Process for Preparing a Product from One or More Biological Substances or Mixtures Thereof, a Product Prepared by This Process and Use of Such a Product

Abstract

The invention relates to a process for producing a product from one or more biological substances or mixtures thereof. Furthermore, the invention relates to a product manufactured according to the process of the invention. Furthermore, the invention relates to the use of such a product.

Claims

1.-34. (canceled)

35. Process for producing a product from one or more biological substances or mixtures thereof, which, optionally after cleaning, after adjustment of the dry matter, optionally subsequent thermal treatment such as boiling, for example, as well as comminution and optionally further pre-processing to change the material properties and/or nutritional physiological properties of the starting material, are extruded, and through the extrusion process a strand or strands are arranged into a starting matrix that has channels, pores or cavities that are completely or partially open to the outside, and within which or between which one or more fungus/fungi and optionally additional fermenting microorganism(s) grow that before, during, or after the extrusion process are introduced or applied into or onto the starting matrix in the form of the vegetative or permanent form, and the fungus/fungi cross-link with the starting matrix and/or grow in this while the starting matrix is subject to a fermentation process or co-fermentation process, and the cross-linking and/or growth of the fungus/fungi decisively influences and/or partially influences the texture and/or firmness, and that the product produced from the starting matrix is if needed subsequently cut into pieces of predetermined dimensions, packaged, and supplied for further purposes of use whereby in the case of edible products, the taste and/or texture is determined by the fungus/fungi growing in the pores, channels and/or cavities and/or by other microorganism(s) introduced into the pores, channels, cavities and/or into the starting material(s) and/or by the duration and/or the temperature profile of the fermentation process and/or by the adjustment of the water content of the product during or after fermentation and/or by the composition of the biological starting material and/or by the volume fraction of pores, channels, cavities in the starting matrix and/or by the arrangement of the pores, channels, cavities and/or by the quantity of the interface between the totality of the strands and the totality of the pores, channels, cavities and/or by the diameter(s) of the strands and/or by gas exchange with the environment and/or by a process-technical pre-treatment adjusting the rheology of the starting material whereby the nozzle or nozzles and the support on which the starting material(s) is discharged from the nozzle or nozzles is/are movable relative to one another, so that either a chaotic distribution of the discharged matrix strands, forming a random heap, or a predetermined distribution of the discharged matrix strands in predetermined angular arrangements (for example 20, 21) relative to one another is effected.

36. Process for the production of a structured body that is permeated with unfilled cavities (open channels, pores or cavities), solid, fermented, and is formed on the basis of modulable substrates (synonymous with starting material), wherein (a) at least one rheologically and texturally adjustable, modulatable mass forms a directional or non-directional mesostructure (synonymous with starting matrix) that is freely adjustable in terms of arrangement over a wide range and that forms the substrate (synonymous with starting matrix) as well as the cavities (synonymous with pores, channels, cavities) for one or more fermentations and a basic structure (synonymous with starting matrix) that is co-decisive for the overall texture; (b) by the introduction of at least one co- and/or superimposed microstructure (synonymous with fungal mycelium or network structure) induced by one or more fermentations, such that partially or completely interconnected filamentous network structures (synonymous with microstructure) caused by fungal growth are produced in, on and between the mesostructure elements (synonymous with extruded strands or strand pieces); (c) by choosing the volume proportion of unfilled cavities, channels or pores, compartments in the total object, by choosing their arrangement as well as by choosing the ratio between mesostructure surface and mesostructure volume, the growth of the mycelium as a whole as well as the penetration and direction of the mesostructure with mycelium and thus in its entirety the network structures are adjustable and (d) the totality of the structuring elements at micro and meso level interact to effectuate an adjustable (i) solidification, (ii) rheological properties and (iii) sensory-relevant texturing.

37. Process according to claim 35, wherein by the extrusion process simultaneous and/or in parallel and/or sequential extrusion process steps a body as a starting matrix is prepared, which consists of several extruded strands lying above and/or next to and/or behind one another, which are connected materially or functionally to connect into one unit at their mutually touching surfaces and form cavities, channels or pores between them, into which the fungus/fungi arrange/s itself/themselves.

38. Process according to claim 35, wherein the growth and/or metabolic activity of the fungus/fungi can be interrupted and/or changed and/or controlled after a specific period of time for the respective starting material.

39. Process according to claim 35, wherein the previously empty pores, channels or cavities occupied by the fungal mycelium/fungal mycelia after fermentation are partially or completely filled with a flowable and/or partially or completely solidifying material, wherein the solidification is carried out via an additional fermentation with the aid of a further bioactive organism, enzymatically, via thermo-reversible mechanisms, ionically induced, by heating or by other processes.

