Method for making plant-based meatloaf or tofu using single cell proteins from microalgae

Abstract

Methods for making a plant-based food product from a microalgae are described. An example method includes obtaining a microalgae, extracting Chlorella protein from the microalgae, modifying a factor associated with the Chlorella protein and/or adding a stimulant to the Chlorella protein to change an amino acid combination of the Chlorella protein, and utilizing the modified Chlorella protein as a protein flour to create the plant-based food product.

Claims

1. A method for making a plant-based food product from a microalgae, the method consisting of: extracting a protein from a microalgae by: adding an alkaline solution to a powder of the microalgae to form a mixture; extracting the protein from the mixture at approximately 50° C. for approximately 6 hours; centrifuging the mixture for approximately 20 minutes to obtain a protein extract solution of the protein; and calculating a protein recovery rate from the protein extract solution of the protein; modifying a culture condition associated with the microalgae to change an amino acid composition of the protein; and utilizing the modified protein as a protein flour to create the plant-based food product, wherein the plant-based food product is selected from the group consisting of: a meatloaf and a tofu.

2. The method of claim 1, wherein a strain of the microalgae is selected from the group consisting of: a Botryococcus strain, a Neochloris strain, and a Chlamydomonas strain.

3. The method of claim 1, wherein the alkaline solution is added in a range between approximately 1% to approximately 10% of a weight of the protein.

4. The method of claim 1, wherein the algae powder comprises a protein content in a range of approximately 30% to approximately 90%.

5. The method of claim 1, wherein the protein recovery rate of the protein extract solution is calculated by: $\mathrm{Protein}\mathrm{recovery}\mathrm{rate}/\%\frac{\begin{array}{c}\mathrm{Supernatant}\mathrm{protein}\mathrm{content}\times \\ \mathrm{supernatant}\mathrm{mass}\end{array}}{\begin{array}{c}\mathrm{Protein}\mathrm{mass}\times \\ \mathrm{algal}\mathrm{powder}\mathrm{protein}\mathrm{content}\end{array}}\times 100.$

6. The method of claim 1, wherein the alkaline solution is a sodium hydroxide (NaOH) solution.

7. The method of claim 1, wherein the culture condition is selected from the group consisting of: a pH level of the microalgae, a wavelength of irradiance of light onto the microalgae during a fermentation process, a feedstock for the microalgae, a carbon source of a culture media, a growth temperature for the microalgae, a flow rate of air into a bioreactor during a fermentation process, a flow rate of air/O.sub.2 mixtures into the bioreactor during the fermentation process, a flow rate of noble gases into the bioreactor during the fermentation process, and/or an incubation time period for the microalgae under a mixotrophic growth condition.

8. The method of claim 1, further comprising: adding a stimulant to a culture media to modify the amino acid composition of the Chlorella protein.

9. The method of claim 8, wherein: the stimulant is a substrate, and the substrate is selected from the group consisting of: a spent grain, okara, and molasses.

10. The method of claim 4, wherein the algae powder comprises a protein content in a range of approximately 60% to approximately 65%.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 depicts a schematic block diagram of a method for making a plant-based food product from a microalgae, according to at least some embodiments described herein.

(2) FIG. 2 depicts a schematic block diagram of an alkaline solution extraction method for Chlorella protein, according to at least some embodiments described herein.

(3) FIG. 3 depicts a schematic block diagram of an enzyme extraction method for Chlorella protein, according to at least some embodiments described herein.

(4) FIG. 4 depicts a schematic block diagram of a first low-temperature deep eutectic solvents (DES) extraction method for Chlorella protein, according to at least some embodiments described herein.

(5) FIG. 5 depicts a schematic block diagram of a second low-temperature DES extraction method for Chlorella protein, according to at least some embodiments described herein.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

(6) The preferred embodiments of the present invention will now be described with reference to the drawings. Identical elements in the various figures are identified with the same reference numerals.

