Two-Stage Heating for Uniform Meat Analogue Production
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Solution Overview
Problem
Existing processes for producing meat analogues fail to provide sufficient uniformity and palatability, and expose meat batter to very high temperatures, leading to instability and suboptimal quality.
Innovation Solution
A two-stage heating process using scraped surface heat exchangers, where meat batter is heated above protein denaturation but below melting point in the first stage, then above melting point in the second stage, followed by cooling and division into pieces, to produce stable and palatable meat analogues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If meat batter is exposed to very high temperatures in conventional heating processes, then the meat analogue is cooked and set, but the product stability deteriorates and palatability decreases
Solution Approach 1:
The heating process is divided into two distinct stages: a first heating stage and a second heating stage, each with different temperature ranges and durations. This segmentation allows controlled protein denaturation followed by controlled melting and restructuring, improving product stability while achieving proper cooking
Solution Approach 2:
The process changes temperature parameters dynamically through two stages: first heating to a temperature that denatures proteins but remains below melting point, then second heating above melting point for controlled melting. This parameter change approach prevents excessive temperature exposure that would harm stability
2Device complexity
If conventional one-step heating is used to cook meat emulsion, then the process is simple, but the uniformity and palatability of the meat analogue are insufficient
Solution Approach 1:
The single heating operation is segmented into two sequential heating stages with distinct temperature profiles. The first stage denatures proteins at controlled temperature, while the second stage melts and restructures the protein matrix. This segmentation achieves superior uniformity and palatability compared to one-step heating
Solution Approach 2:
The first heating stage performs preliminary protein denaturation before the second heating stage. This preliminary action prepares the protein structure for subsequent melting and restructuring, ensuring uniform texture and improved palatability in the final product
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 improved uniformity and palatability, reducing exposure to high temperatures and enhancing product stability compared to conventional methods.
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 to produce a first heat-treated product
Implementation Method 2
heating the meat batter to a temperature above the denaturation temperature of the protein
Implementation Method 3
heating the first heat-treated product to a temperature above the melting temperature of the protein
Implementation Method 4
cooling the second heat-treated product to a temperature below water boiling temperature at ambient pressure when exiting the cooling unit
Data Source
AI summary
Processes for the production of a meat analogue, comprising: a) introducing a meat batter which comprises protein into a first heating unit and 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 to produce a first heat-treated product, and b) transferring 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, c) 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 at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces; as well as an apparatus for the production of a meat analogue.