40. Process according to claim 35, wherein the starting material for the starting matrix is processed by means of extrusion, co-extrusion or multi-extrusion processes to form a product strand and/or product strands and/or product strand pieces, the product strand subsequently remaining as a continuous strand or disintegrating into individual pieces and/or being disintegrated, and the temperature of the product strand and/or of the product strands and/or of the product strand pieces immediately at the die or perforated plate outlet being 2 to 99.5 [° C.], preferably from 5 to 99 [° C.], more preferably from 7 to 80 [° C.], more preferably from 10 to 70 [° C.], more preferably from 12 to 60 [° C.], more preferably from 12 to 45 [° C.], most preferably from 15 to 25 [° C.].

41. Process according to claim 35, wherein the extruded strand or strand pieces are foamed with gas inclusions caused by expansion of a compressed gas, e.g. CO.sub.2, N.sub.2O, O.sub.2, or by gas formation in the course of fermentation, e.g., CO.sub.2, by foaming of the material before discharge into the product, e.g., with CO.sub.2, O.sub.2, N.sub.2, air, or by a chemical reaction, e.g., that of a carbonate with an acid, or by the expansion of water to water vapor within the strands or strand pieces.

42. Process according to claim 35, wherein the fungi/fungus spores/molds/mold spores used for the fermentation originate from the genus Rhizopus, for example Rhizopus oligosporus, Rhizopus stolonifer, Rhizopus oryzae, Rhizopus arrhizus and/or from the genus Actinomocur, for example Actinomocur elegans spp. meitauza and/or from the genus Aspergillus, for example Aspergillus oryzae and/or from the genus Penicillium, for example Penicillium candidum, Penicillium camemberti, Penicillium roqueforti, Penicillium glaucum, and/or from the genus Geotrichum, for example Geotrichum candidum, and/or of another genus capable of—modifying the texture and/or sensory characteristics of the product, as well as the microorganism(s) used for the microbial fermentation or co-fermentation from the genus Bacillus, for example Bacillus subtilis spp. natto and/or from the genus Neurospora, for example Neurospora intermedia and/or from the genus Lactobacillus, for example Lactobacillus bulgaricus, Lactobacillus reuteri and/or from the genus Lactococcus, for example Lactococcus lactis and/or from the genus Propionibacterium, for example Propionibacterium freudenreichhii and/or from the genus Zymomonas, for example Zymomonas mobilis and/or from the genus Leuconostoc, for example Leuconostoc mesenteroides and/or from another genus which is suitable for changing the texture and/or sensory properties of the product.

43. Process according to claim 35, wherein the inoculation of the starting matrix with fungal mycelium and/or fungal spores and/or mold mycelium and/or mold spores is carried out in such a way that they are, for example, mixed with the starting material and/or sprayed onto the starting matrix and/or the product is soaked in and/or with a suspension of the fungal mycelium and/or the fungal spores and/or the mold mycelium and/or the mold spores.

44. Process according to claim 35, wherein the starting material is conveyed in the extrusion process through nozzles or openings, such as in a perforated plate, with an inside diameter of 0.4 to 9 [millimeters], preferably 0.5 to 7 [millimeters], preferably 0.8 to 5 [millimeters], preferably 1 to 3.5 [millimeters], again preferably between 1 and 2.5 [millimeters], in particular 1.1 to 2 [millimeters], the diameters of the openings having the same or different diameters in the case of parallel or consecutive extrusion processes.

45. Product according to claim 35, wherein in the case of edible products, the taste and/or texture is determined by the fungus (i) introduced into the pores, channels and/or cavities and/or by further microorganisms introduced into the pores, channels, cavities and/or into the starting material(s) and/or by the duration and temperature profile of the fermentation process and/or by the adjustment of the water content of the product during or after fermentation and/or by the composition of the biological starting material and/or by the volume fraction of pores, channels, cavities in the starting matrix and/or by the arrangement of the pores, channels, cavities and/or by the quantity of the interface between strands and pores, channels and cavities and/or by the diameter(s) of the strands and/or by gas exchange with the environment and/or by a technical pre-treatment process adjusting the rheology of the starting material.

46. Product according to claim 45, wherein several layers or sheets of extruded product strands are arranged in predetermined or chaotic angular arrangements above and/or next to and/or behind each other.

