METHOD FOR PRODUCING A SHAPED FOOD PRODUCT

Abstract

A method for producing a shaped food product, wherein the method comprises preparing a food matrix by mixing a carrier compound with an ion-dependent gelling compound and with a temperature-dependent gelling compound. The food matrix is provided with a temperature that is above a gelling temperature of the temperature-dependent gelling compound and of shaping the food matrix by means of a shaper, wherein the shaper provides to bring the food matrix into a desired shape of the food product as a shaped food matrix and wherein the food matrix has during the shaping a temperature that is above the gelling temperature of the temperature-dependent gelling compound. The shaped food matrix is brought into contact with a pre-shaping solution, wherein the pre-shaping solution provides gelling of the ion-dependent gelling compound at least at a surface of the shaped food matrix, wherein the gelling of the ion-dependent gelling compound at the surface of the shaped food matrix provides a layering of the shaped food matrix.

Claims

1. Method for producing a shaped food product, wherein the method comprises the following steps: preparing a food matrix by mixing: a carrier compound with an ion-dependent gelling compound and with a temperature-dependent gelling compound, providing the food matrix with a temperature that is above a gelling temperature of the temperature-dependent gelling compound, shaping the food matrix by means of a shaper, wherein the shaper provides to bring the food matrix into a desired shape of the food product as a shaped food matrix, wherein the food matrix has during the shaping a temperature that is above the gelling temperature of the temperature-dependent gelling compound, bringing the shaped food matrix into contact with a pre-shaping solution, wherein the pre-shaping solution provides gelling of the ion-dependent gelling compound at least at a surface of the shaped food matrix, wherein the gelling of the ion-dependent gelling compound at the surface of the shaped food matrix provides a layering of the shaped food matrix, wherein the layering stabilizes the shape of the shaped food matrix and provides a layered shaped food matrix.

2. Method according to claim 1, wherein the layered shaped food matrix is entirely gelled by providing the layered shaped food matrix at a temperature that is below the gelling temperature of the temperature-dependent gelling compound.

3. Method according to claim 2, wherein the food matrix has during the mixing a temperature that is above the gelling temperature of the temperature-dependent gelling compound.

4. Method according to claim 3, wherein the pre-shaping solution has a temperature that is below the gelling temperature of the temperature-dependent gelling compound.

5. Method according to claim 4, further comprising the step: bringing the layered shaped food matrix into contact with a curing solution, wherein the curing solution has a temperature that is below the gelling temperature of the temperature dependent gelling compound.

6. Method according to claim 5, wherein a contact time of the layered shaped food matrix with the curing solution has a duration in which the temperature dependent gelling compound is entirely gelled at the temperature of the curing solution, the entire gelling of the temperature-dependent gelling compound of the layered shaped food matrix provides the shaped food product.

7. Method according to claim 6, wherein the ion-dependent gelling compound comprises at least one polysaccharide and the pre-shaping solution comprises at least one cation, and/or the ion-dependent gelling compound comprises at least one cation and the pre-shaping solution comprises at least one polysaccharide, wherein the at least one cation reacts with the at least one polysaccharide and provides gelling of the ion-dependent gelling compound at the surface of the shaped food matrix.

8. Method according to claim 7, wherein the at least one polysaccharide is alginate, pectin or carrageenan, the at least one cation is a metal cation, in particular a metal cation of the metals calcium, magnesium, iron or zinc.

9. Method according to claim 8, wherein the temperature-dependent gelling compound comprises at least one biopolymer, in particular wherein the at least one biopolymer is agar, microbial gum, gellan gum, carrageenan, furcelleran or gelatin.