(7) Reference will now be made in detail to each embodiment of the present invention. Such embodiments are provided by way of explanation of the present invention, which is not intended to be limited thereto. In fact, those of ordinary skill in the art may appreciate upon reading the present specification and viewing the present drawings that various modifications and variations can be made thereto.

(8) As described herein, a “bioreactor” is an enclosure or partial enclosure, in which cells are cultured, and optionally in suspension.

(9) As defined herein, an “autotroph” refers to an organism that is capable of synthesizing its own food from inorganic substances, using light or chemical energy.

(10) As defined herein, a “feed stock” refers to what kind of food waste one uses to feed microalgae. Different feed stocks include differing nitrogen and carbon sources.

(11) As defined herein, a “heterotroph” refers to an organism that cannot synthesize its own food and is dependent on complex organic substances for nutrition.

(12) As defined herein, a “microalgae” refers to a eukaryotic microbial organism that contains a chloroplast, and optionally, that is capable of performing photosynthesis, or a prokaryotic microbial organism capable of performing photosynthesis.

(13) As defined herein, a “mixotrophic strain” is defined as a strain of an organism that allows it to be both autotrophic and heterotrophic at the same time.

(14) FIG. 1 depicts a schematic block diagram of a method for making a plant-based food product from a microalgae, according to at least some embodiments described herein. The method of FIG. 1 may begin at a process step 102, which includes obtaining the microalgae. In some examples, the microalgae may first be cultivated in a bioreactor system (such as a fermentation tank) prior to obtaining the microalgae. A culture media may include a carbon source and may be located inside of the bioreactor system. The microalgae may be located in the culture media.

(15) A strain of the microalgae may include: a Botryococcus sudeticus strain, a Botryococcus strain, a Neochloris oleabundans strain, a Neochloris strain, a Chlamydomonas reinhardtii strain, or a Chlamydomonas strain, among others. In additional examples, the microalgae is of a mixotrophic strain. In examples, the microalgae may be adapted for both autotrophic growth and heterotrophic growth during a time period.

(16) The process step 102 may be followed by a process step 104, which includes extracting Chlorella protein from the microalgae. Numerous extraction methods may be used, such as mechanical grinding, high-pressure homogenization, ultrasonic treatment, pulse dyslenoid to release the protein molecules to facilitate further extraction processes like water, alkali or enzyme, and then use of isoelectric precipitation, and salting out (salt induced precipitation) methods. Additional extraction methods include: an alkaline solution extraction method (depicted and described in FIG. 2), an enzyme extraction method (depicted and described in FIG. 3), and a low-temperature DES extraction method (depicted and described in FIG. 4 and FIG. 5), among others. It should be appreciated that further extraction methods may be used, which are not explicitly listed herein.

(17) The process step 104 is followed by a process step 106 and/or a process step 108. The process step 106 includes: modifying a factor associated with the Chlorella protein to change an amino acid combination of the Chlorella protein. In examples, the factor may include a pH level of the microalgae, a wavelength of irradiance of light onto the microalgae during the fermentation process, a feedstock for the microalgae, a carbon source of the culture media in which the microalgae is located, a growth temperature for the microalgae, a flow rate of air into the bioreactor during a fermentation process, a flow rate of air/O.sub.2 mixtures into the bioreactor during the fermentation process, a flow rate of noble gases into the bioreactor during the fermentation process, and/or an incubation time period for the microalgae under the mixotrophic growth condition, among others. In examples, the carbon source for the culture media may be glucose, fructose, sucrose, galactose, xylose, mannose, rhamnose, N-acetylglucosamine, glycerol, floridoside, glucuronic acid, corn starch, depolymerized cellulosic material, sugar cane, sugar beet, lactose, milk whey, or molasses, among other examples not explicitly listed herein. The process step 108 may include adding a stimulant to the Chlorella protein to change the amino acid combination of the Chlorella protein. In additional examples, the stimulant is a substrate and may include a spent grain, okara, or molasses, among other examples.

