METHOD FOR PRODUCING A FIRM GEL FOOD BODY MADE OF PLANT PROTEINS, A GEL FOOD BODY, AND USE OF AN AGGREGATOR FOR CARRYING OUT THE METHOD

Abstract

The invention relates to a method for producing a firm, in particular vegan, gel food body, preferably a gel food block, made of plant proteins, the method having the following steps: a) providing a composition consisting of or comprising an aqueous plant protein concentrate solution b) aggregating the composition in a pressure vessel (2) by heating the composition to a maximum temperature, then cooling the composition to a cool temperature below 100° C. and below the peak start temperature (7) c) performing the heating and cooling at a counterpressure in the pressure vessel (2), which counterpressure acts on the composition and is above normal atmospheric pressure, in such a way that the composition is prevented from boiling.

The invention also relates to a gel food body and to the use of an aggregator (1).

Claims

1-15 (canceled)

16. A method for producing a firm, vegan, gel food body, made of plant proteins, the method having the following steps: a) providing a composition comprising an aqueous plant protein concentrate solution with plant proteins, wherein the amount of the plant protein concentrate solution is selected such that the protein content of the composition, in percentage by weight, is between 12% by weight and 28% by weight, wherein the composition is heated and cooled in a pressure vessel, b) performing the heating and cooling at a counterpressure in the pressure vessel (2), which counterpressure acts on the composition and is above normal atmospheric pressure, in such a way that the composition is prevented from boiling, wherein the counterpressure corresponds at least to the saturated vapour pressure of the composition at a relevant process temperature, and wherein the cooling is performed without introduction of shear force, wherein c) the content, in percentage by weight, of the plant proteins in the plant protein concentrate solution is selected from a value range between 12 and 35% by weight, and wherein the plant protein concentrate solution is such that it has an endothermic peak in a DSC curve resulting from a dynamic differential calorimetry measurement and describing the relationship between the specific converted heat energy and the temperature, which peak is characterised by a peak temperature range over which the peak extends, which is delimited by a peak start temperature and a peak end temperature, and wherein the storage modulus G′ of the plant protein concentrate solution increases by at least a factor of 6, when passing through the peak temperature range from the peak start temperature in the direction of the peak end temperature in an oscillation rheology measurement, and wherein the denaturation enthalpy of the proteins of the plant protein concentrate solution which can be determined by means of the dynamic differential calorimetry measurement is at least 10 J/g, and d) wherein the composition is characterised in that it has an endothermic peak in a DSC curve resulting from a dynamic differential calorimetry measurement and describing the relationship between the specific converted heat energy and the temperature, which peak is characterised by a peak temperature range over which the peak extends, which is delimited by a peak start temperature and a peak end temperature, and e) wherein the composition is aggregated in the pressure vessel (2) by heating the composition to a maximum temperature at least partially of at least 100° C. and above the peak start temperature of the endothermic peak of the composition, in a pressure vessel (2) and then cooling the composition to a cool temperature lying below 100° C. and below the peak start temperature of the composition, and wherein the addition of starch and/or hydrocolloids is omitted, and f) wherein the maximum temperature to which the composition is heated is selected from a temperature range between the peak maximum temperature of the composition and the peak end temperature of the composition plus 20%, and in that the average heating rate, at least from reaching the peak start temperature of the composition, is selected from a value range between 4 K/min and 15 K/min.

17. The method according to claim 16, wherein the plant protein concentrate solution has a pH value from a value range between 4.5 and 7.5, and/or wherein the NaCl concentration of the plant protein concentrate solution is selected from a value range between 0 and 1.0 mol/l.

18. The method according to claim 16, wherein the plant protein concentrate solution is such that the denaturation enthalpy of the proteins of the plant protein concentrate solution, which can be determined by means of the dynamic differential calorimetry measurement, is between 10 J/g and 30 J/g.

19. The method according to claim 16, wherein the counterpressure above normal atmospheric pressure corresponds at least to the saturated vapour pressure of the composition at the relevant temperature in addition to a safety margin of at least 0.1 bar.

