PROCESS FOR MAKING A MEAT ANALOGUE PRODUCT

Abstract

The present invention relates to a process for making a meat analogue product, comprising hydrating a plant extract, preparing a binding agent by mixing dietary fibre and protein, mixing the plant extract and binding agent, and molding into a shape. A meat analogue product made by the process is also provided.

Claims

1. A process for making a meat analogue product, comprising a. Mixing 15 wt % to 35 wt % plant extract with water; b. Preparing a binding agent by mixing 0.1 wt % to 10% wt % dietary fibre and 0.3 wt % to 10 wt % plant protein; c. Mixing the hydrated plant extract and binding agent; and d. Molding into a shape; wherein the meat analogue product is substantially free of hydrocolloids, modified starches and emulsifiers, and wherein not less than 30 wt % of the dietary fibre is soluble.

2. A process for making a meat analogue product, wherein the dietary fibre is derived from potato.

3. A process for making a meat analogue according to claim 1, wherein 20 wt % to 30 wt % plant extract is mixed with water.

4. A process for making a meat analogue according to claim 1, wherein the plant extract is derived from legumes, cereals, and oilseeds.

5. A process for making a meat analogue according to claim 1, wherein the plant extract comprises a textured component selected from the group consisting of soy, pea, and sunflower.

6. A process for making a meat analogue according to claim 1, wherein the dietary fiber at 5 wt. % in aqueous solution at 20° C. exhibits the following viscoelastic properties 1) shear thinning behavior with zero shear rate viscosity above 8 Pa.Math.s and 2) G′ (storage modulus) greater than 65 Pa and G″ (loss modulus) lower than 25 Pa of at 1 Hz frequency.

7. A process for making a meat analogue according to claim 1, wherein about 0.5 wt % to about 4 wt % dietary fibre is mixed, and wherein not less than 30 wt % of the dietary fibre is soluble.

8. A process for making a meat analogue according to claim 1, wherein about 0.5 wt % to about 5 wt % plant protein is mixed.

9. A process for making a meat analogue according to claim 1, wherein the plant protein gels upon heating at a temperature at or above 50° C.

10. A process for making a meat analogue according to claim 1, wherein the plant protein is at least partially native.

11. A process for making a meat analogue according to claim 1, wherein the plant protein is potato protein.

12. A process for making a meat analogue according to claim 1, wherein the dietary fiber is comprised of potato fibre.

13. A process for making a meat analogue according to claim 1, wherein beetroot-based color is added.

14. A process for making a meat analogue according to claim 1, wherein a fat source and/or oil are added to the plant extract and binding agent mixture.

15. A meat analogue product obtainable by the process claim 1, wherein said product is a burger, sausage, minced meat or meatballs.

16. A meat analogue product comprising a. Plant extract; b. Flavoring; c. Fat; and d. Binding agent wherein the plant extract is selected from soy, pea, wheat and sunflower and wherein the binding agent comprises 0.1 wt % to 10 wt % dietary fibre and 0.3 wt % to 10 wt % plant protein, and wherein not less than 30 wt % of the dietary fibre is soluble.

17. A meat analogue product according to claim 16, wherein the binding agent comprises potato fibre and potato protein.

18. A meat analogue product according to claim 16, wherein the binding agent is substantially free of hydrocolloids.

19-20. (canceled)

Description

BRIEF DESCRIPTION OF FIGURES

[0131] FIG. 1. Apparent viscosity (Pa.Math.s) of potato fibre water dispersions as a function of shear rate (s.sup.−1) at a range concentrations, at 20° C.

[0132] FIG. 2. Strain sweeps for 5 wt % potato fibre water dispersions, measured at constant Frequency of 1 Hz, at 20° C.

[0133] FIG. 3. Mechanical spectra of potato protein gel (PP1) and ovalbumin (OA) gel obtained after heating protein dispersion at 3 wt % and 4 wt % at 85° C. for 15 min in presence of NaCl 0.1M. Filled symbols correspond to elastic modulus G′ and empty symbols to storage modulus G″.

[0134] Key: dark squares—PP1 (4 wt %); light squares—OA (4 wt %); light triangles—PP1 (3 wt %); and dark triangles—OA (3 wt %).

[0135] FIG. 4. G′ as function of temperature for 6%, 14% potato protein solutions

[0136] FIG. 5. Minimal gelling concentration determination of potato protein isolate at pH 7, heated 30′ at 70° C., Minimal gelling concentration is indicated by gray number. The value considered as the minimal gelling concentration is the concentration where the sample stayed at the bottom of the vial (i.e. did not slide down), when they were turned upside down.

