Two-Stage Heating for Fibrous Meat Analogue Production
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Solution Overview
Problem
Existing processes for producing meat analogues fail to provide sufficient meat-like fibrous structure and uniformity, and the exposure to very high temperatures affects palatability.
Innovation Solution
A two-stage heating process involving a first heating unit to denature proteins below their melting point and a second heating unit to melt proteins, followed by cooling and dividing, using scraped surface heat exchangers to produce a stable meat analogue with improved uniformity and palatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-step heating process is used to heat meat emulsion to high temperature (140-180°C), then the cooking process is simplified and faster, but the meat-like fibrous structure is insufficient and palatability deteriorates
Solution Approach 1:
The heating process is divided into two distinct stages: a first heating unit that heats to below the melting point of proteins (denaturation stage), and a second heating unit that heats above the melting point (melting stage). This segmentation allows each stage to perform its specific function optimally, preventing the formation of excessive hard aggregates while still achieving the desired fibrous structure and palatability.
2Reliability
If exposure to very high temperatures is increased to ensure thorough cooking, then food safety is improved, but palatability and sensory attributes deteriorate
Solution Approach 1:
The process controls the temperature parameters precisely through two stages: first heating below the melting point (denaturation temperature) and then heating above the melting point for a limited time. This parameter control ensures thorough cooking for safety while minimizing excessive heat exposure that would damage sensory attributes and palatability.
3Loss of time
If heating temperature is increased to accelerate protein denaturation and melting, then processing time is reduced, but uniformity of the meat analogue product deteriorates
Solution Approach 1:
The heating process is divided into two distinct stages: a first heating unit that heats to below the melting point of proteins (denaturation stage), and a second heating unit that heats above the melting point (melting stage). This segmentation allows each stage to perform its specific function optimally, ensuring uniform denaturation followed by uniform melting, which produces consistent fibrous structure throughout the product.
Solution Approach 2:
The process controls the temperature parameters precisely through two stages: first heating below the melting point (denaturation temperature) and then heating above the melting point for a limited time. This parameter control ensures thorough cooking for safety while minimizing excessive heat exposure that would damage sensory attributes and palatability.
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 analogues with enhanced uniformity and palatability, reducing exposure to high temperatures and improving the sensory attributes of the final product.
Implementation Method 1
heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter but below the melting point of the protein
Implementation Method 2
heating the first heat-treated product to a temperature above the melting temperature of the protein
Implementation Method 3
cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature
Data Source
AI summary
The present invention relates to an apparatus for the production of a meat analogue that can introduce meat batter which comprises protein into a first heating unit and heat the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, transfer the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, cool the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and divide the cooled second heat-treated product into pieces.