(18) It should be appreciated that changing the amino acid combination of the Chlorella protein by the process step 106 and/or the process step 108 may result in the creation of functional proteins. Proteins are macromolecules consisting of one or more long chains of amino acid residues. Proteins perform a vast array of functions within organisms, including catalyzing metabolic reactions, DNA replication, responding to stimuli, providing structure to cells, and organisms, and transporting molecules from one location to another. Proteins differ from one another primarily in their sequence of amino acids, which is dictated by the nucleotide sequence of their genes, and which usually results in protein folding into a specific three-dimensional structure that determines its activity.

(19) Amino acids are the basic building blocks of the body and are organic compounds that contain amine (—NH2) and carboxyl (—COOH) functional groups, along with a side chain (R group) specific to each amino acid. In the form of proteins, amino acid residues form the second-largest component (water is the largest) of human muscles and other tissues. Amino acids are extremely versatile and more than 200 different amino acids exist. The most commonly known are the 22 proteinogenic amino acids.

(20) Amino acids prove to be beneficial in numerous fields. Thus, modifying the amino acid combination in the Chlorella protein may result in the creation of functional proteins. The modified Chlorella protein may be used as a protein flour with different application functions, different nutritional functions, and/or different functional properties based on the modified factor(s) and/or the applied stimulant(s). Such functional properties performed by proteins in food include: solubility, water absorption and binding, viscosity, gelation, cohesion-adhesion, elasticity, emulsification, fat adsorption, flavor binding, and/or foaming, among others. For example, water absorption and binding may be significant in meats, sausages, breads, and cakes, and may be the result of hydrogen-bonding of water and entrapment of water. Additionally, viscosity may be significant for soups and gravies and may result from thickening. Gelation may be important in meats, curds, and cheeses, and may be a result of protein matrix formation and setting. As such, one can use the modified Chlorella protein powder that has similar nutritional, functional, and applicational profiles to the animal protein it is trying to replace.

(21) The process step 106 and/or the process step 108 may be followed by a process step 110, which may include: utilizing the modified Chlorella protein as the protein flour to create the plant-based food product. The plant-based food product is a meat loaf or a tofu. It should be appreciated that the modified Chlorella protein may be used in multiple food applications not explicitly listed herein.

(22) FIG. 2 depicts a schematic block diagram of an alkaline solution extraction method for Chlorella protein, according to at least some embodiments described herein. Since most proteins are acidic, when a protein is near its isoelectric point (PI—4 to 5), solubility will be minimized. For example, in alkaline conditions, proteins will be more soluble. At the same time, alkaline affects the protein molecule's secondary bonds. Hydrogen bonds can have a certain destructive effect and can change the polarity, so that the protein molecular surface charge changes, which modifies the solubility of the protein molecules, which will separate the protein for extraction.

(23) The method of FIG. 2 begins at a process step 202, which includes adding an alkaline solution to the microalgae powder to form a mixture. In some examples, the microalgae powder is a green bao algae powder comprising a protein content in a range of approximately 30% to approximately 90%. In examples, the microalgae powder comprises a protein content in a range of approximately 60% to approximately 65%.

(24) The mass of Chlorella may be in a range of approximately 1.0 grams to approximately 10.0 grams. In some examples, the mass of Chlorella may be in a range of approximately 5.0 grams to approximately 6.0 grams. In examples, the amount of the alkaline solution is in a range between approximately 0% to approximately 10% of a weight of the Chlorella protein. In further examples, the amount of the alkaline solution is in a range between approximately 1% to approximately 8% of a weight of the Chlorella protein. In other examples, the alkaline solution is a sodium hydroxide (NaOH) solution.

