gelling agent type and processing temperature enable the plant-based cold cuts to achieve high firmness and wafer-thin sliceability while maintaining juiciness, thereby replicating the texture and bite of meat counterparts.
Solution Approach 2:
The patent employs composite materials by combining low-acylated gellan with plant proteins and optional additives such as sodium citrate, agar, and flavorings. This composite formulation creates a production mass that solidifies into a firm, sliceable product with meat-like texture characteristics, resolving the contradiction between plant-based composition and meat-like sensory properties.
2Manufacturing precision
If the product is made with high firmness to allow wafer-thin slicing, then sliceability is improved, but the product may lose juiciness
Solution Approach 1:
The patent resolves this contradiction through parameter changes in the gelling agent selection (low-acylated gellan) and processing temperature (at least 90°C). These parameters enable the formation of a firm gel structure that supports wafer-thin slicing while the specific properties of low-acylated gellan maintain product juiciness, preventing the typical trade-off between firmness and moisture retention.
3Ease of manufacture
If conventional gelling agents are used in plant-based meat substitutes, then the product can be formed, but the texture similarity to meat is insufficient
Solution Approach 1:
The patent applies parameter changes by substituting conventional gelling agents with low-acylated gellan and adjusting the heating temperature to at least 90°C. These changes transform the product properties to achieve both ease of formation and high texture similarity to meat, enabling wafer-thin slicing and maintaining juiciness simultaneously.
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 produces plant-based cold cuts with high firmness, allowing wafer-thin slices and maintaining juiciness, replicating textures of various meat types like cooked ham and cured ham.
Implementation Method 1
a production mass comprising low-acylated gellan in the range of 0.5-4 wt.%, water and a plant base in the range of 3-30 wt.% and/or agar is heated to a minimum of 90°C
Implementation Method 2
the production mass is cooled in the molds so that the gellan solidifies in the optionally open or closed molds
Implementation Method 3
the production mass is cooled in the molds so that the gellan solidifies in the optionally open or closed molds
Data Source
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AI summary
What are proposed are plant-based imitation cold cuts, and a production process for plant-based imitation cold cuts. The plant-based imitation cold cuts contain plant protein in the range of 3-30% by weight, gellan, flavouring, colouring and water, where the gellan is a low-acylated gellan of at least 0.5-4% by weight and the low-acylated gellan (111) has a molecular weight of 200-300 kDa and essentially no side chains composed of acetate groups and/or glycerate groups. Optionally, the imitation cold cuts may comprise a complexing agent, for example sodium citrate, for example within a range of 0.1-0.5% by weight. The plant protein may consist of textured plant protein within a range of 3-30% by weight and one or more further non-textured, e.g. pulverulent, protein concentrates in the range of 0-15% by weight. In order to produce the imitation cold cut, the low-acylated gellan is boiled with sodium citrate and/or textured plant protein and/or agar to at least 90-95°C, then the further ingredients (colours, flavourings, salt, a further plant protein source, acids) are added, and the production mixture is poured into moulds. Lastly, the production mixtures are cooled in the moulds, such that the gellan solidifies in the moulds.