47. Product according to claim 45, wherein the starting material for the starting matrix consists of biological substances or mixtures thereof that allow and/or promote a desired germination and/or growth of the fungus/fungi or their spores/permanent forms and optionally of the microorganism(s) or their permanent forms due to the material composition as well as the adjusted dry matter content and/or further suitable treatment steps, such as, for example, biological substances with increased protein content in the dry matter, such as, for example, peas, soy, quinoa, chickpeas, tofu, seitan, cream cheese masses, processed cheese masses, ricotta and/or with increased fiber content in the dry matter, such as okara, spent grains, whole grain cereal products, largely insoluble residues from fat/protein extraction—and/or increased fat content in the dry matter, such as almonds, cashew, soy and/or high carbohydrate content in the dry matter, such as wheat or other cereals or pseudo-cereals and/or hydrocolloids such as gels based on gelatin, pectin, starch and/or pastes such as concentrated dispersions of any powders such as milk protein, whey protein isolate or plant-based protein concentrates or isolates, whereby in each case the adjustment of the water content is effected in such a way that the substances have a yield stress.

48. Product according to claim 45, wherein the proportion of cavities, channels or pores is 20 to 85 [%, volume fraction], preferably 20 to 75 [%, volume fraction], again preferably from 25 to 75 [%, volume fraction], again preferably between 25 and 70 [%, volume fraction], in particular preferably between 25 and 60 [%, volume fraction], most preferably between 30 and 55 [%, volume fraction].

49. Product according to claim 45, wherein the firmness of the product measured after fermentation compared to the firmness of the underlying starting matrix before fermentation increases by at least a factor of 20, preferably by at least a factor of 12, more preferably by at least a factor of 8, even more preferably by at least a factor of 5, even more preferably by at least a factor of 3.5, even more preferably by at least a factor of 2, even more preferably by at least a factor of 1.5, more preferably by at least a factor of 1.2, most preferably by at least a factor of 1.1, wherein the firmness is determined as the maximum force with a penetration measurement by means of a flat, round cylinder geometry with a diameter of 8 millimeters, which penetrates at a speed of 0.5 cm per second into a product body of the dimension 20 millimeters×20 millimeters×20 millimeters with a penetration depth of 10 millimeters at room temperature.

50. A meat substitute comprising the product according to claim 45.

Description

[0131] In the drawing, the invention is illustrated—partly schematically—by means of embodiments: It shows:

[0132] FIG. 1 shows the exit of several extruded matrix strands from an extruder, partly broken off;

[0133] FIG. 2 shows the application of extruded matrix strands to another strand layer by means of a nozzle, broken off;

[0134] FIG. 3 shows several extrusion nozzles connected in parallel;

[0135] FIG. 4 a perforated plate with variously shaped openings from which strands of material can emerge;

[0136] FIG. 5 an extrusion device with different extrusion nozzles and a motor-driven, rotating knife downstream in the conveying direction of the extruded strands;

[0137] FIG. 6 a chaotic heap of extruded material strands;

[0138] FIG. 7 strand pieces, chaotically arranged;

[0139] FIG. 8 cut strands;

[0140] FIG. 9 side view of a matrix body consisting of extruded material strands arranged at right angles to each other in different planes;

[0141] FIG. 10 top view of the embodiment shown in FIG. 9;

[0142] FIG. 11 another embodiment in which the material strands are arranged at angles to each other;

[0143] FIG. 12 a representation similar to FIG. 9 on a larger scale, shown in perspective;

[0144] FIG. 13 preparation of the starting material and formation of the starting matrix, fermentation, packaging

[0145] FIG. 14 preparation of the starting material and formation of the starting matrix, fermentation, packaging;

[0146] FIG. 15 preparation of the starting material and formation of the starting matrix, fermentation, packaging

[0147] The reference sign 1 shows a part of an extruder that has several outlet nozzles, not shown in detail, from which, in the embodiment shown, a total of four product strands 2 emerge, which combine under the influence of gravity to form a chaotic heap 3. Depending on the requirements, the product strands 2 can be subdivided, in particular cut off, in a time- or volume-controlled manner, after which the heap 3 is transported away intermittently.

[0148] In the embodiment shown in FIG. 2, a nozzle 4, which may be motor-driven, is shown, with several product strands 5 arranged parallel to and at a distance from each other. In the embodiment shown, the nozzle 4 ejects the product strand 6 at right angles to the longitudinal axis of the product strands 5. Several such layers of product strands 5, 6 can be arranged one above the other and/or next to each other and complement each other to form an object.

