Plant-Based Meat Structure Using Hierarchical ECM Binding
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Solution Overview
Problem
Current methods for creating plant-based meats struggle to replicate the complex structure and texture of animal meat, particularly in producing long and thin muscle-like fibers that mimic whole-cuts, while being energy inefficient and costly.
Innovation Solution
The use of plant-based extra-cellular matrix (ECM) types, such as endomysium, perimysium, and epimysium, to bind and structure plant-based muscle fibers into fascicles and muscles, allowing for precise control over mechanical and functional properties, achieved through low-viscosity liquid application and delayed gelation at room temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If macro top-down approaches (HME, SCT, FS) are used to produce plant-based meat, then meat texture can be recreated, but the ability to create long and thin muscle-like fibers is limited and energy consumption is high
Solution Approach 1:
The invention segments the meat production process into hierarchical levels: whole-cuts are divided into muscles, muscles into fascicles, and fascicles into individual muscle fibers. Each level is structured separately and then assembled, enabling precise control over fiber dimensions (10 cm long and sub-100 micron thin) while reducing energy consumption by avoiding high-temperature or low-temperature processing of bulk plant proteins.
Solution Approach 2:
The invention transitions from macro-scale bulk processing to micro-scale fiber construction by creating individual muscle-like fibers that are then assembled into fascicles and whole-cuts. This dimensional shift enables the creation of long, thin fibers with precise structural control while eliminating the need for energy-intensive heat treatment or freezing of large protein masses.
2Shape
If electro-spinning is used to create muscle fiber like structures, then fiber structure can be achieved, but throughput is too low to be economical
Solution Approach 1:
The invention uses self-assembly mechanisms where plant protein solutions spontaneously form muscle fiber-like structures through controlled phase separation and self-organization processes. This eliminates the need for energy-intensive electro-spinning equipment while maintaining fiber structure integrity and achieving high throughput through scalable solution-based processing.
3Shape
If wet spinning is used to create muscle fiber like structures, then fiber structure can be achieved, but considerable waste is generated and scaling is difficult
Solution Approach 1:
The invention optimizes solution parameters including protein concentration, pH, ionic strength, and temperature to enable spontaneous fiber formation without requiring acid/alkaline baths. This parameter optimization eliminates considerable waste generation while maintaining muscle fiber structure and enables easy scaling through conventional solution processing techniques.
4Shape
If 3D printing is used to create plant-based meat structure, then structure can be deposited, but it is not well suited to create long and thin muscle-like fibers with sufficient strength and length
Solution Approach 1:
The invention performs preliminary action by pre-forming individual muscle fiber structures through self-assembly before assembling them into fascicles and whole-cuts. This preliminary structuring enables the creation of long, thin fibers with sufficient strength and length that can then be systematically arranged into complex meat architectures, overcoming the limitations of direct 3D printing approaches.
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
This approach results in plant-based meats with unmatched texture, appearance, and mouthfeel that closely mimic natural meat, improving consumer appeal and reducing energy consumption and production costs.
Implementation Method 1
delayed gelation at room temperature
Data Source
AI summary
Whole-cut imitators are disclosed mimicking animal muscles that have a basic structure that is common to most if not all animal species that are consumed for meat. The animal muscle mimics are made from plant proteins and other components that comprise whole-cuts that are in turn comprised of muscle fascicles, which in turn are made of plant-based muscle fibers. The muscles, fascicles and plant-based muscle fibers are bound together by extra-cellular matrix, (ECM), of which there are three kinds, a first ECM that binds plant-based muscle fibers together that is called the endomysium, a second ECM that coats and binds fascicles that is called the perimysium, and a third ECM that coats and binds muscles together that is called the epimysium.