[0137] 2% potato protein dispersions heated 30′ at 70° C. at pH 7 or 4, alone or in the in the presence of various concentrations of NaCl (indicated below the picture). Gels are indicated by the grey number. Gel is considered where vial the sample stayed at the bottom of the vial (i.e. did not slide down), when they were turned upside down.

[0138] FIG. 6. DSC thermogram of two potato protein isolates (PP1 and PP2)

[0139] FIG. 7. Cooked burger patties made with texturized pea protein containing 2% wt methylcellulose or 1% wt potato fiber combined with 0.5, 0.75 and 1% wt potato protein.

[0140] FIG. 8. Burger patty made with textured pea/gluten protein obtained by high moisture extrusion, containing 1.5% wt fiber and 3% wt potato protein in the final mixture, before and after cooking.

EXAMPLES

Example 1: Rheological Behavior of Potato Fibre

[0141] Potato fibres (Hi Fibre 115, according to supplier specification comprises about 92% total fibre, about 2% protein, wherein 98% of the ingredient is derived from potato source and about 2% of the ingredient is derived from soluble psyllium husk) were selected based on their rheological response when dispersed in water. The desired functionality from the fibre is mostly related to binding of the meat pieces, hence enabling molding into burger shape that does not crumble as well as preventing water leakage during cold storage.

[0142] FIG. 1 shows shear viscosity of potato fibre dispersions at a range of concentrations. A Newtonian fluid behavior is observed at low concentrations (below 1 wt %) whereas a shear thinning response becomes apparent at concentrations equal or above 1 wt %. The onset concentration for shear thinning response for this potato fibre is rather low compared to fibres comprising large amounts of insoluble polysaccharides (e.g. cellulose, hemicellulose). This is mainly due to the increased amount of soluble, high molecular polysaccharide chains from the potato fibre (primarily galacturtonic and glucuronic type, but also glucans, mannoses, xyloses, rhamonoses and arabinoses) which are solubilized in the water continuous phase and hence occupy large hydrodynamic volumes.

[0143] The viscoelastic properties of 5 wt % potato fibre water dispersions are shown in FIG. 2, with G′ being significantly greater than G″ and constant over wide range of applied strain (corresponding to the linear viscoelastic region) until the microstructure breaks down and the material yields. The fact that potato fibre dispersions show G′>G″ indicates the dominant solid-like response over the applied strain ranges, which is attributed to the chain entanglement between the previously mentioned polysaccharides that are solubilized in the water-continuous phase. The insoluble fibre fraction of the potato fibre is acting as a filler, with less contribution to the viscoelastic response of the fibre suspension.

[0144] This particular viscoelastic response is not measured when fibres with greater insoluble fraction (comprising primarily cellulose, hemicellulose, and lining) are used at the same concentration. Those fibres behave as particulate dispersions in which insoluble fibre particles have the tendency to sediment thereby displaying lower viscosity values and without any elastic contribution at equal concentration ranges. For these insoluble fibre rich ingredients, increased concentrations are needed for the particulate dispersions to exhibit solid-like behavior. This occurs when the suspensions are densely packed, with an effective phase volume greater than their maximum packing fraction which leads to solid-like linear viscoelastic response that exhibits flows only if a sufficient shear stress is applied (i.e. the yield stress).

Example 2: Rheological Properties of Potato Protein

Mechanical Spectra of Potato Protein Gels

[0145] Gelling properties of potato protein isolate PP1 from a commercial source and ovalbumin from a commercial source were compared using small deformation rheology. Gelation of protein dispersion was performed in situ in an Paar Physica MCR501 (Anton Paar Ostfildern, Germany) stress-controlled rheometer, using a concentric cylinder setup (inner and outer cylinder are 8.33 and 9.04 mm respectively). The rheomether was equipped with a Peltier heating and cooling device. Protein dispersion was placed in the geometry and a thin layer of paraffin oil was carefully placed on top to prevent evaporation during the experiment.

[0146] The temperature was raised from 20° C. to 85° C. at 5° C./min. After 15 minutes holding at 85° C., the temperature was decreased to 20° C. at −5° C./min. After reaching 20° C., the system was left to equilibrate at 0.05% strain and 1 Hz for 10 minutes. A frequency sweep was subsequently performed.

[0147] FIG. 3 shows the mechanical spectra obtained after cooling. All systems formed strong gels with G′ value being higher than G″ over the whole frequency range with a decade of difference between the two moduli.

[0148] Interestingly this first screening showed that similar profiles were obtained for PP1 and Ovalbumin at 3 wt % and 4 wt % protein in the presence of 0.1M NaCl suggesting similar gel strengths.

G′ for 6%, 14% Potato Protein Solutions as Function of Temperature, at pH=6.

[0149] A solution of potato protein was prepared by dispersing the protein in a degassed water and stirring overnight. The pH was adjusted to pH of 6 using HCl.

[0150] Evolution of G′ was measured as function of temperature in stress-controlled rheometer (MCR 502, Anton Paar) with a sandblasted concentric cylinder geometry. Samples were placed and left to stabilize for 5 minutes at 20° C. After that, the following heating/cooling sequence was applied: heating ramp from 20° C. to 90° C. at 5° C./min, holding at 90° C. for 20 minutes, followed by cooling from 90° C. to 20° C. at 4° C./min. Measurements were carried out at a constant strain of 0.5% and a constant frequency of 1 Hz (FIG. 4).

[0151] In order to prevent evaporation, the samples were covered using mineral oil during rheological measurements.

Minimal Gelling Concentration of Potato Protein Determination

[0152] Dispersions having increasing protein concentrations were prepared by dissolving corresponding amount of potato protein isolate in Millipore® water. Subsequently pH was adjusted to 4 or 7 by using 1M and 2M HCl or NaOH. After preparation, 3 mL of each sample was transferred into a 4 mL glass vial with screw-cap and heated in a water bath without stirring. Samples were heated 30 minutes at at 70° C. After cooling on ice, the sol-gel transition of the samples was analysed using the ‘tilting-test’, i.e. vials with samples were turned upside down and when the sample stayed at the bottom of the vial (i.e. did not slide down), it was considered as a gel.

[0153] The minimal gelling concentration in the presence of 10 mM NaCl at pH 7 decreased to 2% protein while at pH 4 20 mM NaCl had negative impact on gel formation.

[0154] To test the influence of salt addition on minimal gelling concentration, 2M NaCl solution was prepared and added in different amounts to chosen protein dispersions to achieve 10 mM and 20 mM NaCl.

Example 3: Denaturation Temperature of Potato Protein Isolates

[0155] Heating causes denaturation of proteins as a result of disruption of bonds that are involved in the formation and maintenance of the protein structure. Denaturation temperatures of potato protein isolates were determined by differential scanning calorimetry (DSC). Presence of endothermic peaks observed in thermograms (FIG. 6) suggest that both evaluated potato protein isolates (PP1 and PP2) contain native proteins that denature upon heating above 65° C.

Example 4: Textured Soy Recipes

[0156] Water was added to textured soy in a Hobart mixer and stirred until properly hydrated. Salt, color and savory powders were dry mixed separately and then added to the hydrated texturized protein. Canola oil and methylcellulose, fibre or fibre/protein combination were then added to the mixture, which was subsequently hand mixed until homogeneous appearance.

[0157] Shea/coconut fat flakes were then incorporated and the final mixture was gently mixed by hand, molded to a burger shape and kept in the fridge (4° C.) overnight. Molding was done for 100 g of the mix using a round mold. The next day, burgers were cooked by first searing the burger both sides in a skilled pan and cooked in the oven at 180° C. for 12 minutes.

TABLE-US-00001 Recipes: 1 2 3 4 5 6 Water 61.8 62.4 61.8 61.8 61.8 62.4 Textured Soy 23.1 23.4 23.1 23.1 23.1 23.4 Beetroot powder 0.3 0.3 0.3 0.3 0.3 0.3 Savory Base 0.4 0.4 0.4 0.4 0.4 0.4 Salt 0.8 0.8 0.8 0.8 0.8 0.8 Total of base 86.4 87.1 86.4 86.4 86.4 87.1 Potato fibre (Hi Fibre 115) 2.0 3.0 3.0 3.0 3.0 2.0 Potato protein 1.0 2.0 2.0 Soy protein (SP1) 3.0 2.0 Canola oil 2.9 2.0 Fat flakes 6.0 2.9 2.9 2.9 2.9 2.9 Total 100 6.0 6.0 6.0 6.0 6.0 100 100 100 100 100 (All values expressed in the above table are wt %)

Example 5: Results Obtained with the Textured Soy

[0158] Based on the performance of all the evaluated recipes, i.e. their ability to be molded into burgers, shape retention during cooking, appearance and sensory characteristics, the combination of 3 wt % potato fibre and 2 wt % potato protein has been identified as the most promising solution.

Example 6: Burger Molding and Storage in Cold Conditions

[0159] Molding burgers into appropriate shape was not possible for samples which only contained protein as a binder. This is mainly due to a reduced viscosity of the protein-water solutions compared to the methylcellulose solution at the same concentration in cold conditions.

[0160] All recipes containing fibres or fibre-protein combinations could be molded into burgers the same way as with methylcellulose and were stable upon storage at 4° C. (no water leakage was observed after 2 weeks storage).

Example 7: Burger Cooking

[0161] Burgers containing higher amount of fibres (4 wt %) and burgers with fibre-protein combinations as a binder retained the structure upon pan-searing and oven cooking.

[0162] Interestingly, burgers containing protein in the recipe showed a significant color change, browning upon searing, which did not occur with either methylcellulose or fibres alone. This effect is most likely due to Mallard reaction occurring between protein and the sugar from the beetroot-based Fiesta colorant.

Example 8: Panel Tasting of Burgers

[0163] Tasting of burgers was performed with 8 panelists. [0164] Methylcellulose reference was described as somewhat dry. [0165] Samples containing only higher amount of fibre (4 wt %) had a quite/too crunchy surface. [0166] Most of the panelists liked recipes containing potato fibre and protein combinations. The best burger was the one containing 3 wt % of potato fibre and 2 wt % of potato protein—described as having the best texture by far (better than the methylcellulose reference) and somewhat meaty taste. Second best was the burger with 3 wt % of potato fibre and 2 wt % of soy protein (SP1). [0167] Samples containing 2 other fibres were perceived as gummy by 2 panelists or as presenting some off-flavors, mouth/tongue coating and were described as somewhat slimy. [0168] Samples containing soy protein and potato fibre were cohesive but perceived as soft in texture.

[0169] Samples containing only protein as a binder could not be molded, mainly due to a reduced viscosity of the protein-water solutions compared to the methylcellulose solution at the same concentration in cold conditions.

TABLE-US-00002 Consistency Texture Acceptable Binder (dough) (burger) (Y/N) Methylcellulose 1.9 wt % Cohesive Firm and juicy Y Potato fibre 3 wt % Cohesive Soft and mushy N Potato fibre 3 wt % Cohesive Firm and juciy Y Potato protein 1 wt % (more body) Potato fibre 3 wt % Cohesive Firm and juciy Y Potato protein 2 wt % (more body)

Example 9 Textured Pea Recipes

[0170] Water was added to textured pea in a Hobart mixer and stirred gently until properly hydrated. Vinegar, colors, flavors and spices were then added to the hydrated texturized protein. Canola oil was added as well. This mass was used as a base for different recipes. To the adequate amount of the base, methylcellulose or fibre/protein combinations were added and mixed. Fat flakes were added at the end and the final mixture was gently mixed by hand, molded to a burger shape and kept in the fridge (4° C.) until cooking. The burgers were cooked in a skilled pan on both sides until internal temperature was over 70° C.

[0171] All patties were shapeable and retained the form upon cooking. Only the patty containing methylcellulose shrank upon cooking, was sticking to the pan and burned ring was formed around it due to the fluid leaking (FIG. 7). The texture of all patties was acceptable, with the exception of the one containing gluten and faba bean proteins that was described as mushy. The hemp protein recipe was less firm than the potato protein recipe but less mushy than the faba protein recipe.

TABLE-US-00003 Recipes: Base 1 2 3 4 5 6 7 8 Water 61.19 Textured pea 27.26 vinegar 1.65 Natural colours 1.09 Savory Base 0.2 Beef flavor 1.14 Salt 0.17 Spices 1.59 oil 5.69 Total of base 100 94 94.25 94.5 92 94.5 93.5 89 93.5 Methylcellulose 2 Potato fibre 1 1 1 0.5 0.5 1 0.5 Potato protein 0.75 0.5 3.0 1 2 Gluten 5 Faba bean conc. 1 Hemp protein conc. 2 Fat flakes 4 4 4 4 4 4 4 4 Total 100 100 100 100 100 100 100 100 (All values expressed in the above table are wt %)

Example 10

[0172] Pea/gluten protein textured by high moisture extrusion was mixed with vinegar, colors, flavors and spices in the similar ratio as in the example 9. Separately, potato protein water dispersion was mixed with the oil and then potato fiber was added to form a highly viscous paste. This paste was added to the textured protein mass to achieve 1.5% wt fiber and 3% wt potato protein in the final mixture. Fat flakes were added at the end and the final mixture was gently mixed by hand, molded into a burger shape and kept in the fridge (4° C.) until cooking. The burgers were cooked in a skilled pan on both sides until internal temperature was over 70° C. The patties were easily shapeable and retained the form upon cooking. Upon tasting, the patties were described as having a firm bite. FIG. 8 shows burger patty made with textured pea/gluten protein obtained by high moisture extrusion, before and after cooking.