[0149] In the embodiment according to FIG. 3, four nozzles 7 are arranged parallel and at a distance from each other and are assigned to an extruder not shown, from which product strands 8 emerge and are separated, for example, in a time-controlled or volume-controlled manner. The product strands 8 can combine to form a chaotic heap 9 or be combined in some other way to form a product body.

[0150] FIG. 4 shows a perforated plate 10 that is assigned to an extruder that is not shown. The perforated plate 10 has outlet openings 11 of different diameters from which product strands emerge.

[0151] In the illustration in FIG. 5, 12 shows a part of an extruder that has nozzles 13 of the same or different diameters from which product strands emerge. Downstream in the conveying direction is a rotating knife 14 which cuts the product strands. These can then be transported away individually or arranged at any angle to each other to form a body.

[0152] FIG. 12 shows a product 15 consisting of several layers of product strands arranged one above the other. In the embodiment shown, a fungal mycelium 16 grows in the cavities. For reasons of simplification, this is only shown in two places. Of course, the corresponding fungus grows in the various cavities of the product body 15.

[0153] FIG. 6 shows another chaotic heap 17 consisting of a practically endless strand, while FIG. 7 shows a heap 18 consisting of divided product strands. In FIG. 8, the heap 19 consists of divided product strands.

[0154] FIGS. 9, 10 and 11 show different product bodies. For example, the product body 20 in FIG. 9 has a similar structure to the product body in FIG. 12 and consists of several layers of product strands each running at right angles to each other with their longitudinal axes, which also applies to the embodiment according to FIG. 10, while in the embodiment according to FIG. 11 the product body 21 consists of product strands 22 running at an acute angle to each other. However, the angles can also be different from layer to layer.

[0155] The features described in the claims and in the description, as well as those apparent from the drawing, may be essential to the realization of the invention either individually or in any combination.

LIST OF REFERENCES

[0156] 1 Extruder [0157] 2 Product strand, strand, matrix strand, mesostructure element, structuring element [0158] 3 Heap [0159] 4 Nozzle [0160] 5 Product strand, strand, matrix strand, mesostructure element, structuring element [0161] 6 Product strand, strand, matrix strand, mesostructure element, structuring element [0162] 7 Nozzle [0163] 8 Product strand, strand, matrix strand, mesostructure element, structuring element [0164] 9 Heap [0165] 10 Perforated plate [0166] 11 Outlet opening [0167] 12 Extruder [0168] 13 Nozzle [0169] 14 Knife [0170] 15 Product, product body, body [0171] 16 Fungus, fungal mycelium, microorganism, network structures [0172] 17 Heap [0173] 18 Heap [0174] 19 Heap [0175] 20 Product body, product, body [0176] 21 Product body, product, body [0177] 22 Product strand, strand, matrix strand, mesostructure element, structuring element [0178] 23 Channels, pores, cavities, unfilled cavities

BIBLIOGRAPHY

[0179] [1] Heine, D., Rauch, M., Ramseier, H., Müller, S., Schmid, A., Kopf-Bolanz, K., Eugster, E. (2018). Plant proteins as meat substitutes: a review for Switzerland. Agrarforschung Schweiz 9(1), 4-11. [0180] [2] Bio Suisse—Guidelines for the production, processing and trade of Bud products. Version as of 1 Jan. 2019. Link: https://www.bio-suisse.ch/media/VundH/Regelwerk/2019/DE/rl_2019_1.1_d_gesamt_11.12.2018.pdf [0181] [3] O'Toole, D. K. (2004). Soymilk, Tofu, and Okara. In: Encyclopedia of Grain Science (2004). Edited by Wrigley, C. W., Corke, H., and Walker, C. E. Academic Press. [0182] [4] Shurtleff, W., and Aoyagi, A. (1979). The Book of Tempeh. A Cultured Soyfood. [0183] [5] Zieger, T. (1986). Experiments on the production of tempe gembus and meidouzha. Diploma thesis carried out at the Institute for Food Technology of the University of Hohenheim. [0184] [6] GB 1 277 002 A [0185] [7] U.S. Pat. No. 3,885,048 A [0186] [8] GB 2 007 077 A [0187] [9] DATABASE GNPD [Online] MINTEL; 27. Mai 2015, anonymous: «Light Manioc Pasta”, XP055633351

SUMMARY

[0188] The invention relates to a process for producing a product from one or more biological substances or mixtures thereof. Furthermore, the invention relates to a product manufactured according to the process of the invention. Furthermore, the invention relates to the use of such a product.