10. Production line for producing a shaped food product, in particular a shaped vegan cheese alternative, the production line comprises: a filling unit, a shaper, wherein the shaper is arranged below an outlet of the filling unit, wherein the outlet is configured to provide a food product filled into the filling unit to the shaper at a filling area, is configured as a cylinder, wherein the cylinder has a base plane and a lateral surface, and is rotatable around a rotation axis, wherein the rotation axis is perpendicular to the base plane and extends through the midpoint of the base plane, wherein the lateral surface of the cylinder comprises at least one mould, wherein the at least one mould is configured to provide the food product in a desired shape, a pre-shaping basin, wherein a volume of the pre-shaping basin is delimited on a cylinder side by a pre-shaping basin portion of the lateral surface, wherein the pre-shaping basin portion of the lateral surface rotationally extends over an angular region of at least 45° to 135°, wherein an angle of 0° is defined by a vector extending vertically downwards and being perpendicular to the rotation axis.

11. Production line according to claim, wherein the production line further comprises at least one fluid nozzle, wherein the at least one fluid nozzle is configured to direct at least one fluid jet towards the lateral surface of the cylinder, in particular wherein the at least one fluid jet provides such a fluid pressure on the lateral surface of the cylinder that the shaped food product is released from the at least one mould.

12. Production line according to claim 11, wherein the production line further comprises a curing.

13. Production line according to claim 12, wherein the curing basin is located on a first side of the cylinder and the pre-shaping basin is located on a second side of the cylinder, wherein a vertical plane separates the first side from a second side, the vertical plane comprises or is parallel to the rotation axis.

14. Production line according to claim 13, wherein the production line further comprises a control unit, wherein the control unit is configured to prepare a food matrix by mixing: a carrier compound with an ion-dependent gelling compound and with a temperature-dependent gelling compound, provide the food matrix with a temperature that is above a gelling temperature of the temperature-dependent gelling compound, shaping the food matrix by means of a shaper, wherein the shaper provides to bring the food matrix into a desired shape of the food product as a shaped food matrix, wherein the food matrix has during the shaping a temperature that is above the gelling temperature of the temperature-dependent gelling compound, bring the shaped food matrix into contact with a pre-shaping solution, wherein the pre-shaping solution provides gelling of the ion-dependent gelling compound at least at a surface of the shaped food matrix, wherein the gelling of the ion-dependent gelling compound at the surface of the shaped food matrix provides a layering of the shaped food matrix, wherein the layering stabilizes the shape of the shaped food matrix and provides a layered shaped food matrix.

15. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The invention is illustrated in more detail below, purely by way of example, with reference to working examples shown schematically in the drawing. Identical elements are labelled with the same reference numerals in the figures. The described embodiments are generally not shown true to scale and they are also not to be interpreted as limiting the invention.

[0044] FIG. 1 shows a schematic illustration of the production line from the side.

[0045] FIG. 2 shows a schematic illustration of the production line from above.

[0046] FIG. 3 shows a schematic illustration of the shaper, the pre-shaping basin portion and the curing basin.

DETAILED DESCRIPTION OF THE DRAWINGS

[0047] FIG. 1 shows a schematic illustration of the production line 1 from the side, which comprises the filling unit 2 configured as filling funnel and the shaper 3, wherein the shaper 3 is arranged below an outlet of the filling funnel 2 and is configured as a cylinder. The cylinder has the base plane 4 and the lateral surface 5 and is rotatable around the rotation axis 6, wherein the rotation axis 6 is perpendicular to the base plane 4 and extends through the midpoint of the base plane 4. Further, the production line 1 comprises the pre-shaping basin 7, wherein the volume of the pre-shaping basin 7 is delimited on a cylinder side by the pre-shaping basin portion 13 of the lateral surface, wherein - according to the invention - the pre-shaping basin portion 13 of the lateral surface rotationally extends over the angular region of at least 45° to 135°. According to the embodiment shown in FIG. 1, the pre-shaping basin portion 13 extends over the larger angular region of 20° to 160°, wherein the angle of 0° is defined by a vector 8 extending vertically downwards and being perpendicular to the rotation axis 6 (for illustration purposes, the angles 0°, 20°, 160°, 180°, 200° and 360° are shown in FIG. 1). The volume of the pre-shaping basin 7 is further delimited by the seal 15 in the angular region of 0° to 20° of the pre-shaping basin portion 13.

[0048] In other words, the side view of the plant 1 is visualized, wherein the cylindrical demolding drum 3 is seen from the side with the filling hopper 2 above it.

[0049] In the following description of the FIGS. 1 to 3, the production line 1 is used by way of example to produce a shaped food product according to claims 1 to 9.

[0050] For the steps of filling the food matrix into the filling funnel 2 and shaping the food matrix, it is advantageous that the temperature of the food matrix is above the gelling temperature of the temperature-dependent gelling compound, as this ensures that the temperature-dependent gelling compound is not gelled and the viscosity of the food matrix is reduced to such an extent that it can flow onto the shaper 3 and into the moulds and can be shaped in the moulds without any difficulties.

[0051] The lateral surface forms a pre-shaping basin portion 13 in the angular region/range of 20° to 160° (the lateral surface of the cylinder forms a part of the side wall of the pre-shaping basin 7, thus defining the volume of the pre-shaping basin 7).

[0052] By rotating the cylinder (shaper 3) counterclockwise around the rotation axis 6 (this rotation direction is the physical rotation of the cylinder and not the geometric definition of the angle 0° and the other angular regions), the lateral surface and thus also the moulds filled with the food matrix move towards the pre-shaping basin 7, in which the pre-shaping solution is contained. Since the lateral surface forms the pre-shaping basin portion 13 in the angular region of 20° to 160°, the moulds filled with the food matrix (at their opening/at the interface between food matrix and air) are brought into contact with the pre-shaping solution by the rotation of the cylinder (they are immersed in the pre-shaping solution/an interface is formed between food matrix and pre-shaping solution).

[0053] Due to the contact of the shaped food matrix, in particular the ion-dependent gelling compound in the shaped food matrix, with the pre-shaping solution, a cross-linking reaction/gelling of the ion-dependent gelling compound at the mould opening/at the interface between the shaped food matrix and the pre-shaping solution is started, wherein the gelling of the ion-dependent gelling compound at the surface of the shaped food matrix results in a layering of the shaped food matrix, wherein the layering stabilizes the shape of the shaped food matrix yielding a layered shaped food matrix.

[0054] The pre-shaping solution may also flow into the mould, e.g. into a gap which may be provided between the shaped food matrix and the inner wall of the mould. By that, gelling may be provided over the entire surface of the shaped food matrix.

[0055] In addition, it is conceivable to configure the cylinder as a hollow cylinder, wherein the inside of the cylinder/cavity in the cylinder can be filled with the pre-shaping solution. The pre-shaping solution can be flowed/pumped into the moulds through internal openings/holes in the moulds, which create a connection between the moulds and the cavity in the cylinder, wherein the gelling of the ion-dependent gelling compound can be achieved from the side of the moulds located at the internal opening. In this way, the shaped food matrix in the moulds can be completely covered/enclosed with the pre-shaping solution and thus a gelling of the ion-dependent gelling compound on the entire surface of the shaped food matrix can be achieved, resulting in an entirely layered shaped food matrix.

[0056] By way of example, the ion-dependent gelling compound comprises a polysaccharide which contains negatively charged acid groups and the pre-shaping solution comprises a cation, in particular a multivalent metal cation, wherein the acid groups of the polysaccharide complex the multivalent metal cation and thus form a thermoirreversible polysaccharide network as a layer on the surface of the shaped food matrix (interface between shaped food matrix and pre-shaping solution). The cross-linking reaction takes place so fast that the layer is formed before the shaped food matrix can flow out of the mould again due to gravity or the centripetal force resulting from the further rotation of the cylinder (the layered shaped food matrix maintains its shape during further rotation of the cylinder, even when the moulds have emerged from the pre-shaping solution and again have an interface with the air.

[0057] It is also conceivable that the ion-dependent gelling compound contains the cation and the pre-shaping solution contains the polysaccharide.

[0058] In other words, the still hot and liquid food matrix comes into contact with cold shaping brine (approx. 4° C.) directly after filling into the moulds (spherical form) of the shaping drum (shaper/cylinder). This leads to instant/immediate gelling directly on the surface of the sphere. The drum continues to rotate and the surface of the sphere is constantly in contact with the cold brine and thus also in contact with the metal salt contained in the brine. The instant gelling on the surface of the sphere prevents the mould from leaking even though the temperature-dependent gelling compound has not yet gelled.

[0059] By way of example, the pre-shaping solution has a temperature that is below the gelling temperature of the temperature-dependent gelling compound. Hence, when the shaped food matrix is immersed in the pre-shaping solution, in addition to the cross-linking of the ion-dependent gelling compound, the gelling of the temperature-dependent gelling compound also takes place, which gives the shaped food matrix additional structural stability (increases the viscosity of the shaped food matrix).

[0060] The production line 1 further comprises the fluid nozzle 9, wherein the fluid nozzle 9 is configured to direct ten to fifteen liquid jets towards the lateral surface 5 of the cylinder, and the curing basin 10, wherein the curing basin 10 is located on a first side (in this example on the right side) of the cylinder and the pre-shaping basin 7 is located on a second side (in this example on the left side) of the cylinder, wherein a vertical plane separates the first side from a second side. Here, the vertical plane comprises the rotation axis 6.

[0061] The liquid jets are directed towards the lateral surface of the cylinder and have such a high pressure that the liquid jets press the layered shaped food matrix out of the respective mould so that the layered shaped food matrix falls into the curing basin 10 where it is immersed in the curing solution (the layered shaped food matrix is exposed to air for a short time when it falls out, because the curing basin 10 is located below the cylinder and the curing solution is provided in the curing basin 10 without contact with the cylinder). The curing solution has, for example, a temperature that is below the gelling temperature of the temperature-dependent gelling compound.

[0062] The layer (and the gelling of the temperature-dependent gelling compound) stabilizes the layered shaped food matrix in such a way that the shape of the layered shaped food matrix is maintained despite the impact of the liquid jet as well as the release from the mould and the subsequent immersion in the curing solution (i.e. the layer is stable enough and does not crack during these process steps, which prevents the food matrix from leaking/flowing out due to the not yet entirely gelled temperature-dependent gelling compound).

[0063] In order to ensure that the layered shaped food matrix (sphere/ball) is released from the mould on the lateral surface 5 of the cylinder at a rotation angle of approx. 300° (on the other side of the drum/cylinder), it is advantageous that at this position the drum/cylinder is no longer immerged in a solution but instead is out in air, so that the layered shaped food matrix (sphere/ball) is not pressed into the drum/mould by any liquid.

[0064] The layered shaped food matrix has a contact time duration with the curing solution in which the temperature dependent gelling compound is entirely gelled at the temperature of the curing solution which provides the shaped food product.

[0065] The contact time duration with the curing solution in which the temperature-dependent gelling compound is entirely gelled can be realized in various ways, wherein the ways listed below are merely exemplary and further ways are conceivable. For example, the layered shaped food matrix can remain in the curing basin after it has been immersed in the curing solution and can be removed and packed manually after the corresponding contact time duration. However, it is also conceivable to design the curing basin as an elongated basin, wherein either a conveyor belt or a continuous flow of the curing solution transports/conveys the layered shaped food matrix to an end/outlet of the basin. The conveying/flow speed can be adjusted in such a way that at the end/outlet of the basin the contact time duration with the curing solution in which the temperature-dependent gelling compound is entirely gelled is reached and the shaped food product can be removed from the elongated basin. In this way, a continuous production process of the shaped food product is enabled.

[0066] In another example, the layered shaped food matrix can be packaged directly after release from the mould, wherein the curing solution is inside the packaging and thus the contact time duration with the curing solution in which the temperature dependent gelling compound is entirely gelled is achieved. In this way, the shape of the shaped food product can first be stabilized in a first process step and the curing and thus the final formation of the shaped food product can take place in a second process step after packaging.

[0067] Due to the fact that the contact time of the shaped food matrix with the pre-shaping solution is time-limited (e.g. by the rotation of the cylinder the moulds are immersed in the pre-shaping solution and emerge after a desired immersion time based on the rotation speed of the cylinder), the gelling of the ion-dependent gelling compound only takes place on the surface of the shaped food compound (interface between shaped food matrix and pre-shaping solution). Therefore, in the inside/core of the layered shaped food matrix, only the temperature-dependent gelling compound is gelling, which is why the shaped food product can be melted when heated above the gelling temperature of the temperature-dependent gelling compound.

[0068] In this context, it can be advantageous that deionized water is used for the production of the carrier compound and the curing solution, as otherwise (due to the magnesium and calcium cations contained in tap water) the cross-linking reaction of the ion-dependent gelling compound can take place up into the depth (up to the inner core) of the shaped food product, thus making it impossible for the shaped food product to melt.

[0069] FIG. 2 shows a schematic illustration of the production line 1 from above, which comprises the filling unit 2 configured as filling funnel and the shaper 3, wherein the shaper 3 is arranged below an outlet of the filling funnel 2 and is configured as a cylinder. The lateral surface 5 of the cylinder comprises moulds 11, wherein the moulds 11 are configured to provide the food product in a spherical shape. Further, the pre-shaping basin 7 as well as the curing basin 10 are shown.

[0070] In other words, the filling hopper 2 is shown from above, the cylindrical forming drum 3 to be filled below has depressions 11 for forming the compound. The area of the pre-shaping solution 7 can be seen on the left, the area of the curing solution 10 can be seen on the right.

[0071] The food matrix is filled into the filling funnel 2 and is transported onto the filling area 12 of the shaper 3 (flows onto the shaper 3 in the filling area 12). The shape and size of the filling area 12 can be rectangular as shown in FIG. 2 and extend almost over the entire length of the shaper 3, but any other conceivable shape and size of the filling area 12 is possible, up to a circular area with a diameter of a few centimetres. In this filling area 12, the food matrix flows into the moulds 11, which are arranged on the lateral surface 5 of the cylinder, and takes on the spherical shape determined by the moulds 11.

[0072] FIG. 3 shows a schematic illustration of the shaper 3, the pre-shaping basin portion 13 and the curing basin 10. The pre-shaping basin portion 13 delimits the volume of the pre-shaping basin 7 over an angular region of 20° to 160° relative to the vector 8 which defines the angle 0°. The curing basin 10 is located on a first (right) side of the cylinder and the pre-shaping basin 7 is located on a second (left) side of the cylinder, wherein a vertical plane separates the first side from a second side. The rotation axis is in the vertical plane. The curing basin 10 is located below the cylinder and is configured so that the curing solution is provided in the curing basin 10 without contact with the cylinder. FIG. 3 further shows the fluid nozzle 9 which is configured to direct ten to fifteen liquid jets towards the lateral surface 5 of the cylinder, providing a liquid pressure which releases the layered shaped food matrix from the mould 11 into the curing basin 10.

[0073] In other words, the illustration shows the seal 15 between the demolding drum 3 and the base, which allows pre-shaping solution to protrude. In addition, a spray nozzle 9 is illustrated on the right. Its water jet releases the layered shaped food product from the demolding drum 3, which then falls into the curing brine.

[0074] Although the invention is illustrated above, partly with reference to some preferred embodiments, it must be understood that numerous modifications and combinations of different features of the embodiments can be made. All of these modifications lie within the scope of the appended claims.