20. The method according to claim 19, wherein the safety margin is at at least 0.5 bar.

21. The method according to claim 16, wherein the pressure vessel (2) is actively subjected to the counterpressure before and/or during and/or after heating, and/or wherein the counterpressure is maintained during cooling at least until the aggregated composition has cooled completely below 100° C.

22. The method according to claim 16, wherein the heating is carried out without introduction of shear force.

23. The method according to claim 16, wherein the composition is kept hot prior to cooling for a period of time between 0.5 to 10 min at a heat-holding temperature lying between the peak maximum temperature of the composition and the maximum temperature.

24. The method according to claim 16, wherein the average cooling rate, at least until reaching the peak start temperature of the composition, is at least 4 K/min, and/or is selected from a value range between 4 K/min and 15 K/min.

25. The method according to claim 16, wherein the plant proteins of the plant protein concentrate are extracted from one or more plant raw materials selected from the group consisting of almond, mung bean, coconut, chickpea, peanut, cashew, oat, pea, bean, rice, wheat gluten, lentils, amaranth, beans, white beans, kidney beans, fava beans, soy beans, cereals and combinations thereof.

26. The method according to claim 16, wherein the fat content of the composition is adjusted to a value from a value range between 0% by weight and 30% by weight and/or wherein the sugar content of the composition is adjusted by adding sugar to a value from a value range between 0% by weight and 60% by weight, and/or wherein the NaCl content of the composition is adjusted to a value from a range between 1.1 and 1.6% by weight.

27. The method according to claim 16, wherein the composition comprises at least one functional ingredient selected from the group of ingredients consisting of: colouring substance, flavouring, preservative, flavour-enhancing ingredient and combinations thereof.

28. The method according to claim 16, wherein the ingredients of the composition are emulsified, and wherein gas bubbles are removed from the emulsion under a negative pressure atmosphere and/or foam formed in the emulsion is removed.

29. The method according to claim 16, wherein, to carry out the differential calorimetry measurement, 50 to 100 mg of the plant protein concentrate with the known protein content are weighed into a steel vessel with a volume of 100 μl and closed pressure-tight, wherein a further steel vessel is filled with water and serves as a reference for the measurement, and wherein a Mettler Toledo Tpe DSC 1 Star is used as measuring system and the differential calorimetry measurement consists of performing a temperature scan with a heating rate of 2 K/min, and wherein, to carry out the oscillation rheology, the plant protein concentrate solution is filled into a suitable steel vessel (beaker: C25 DIN system), specifically between 10 and 15 ml, and wherein the steel vessel is closed pressure-tight, and wherein the rheological properties are measured by means of the cylinder (C25 DIN system), which is located in the steel vessel (beaker) with the protein concentrate solution, and wherein the cylinder in the beaker is driven by a magnetic coupling so that the system is absolutely pressure-tight, and wherein the Bohlin Gemini HR.sup.nano coaxial cylinder (C25 DIN3019) measuring system is used for the measurement and the measuring system preferably oscillates only through a small angle, and wherein G′ and G″ are measured and the two portions G′ and G″ change with the subsequent temperature program, wherein the starting temperature is 25° Celsius and then a rapid heating with a heating rate between 3 K/min and 5 K/min takes place up to the relevant peak end temperature from the previous differential calorimetry measurement, wherein a short holding time between 2 and 5 min is observed at this temperature so that the plant protein concentrate is also completely exposed to this temperature, and wherein thereafter cooling is performed rapidly at a cooling rate between 3 K/min and 5 K/min, and/or wherein, to carry out the differential calorimetry measurement of the composition, 50 to 100 mg of the composition are weighed into a steel vessel with a volume of 100 μl and closed pressure-tight, and wherein a further steel vessel is filled with water and serves as a reference during the measurement, and wherein a Mettler Toledo Type DSC 1 Star is used as measuring system, and wherein the differential calorimetry measurement consists of performing a temperature scan with a heating rate of 2 K/min.

30. A firm, vegan, elastic gel food body, which is free from starch, free from hydrocolloids and is obtained by a method according to claim 16, comprising a continuous aqueous phase of mutually aggregated plant proteins and having a content, in percentage by weight, of the mutually aggregated plant proteins from a value range between 12 and 28% by weight, wherein a fat content of the gel block is between 0 and 30% by weight, and wherein the elasticity of a gel food body according to the invention to be determined by means of a texture analyser is between 85% and 100%.

31. A gel food body according to claim 30, wherein to measure the elasticity, the sample has a circular cylinder shape with a diameter of 47 mm and a height of 25 mm and shall be tempered to 16° Celsius, wherein, in order to determine the elasticity, a double compression of the sample is to be carried out, wherein, after a first measurement, a measuring stamp is returned to its starting point and the sample is left to rest for 15 s before a further compression occurs, and wherein the elasticity is calculated from the ratio of the positive peak areas of both measurements in a graph in which the applied force is plotted over time.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0080] Further advantages, features and details of the invention will become apparent from the following description of preferred embodiment examples and from the figures.

[0081] These show in:

[0082] FIG. 1 a preferred production process for producing a protein concentrate solution using the example of almond,

[0083] FIG. 2 the course of aggregation of a composition based on an almond protein concentrate solution,

[0084] FIG. 3 a typical DSC graph of a plant protein concentrate solution,

[0085] FIG. 4 a production process for producing a composition (formulation) based on an almond protein concentrate,

[0086] FIG. 5 a production process for producing a composition (formulation) based on a mung bean protein concentrate solution,

[0087] FIG. 6 a graph showing the firmness, breaking strength, elasticity and water content of different natural cheeses.

[0088] FIG. 7 a graph in which the parameters according to FIG. 6 are shown for gel food bodies based on different plant protein concentrates, in which lupine denotes a product not included in the invention,

[0089] FIG. 8 a graph showing the bending capacity and bending strength of different natural cheeses,

[0090] FIG. 9 a graph showing the parameters according to FIG. 8 for gel food bodies produced on the basis of compositions based on different plant protein concentrate solutions,

[0091] and

[0092] FIG. 10 in a schematic representation, a possible embodiment of an aggregator.

[0093] The information and parameter values disclosed in the description of the figures are not intended to limit the invention. However, they are to be regarded as essential to the invention and thus disclosed such that they could be claimed.

DETAILED DESCRIPTION

[0094] In the figures, like elements are denoted by like reference signs.

[0095] FIG. 1 shows a possible process for producing a protein concentrate solution using the example of almond.

[0096] At I, almond flour is provided, for example comprising 45 to 55% by weight protein and 11 to 16% by weight fat, the protein content preferably being at least 50% by weight and the fat content preferably being at most 13% by weight.

[0097] At II, the plant protein is extracted in water at a dilution of 1:4, the pH value preferably being adjusted to between 5.8 and 6.5. A pH value of 6.0 is particularly preferred. The extraction is carried out in particular at a temperature between 15 and 25° Celsius, very particularly preferably at 20° Celsius, the extraction time being at least one hour, preferably during stirring, in particular at a speed between 300 and 600 rpm, preferably 400 rpm.

[0098] This is followed by centrifugation at III and a residue is obtained at IV. The supernatant is denoted by V. The centrifugation at III. is preferably carried out for at least one hour at a preferred temperature between 15 and 25° Celsius, very particularly preferably 20° Celsius. The centrifugation is preferably carried out at between 14,000 and 27,000 g, very particularly preferably at 27,000 g.

[0099] An acid precipitation of the protein of the supernatant is then carried out at VI, in particular at a pH value between 4.8 and 5.2, very particularly preferably of 5.2. The precipitation is preferably carried out over a period of time of at least 30 minutes, very particularly preferably of one hour, in particular at a temperature from a range of values between 15 and 25° Celsius, in particular of 20° Celsius.

[0100] The precipitated protein is then centrifuged at VII, in particular at 14,000 to 27,000 g, in particular at 27,000 g, very particularly preferably for at least 20 minutes, even more preferably for 45 minutes, in particular at a temperature between 4 and 8° Celsius, very particularly preferably at 8° Celsius.

[0101] A supernatant is obtained at VIII. The residue at IX. is acidic protein concentrate (protein precipitate) with a protein weight content between 45 and 50%.

[0102] At X the pH value as well as the protein and NaCl concentration are adjusted. Preferably, the pH is adjusted to a value in a range between 5.2 and 6.5, very particularly preferably to 5.4. Preferably, the protein content is adjusted to 16 to 30% by weight, particularly preferably to 18 to 22%, and the NaCl content is adjusted to 0 to 3.3% by weight, very particularly preferably to 1.6 to 1.9% by weight. The process result at XI is a protein concentrate solution suitable for carrying out a method according to the invention.

[0103] FIG. 2 shows the course of aggregating a composition to obtain an aggregated product, i.e. a gel food body. An aggregator 1 is used for this purpose, as shown by way of example in FIG. 10. A pressure vessel 2 designed for overpressure can be seen. The pressure vessel 2 delimits an internal volume 3 (vessel volume) for accommodating a composition designed according to the concept of the invention. The pressure vessel 2 can be closed in a pressure-tight manner and can be subjected to a counterpressure above atmospheric pressure with the aid of counterpressure setting means 4.

[0104] Heating means 5 and cooling means 6 are also assigned to the pressure vessel 2. The heating means 5 are designed in the present case, for example, as electrical heating cartridges in the vessel wall, while the cooling means 6 comprise cooling channels through which a cooling medium can be conveyed.

[0105] At I, a composition is provided in the form of an emulsion based on an almond protein concentrate solution. The composition comprises, for example, between 13 and 24% by weight protein, between 0 and 2.8% by weight NaCl, between 0 and 1.8% by weight flavouring, in the present case cheese flavouring, and between 10 and 30% by weight fat. At II, such a composition is placed in an aggregator and at III a counterpressure of, for example, at least 1.3 bar is set. At IV, a heating phase takes place, in particular with a heating rate of 6.5 and 8 K/min. to a maximum temperature between 108° Celsius and 120° Celsius. At V, the heating phase is followed by an optional heat-holding time at a maximum temperature of between 0 and 10 min, whereupon at VI. a cooling phase takes place, in particular at a cooling rate of between 7 and 8.5 K/min. At VII, a gel food body according to the invention is obtained.

[0106] In the following Table 10, preferred aggregation conditions are shown using the example of an almond protein concentrate solution:

TABLE-US-00010 TABLE 10 Aggregation conditions using the example of almond protein concentrate MIN MAX OPTIMUM Heating phase 6.5 8.0 8.0 Holding time (min) 0 10 0 Cooling phase 7.0 8.5 8.5 Temperature (° C.) 108 120 113

[0107] The following table 11 shows preferred minimum and maximum as well as optimum maximum temperatures to which different compositions based on different plant protein concentrate solutions shown in the table are heated in the aggregator during the heating phase, wherein T-min denotes a preferred minimum maximum temperature to be set, T-max denotes a preferred maximum maximum temperature to be selected and T-opt denotes an optimum maximum temperature to be set for aggregation.

TABLE-US-00011 TABLE 11 preferred minimum, maximum and optimum maximum temperatures for the aggregation of a composition based on different plant protein concentrate solutions. T.sub.min(° C.) T.sub.max(° C.) T.sub.opt.(° C.) Almond protein 108 120 113 Mung protein 95 108 100 Coconut protein 108 120 113 Chickpea protein 108 120 113 Oat protein 118 125 120 Peanut protein 110 120 115

[0108] FIG. 3 shows a typical DSC curve from a dynamic differential calorimetry measurement of a suitable plant protein concentrate solution. It can be seen that the specific heat energy converted is plotted over temperature in the graph. The curve shows an endothermic peak, where the peak area represents the denaturation enthalpy ΔH of the contained proteins.

[0109] The peak extends over a peak temperature range from a peak start temperature T.sub.A to a peak end temperature T.sub.E. The peak has a maximum at a peak maximum temperature T.sub.M. The maximum temperature to which a composition is preferably heated for aggregation is preferably in the range of the peak end temperature T.sub.E, in any case above the peak maximum temperature T.sub.M.

[0110] The separate presentation of a DSC curve from a dynamic differential calorimetry measurement of a composition (formulation) has been omitted. The above explanations of the endothermic peak and the associated temperatures apply analogously. By adding ingredients, especially salt, the endothermic peak of the DSC curve of the composition may be shifted on the temperature axis compared to the endothermic peak of the DSC curve of the corresponding protein concentrate solution, in case of NaCl addition further to the right. Likewise, the peak may be shifted further to the left, i.e. towards lower temperatures, by corresponding dilution of the aqueous phase protein concentrate solution, in particular of its NaCl content in conjunction with the production of the composition, for example by addition of water. The peak temperatures from the DSC curve of the composition are decisive for the selection of the maximum temperature for aggregating the composition.

[0111] FIG. 4 shows a possible production of a composition using the example of almond. At I, a protein concentrate solution based on almond protein is provided. This is preferably characterised by a protein content of between 16 and 30% by weight, in particular between 18 and 22% by weight, and by an NaCl content of between 0 and 3.3% by weight, preferably between 1.6 and 1.9% by weight. The protein concentrate solution is further preferably characterised by a pH value between 5.2 and 6.5, in particular of 5.4.

[0112] At II, melted fat, in particular coconut fat, is added, preferably at a temperature between 45 and 60° Celsius. At III, flavouring is added, for example between 0 and 2% by weight.

[0113] At IV, an emulsification step takes place, in particular for 1 to 3 min at preferably 8,000 to 20,000 rpm. Very particularly preferably, emulsification is carried out for 2 min at a rotation speed of between 15,000 and 20,000 rpm.

[0114] An evacuation step is then carried out at five to remove gas bubbles and/or to destroy the foam formed during the emulsification process, in particular for 2 to 5 min, even more preferably for 3 min. The pressure for the evacuation is preferably reduced to 100 to 300 mbar, very particularly preferably to 150 mbar—the evacuation is preferably carried out at a temperature between 20 and 25° Celsius.

[0115] As a result, a composition in the form of a protein-based almond emulsion is then obtained at VI, which is preferably characterised by a protein weight content of between 13 and 24% by weight, preferably between 15 and 17.5% by weight, an NaCl content of between 0 and 2.8% by weight, in particular between 1.3 and 1.6% by weight, a flavouring content of between 0 and 1.8% by weight and a fat content of between 10 and 30% by weight, in particular between 15 and 20% by weight.

[0116] FIG. 5 shows an exemplary production process for a composition based on a mung bean protein concentrate solution. This is prepared at I. and is preferably characterised by a protein weight content of between 16 and 30% by weight, in particular between 18 and 22% by weight, an NaCl content of between 0 and 3.3% by weight, in particular between 1.4 and 1.7% by weight, and a pH value of between 5.2 and 6.5, preferably of 5.8.

[0117] Steps II to V are then identical to those as explained in conjunction with FIG. 4. As a method result, at VI a composition in the form of a protein-based mung bean emulsion is obtained, wherein the preferred protein, NaCl, flavouring and fat contents correspond to those from the embodiment example according to FIG. 4.

[0118] FIG. 6 shows that the characterisation of the selected standard products (different types of cheese) shows that the four parameters shown—firmness, breaking strength, elasticity and water content—correlate with each other.

[0119] The firmness and breaking strength increase as the water content decreases, while the elasticity decreases at the same time. While young Gouda still has an elasticity of 95%, this drops to 85 and 46% for medium-aged and aged Gouda respectively. Edam and Emmental are both in a range similar to young Gouda, namely 95 and 93%. The firmness and breaking strength are highest in aged Gouda at 70 and 72N respectively, with the water content being lowest here at 31% by weight. The medium-aged Gouda has a structure that is almost half a firm (firmness: 32.7N; breaking strength: 37.9N), with the water content being only 4.5% by weight higher. The water content of Edam and Gouda is the highest at 45 and 41%, the firmnesses are consequently the lowest at 17.6 and 17.2N, and 27.3 and 29.1 N breaking strength respectively. Emmental comes in just behind the two, with a firmness of 25N and a breaking strength of just under 42N.

[0120] When looking at the plant gels or gel food bodies according to FIG. 7, it can be seen that the correlation of the water content only applies to a limited extent.

[0121] The water content of the aggregated concentrates is around 70 and 73% by weight for almond and mung bean respectively. In the formulations (see Example 2 and Example 6), this drops to 55 and 57% by weight (almond and mung bean) due to the addition of fat. The firmnesses and breaking strengths as well as the elasticities can be compared with the conventional types. The almond gel without the addition of fat has the highest firmness (38N) and breaking strength (65N), and shows a very high elasticity (95%), which is comparable to a young Gouda. When fat is added, the firmness of the almond formulation decreases significantly to a value of 17.2N, which is also comparable to a young Gouda or Edam. The breaking strength of the almond sample is 26N, which is in the region of that of Edam. The elasticity remains almost identical, around 95%. The mung bean sample without the addition of fat has a firmness equivalent to medium-aged Gouda (32N), with a slightly higher breaking strength of 52N. Elasticity, at 91%, is just below that of an Emmental sample. The mung bean formulation benefits from the addition of fat in terms of elasticity and achieves a value of almost 96% here. The firmness and breaking strength are 31 and 42N respectively. As in the oscillation measurements, the aggregated lupine protein concentrate shows significantly worse values in all areas. The firmness and the breaking strength are equal, since the sample breaks already at a low penetration depth. These values are around 0.9N. The elasticity of the sample is also extremely low at 27.5%. It can be seen from this that the aggregate made from a lupine protein concentrate-based composition is not part of the invention, but merely serves as a comparative approach.

[0122] As can be seen from FIG. 8, easily recognisable differences can be found in the determination of the bending capacity and bending strength for the cheese standards.

[0123] The slices of young Gouda, Edam and Emmental are still intact after a complete compression cycle and therefore have a bending capacity of 100%. A force of about 125 mN is needed for a complete compression of Edam, whereas Emmental requires on average about 50 mN more force. Young Gouda has the highest bending strength. Here, the value is around 260 mN. The older and less elastic cheeses, middle-aged and old Gouda, cannot withstand the bending test. After about 83% of the distance, the medium old Gouda breaks. The bending strength (corresponding to the force at break) is correspondingly lower, namely 115 mN. The aged Gouda has an extremely poor bending capacity. It breaks already after 6.5% of the distance, after a required force of just under 52 mN.

[0124] Compared to the conventional cheese products, there are many parallels in the plant products or gel food bodies as shown in FIG. 9.

[0125] The samples without additives (22% by weight protein, almond: 1.6% by weight NaCl, mung. 1.4% by weight NaCl) both show a very high bending capacity. The almond sample shows an analogous behaviour here to the young Gouda, Edam and Emmental, with 100% bending capacity. The bending strength is comparatively very high, at 1037 mN. The sample from mung protein concentrate shows a bending capacity of almost 96%, with a bending strength of 424 mN. When 20% by weight fat is added to the almond protein concentrate (see formulation example 2), the bending capacity drops to 87%, which is equivalent to a structure between a young and a medium-aged Gouda. The bending capacity drops significantly to 176 mN, which is in the region of that of Emmental. When fat is added to the mung protein concentrate (see formulation example 6), the bending capacity increases again, reaching almost 100%. The bending strength here, at 420 mN, is again somewhat higher than the conventional cheese types. The bending test could not be carried out on the aggregate of a composition based on lupine protein concentrate solution, as no firm end product was formed during aggregation.

LIST OF REFERENCE SIGNS

[0126] 1. Aggregator [0127] 2. Pressure vessel [0128] 3. Internal volume [0129] 4. Counterpressure setting means [0130] 5. Heating means [0131] 6. Cooling means [0132] T.sub.A Peak start temperature [0133] T.sub.E Peak end temperature [0134] T.sub.M Peak maximum temperature