(25) The process step 202 is followed by a process step 204, where an extraction of the mixture is carried out at approximately 50° C. for approximately 6 hours. The process step 204 is followed by a process step 206, where the mixture is centrifuged at approximately 800 rpm for approximately 20 minutes to obtain a protein extract solution of the Chlorella protein. The process step 206 is followed by a process step 208, where a protein recovery rate is calculated from the protein extract solution of the Chlorella protein. The protein recovery rate may be calculated by Equation 1 shown below:

(26) $\begin{array}{cc}\mathrm{Protein}\mathrm{recovery}\mathrm{rate}/\%\frac{\begin{array}{c}\mathrm{Supernatant}\mathrm{protein}\mathrm{content}\times \\ \mathrm{supernatant}\mathrm{mass}\end{array}}{\begin{array}{c}\mathrm{Chlorella}\mathrm{mass}\times \\ \mathrm{algal}\mathrm{powder}\mathrm{protein}\mathrm{content}\end{array}}\times 100& \left[\mathrm{Equation}1\right]\end{array}$
It should be appreciated that the method of FIG. 2 may also be used to extract soy protein, pea protein, sea buckthorn protein, and other plant proteins from different materials not explicitly listed herein.

(27) FIG. 3 depicts a schematic block diagram of an enzyme extraction method for Chlorella protein, according to at least some embodiments described herein. The method of FIG. 3 begins at a process step 302, which includes dissolving approximately 25.0 grams of algae powder in approximately 375 mL of water. The process step 302 is followed by a process step 304, where an alkaline protease is added to the solution. The alkaline protease may be added in an amount between 0.001% to 0.5%. In other examples, the alkaline protease may be added in an amount between 0.01% to 0.2%. In examples, the alkaline protease is cellulase, pectinase, or alkaline protease 37071. However the alkaline protease is not limited to these examples provided herein.

(28) The process step 304 is followed by a process step 306, where a pH of the solution is adjusted to a pH of 8.0. The process step 306 is followed by a process step 308, where the solution is hydrolyzed at 55° C. for approximately 24 hours with the sodium hydroxide solution. The process step 308 is followed by a process step 310, where the solution is centrifuged for approximately 20 minutes to obtain a protein extract solution. The process step 310 is followed by an optional process step 312, where the protein recovery rate is calculated from the protein extract solution via Equation 1. The process step 312 may be followed by additional process steps (not shown) including: extracting the Chlorella and drying the Chlorella.

(29) FIG. 4 and FIG. 5 depict schematic block diagrams of a first and a second low-temperature deep eutectic solvent (DES) extraction method for Chlorella protein, according to at least some embodiments described herein. DES is a stable solvent formed by the combination of two or three substances by hydrogen bonds between molecules. The composition of DES interacts with a protein (e.g. hydrogen bonding), extracts the protein from raw material, and then separates the protein by washing or alcohol. DES raw materials have a low cost, are easy to biodegrade, and provide better environmental compatibility.

(30) A first method of FIG. 4 begins with a process step 402, which includes mixing a eutectic solvent (e.g., glycerol:choline chloride having a molar ratio of 1:2) with algae powder:cryogenic co-melt solvent having a molar ratio of 1:9. It should be appreciated that other eutectic solvents may be used.

(31) The process step 402 is followed by a process step 404, where the solution is reacted at approximately 60° C. for approximately 3 hours. The process step 404 is followed by a process step 406, where the solution is centrifuged for approximately 20 minutes to obtain a protein extract solution. The process step 406 is followed by an optional process step 408, where the protein recovery rate is calculated from the protein extract solution via the Equation 1.

(32) A second method of FIG. 5 begins with a process step 502, which includes mixing a eutectic solvent (e.g., urea:choline chloride having a molar ratio of 1:2) with algae powder:cryogenic co-melt solvent having a molar ratio of 1:9. The process step 502 is followed by a process step 504, where the solution is reacted at approximately 60° C. for approximately 3 hours. The process step 504 is followed by a process step 506, where the solution is centrifuged for approximately 20 minutes to obtain a protein extract solution. The process step 506 is followed by an optional process step 508, where the protein recovery rate is calculated from the protein extract solution via Equation 1.

(33) When introducing elements of the present disclosure or the embodiments thereof, the articles “a,” “an,” and “the” are intended to mean that there are one or more of the elements. Similarly, the adjective “another,” when used to introduce an element, is intended to mean one or more elements. The terms “including” and “having” are intended to be inclusive such that there may be additional elements other than the listed elements.

(34) Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made only by way of illustration and that numerous changes in the details of construction and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention.