Structured Plant Protein Extrusion for Meat-Like Texture
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Solution Overview
Problem
Existing food products, particularly imitation meat and fish products, face challenges in replicating the natural textural properties of original substances, leading to difficulties in mimicking the sensory perceptions of taste, odor, and color, which affects consumer acceptance.
Innovation Solution
A process involving extrusion of plant protein materials under elevated temperature and pressure to form structured protein products with substantially aligned protein fibers, mimicking the texture and eating quality of animal meat, using a die assembly to create a restructured meat composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If plant protein materials are extruded under elevated temperature and pressure to form structured protein products, then the texture and consistency of the product is improved to resemble cooked muscle meat, but the process complexity and equipment requirements increase
Solution Approach 1:
The patent applies parameter changes by controlling temperature and pressure during extrusion to transform plant protein materials into structured protein products with meat-like texture. The specific parameters (temperature range, pressure level, extrusion speed) are optimized to achieve the desired structural transformation without requiring overly complex equipment.
Solution Approach 2:
The patent replaces traditional mechanical mixing and chopping methods with an extrusion process that uses thermal and pressure fields to achieve structuring. This substitution reduces mechanical complexity while achieving more uniform and natural-looking protein fiber alignment.
2Ease of operation
If protein fibers are aligned through extrusion to mimic animal meat structure, then the sensory perception of taste and mouth feel is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The extrusion process enables the protein material to self-structure and self-align fibers during the extrusion itself, rather than requiring post-processing alignment operations. The material's own properties and the extrusion forces work together to achieve the desired fiber alignment, reducing manufacturing precision requirements.
Solution Approach 2:
The patent utilizes phase transitions of protein materials during extrusion (from semi-solid to molten state and back to structured solid) to achieve fiber alignment. This phase change mechanism provides natural structuring that is less dependent on precise mechanical control compared to purely mechanical alignment methods.
3Reliability
If unstructured protein products are converted to structured products with definite shape, then the product quality and consumer acceptance are improved, but the processing time and energy consumption increase
Solution Approach 1:
The patent applies preliminary action by pre-cooking or pre-denaturing the protein material before extrusion, which prepares the protein structure for more efficient structuring during extrusion. This reduces the total energy required compared to heating and structuring in a single step, while still achieving high product quality.
Solution Approach 2:
The extrusion process maintains continuous heating and pressure application throughout the material's passage through the die, ensuring consistent and efficient energy utilization. This continuous action avoids the energy waste associated with repeated heating cycles while maintaining high structural quality.
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 a restructured meat composition with aligned protein fibers that replicates the texture and consistency of cooked muscle meat, enhancing the sensory experience and consumer acceptance by improving the structural attributes of the product.
Implementation Method 1
extruding a plant protein material under conditions of elevated temperature and pressure
Implementation Method 2
extruding a plant protein material under conditions of elevated temperature and pressure
Implementation Method 3
extruding a plant protein material under conditions of elevated temperature and pressure through a die assembly to form a structured plant protein product having protein fibers that are substantially aligned
Data Source
AI summary
The invention provides protein compositions containing structured protein products having protein fibers that are substantially aligned.