PROCESS AND APPARATUS FOR THE PRODUCTION OF A MEAT ANALOGUE

Abstract

Processes for the production of a meat analogue, comprising: a) introducing a meat batter which comprises protein into a first heating unit and heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, and b) transferring the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, c) cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces; as well as an apparatus for the production of a meat analogue.

Claims

1. A process for the production of a meat analogue, comprising: a) introducing a meat batter which comprises protein into a first heating unit and heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, and b) transferring the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, c) cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces, wherein a ratio of a residence time of the meat batter in the first heating unit to a residence time of the first heat-treated product in the second heating unit is from about 3:2 to about 14:2.

2. The process of claim 1, wherein a volume ratio of the first heating unit to the second heating unit is above about 1.5:1.

3. The process of claim 1, wherein the first and second heating units are heated by supplying steam to respective heat jackets and wherein a temperature of the steam applied to the first heating unit is from about 155° C. to about 162° C.

4. The process of claim 1, wherein at least one of the first and second heating units comprises a scraped surface heat exchanger.

5. The process of claim 1, wherein the first and second heating units both comprise a scraped surface heat exchanger.

6. The process of claim 1, wherein the meat batter is heated in the first heating unit to a temperature of from about 90° C. to about 125° C.

7. The process of claim 1, wherein the first heat-treated product is heated in the second heating unit to a temperature of from about 140° C. to about 170° C.

8. The process of claim 1, wherein the ratio of residence time of the meat batter in the first heating unit to a residence time of the first heat-treated product in the second heating unit from about 3:2 to about 7:2.

9. The process of claim 1, wherein a pressure in the first heating unit is from about 800 to about 2000 kPa, and/or a pressure in the second heating unit is from about 800 to about 2000 kPa.

10. The process of claim 1, wherein the meat analogue produced has improved palatability as compared to meat analogues prepared by conventional processes.

11. A meat analogue prepared by a process comprising a) introducing a meat batter which comprises protein into a first heating unit and heating the meat batter to a temperature above the denaturation temperature of the protein in the meat batter, but below the melting point of the protein to produce a first heat-treated product, and b) transferring the first heat-treated product to a second heating unit and heating the first heat-treated product to a temperature above the melting temperature of the protein to produce a second heat-treated product, c) cooling the second heat-treated product by moving through a cooling unit, so that the second heat-treated product has a temperature below water boiling temperature at ambient pressure when exiting the cooling unit, and d) dividing the cooled second heat-treated product into pieces, wherein a ratio of a residence time of the meat batter in the first heating unit to a residence time of the first heat-treated product in the second heating unit is from about 3:2 to about 14:2.

12. A human food product comprising the meat analogue of claim 11.

13. A pet food product comprising the meat analogue of claim 11.

14. An apparatus for the production of a meat analogue comprising: i) a first heating unit, ii) a first transfer means for transferring a meat batter which comprises protein into the first heating unit, the first heating unit being operable to heat the meat batter to a temperature above the denaturation temperature of the protein but below the melting temperature of the protein, iii) a second heating unit being operable to heat a first heat-treated product obtained from the first heating unit to a temperature above the melting temperature of the protein in the first heat-treated product, wherein the first heating unit and the second heating unit are arranged in series, iv) a cooling unit located downstream the second heating unit and operable to cool down a second heat-treated product obtained from the second heating unit below water boiling temperature at ambient pressure when exiting the cooling unit, and v) a dividing unit located downstream the cooling unit suitable for dividing cooled down second heat-treated product obtained from the cooling unit into pieces wherein the apparatus is operable such that a ratio of a residence time of the meat batter in the first heating unit to a residence time of the first heat-treated product in the second heating unit of from about 3:2 to about 14:2.

15. The apparatus of claim 14, wherein a volume ratio of the first heating unit to the second heating unit is above about 1.5:1.

16. The apparatus of claim 14, wherein at least one of the first and second heating units comprises a scraped surface heat exchanger.

17. The apparatus of claim 14, wherein the first and second heating units both comprise a scraped surface heat exchanger.

18. The apparatus of claim 14, wherein the cooling unit is operable to cool down the second heat-treated product to a temperature of less than about 80° C.

19. The apparatus of claim 14, wherein the first heating unit is operable to heat the meat batter to a temperature of from about 90° C. to about 125° C.

20. The apparatus of claim 14, wherein the second heating unit is operable to heat the first heat-treated product to a temperature of from about 140° C. to about 170° C.

Description

5. EXAMPLES

[0073] The presently disclosed subject matter will be better understood by reference to the following Examples, which are provided as exemplary of the disclosure, and not by way of limitation.

Example 1

[0074] The present Example provides processes for the production of meat analogues in accordance with certain embodiments of the present disclosure.

[0075] Three parts of a slurry containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing min. 75% protein (vital wheat gluten) to form a semi-solid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semi-solid mixture are based on the total weight of the semi-solid mixture). The mixture was fed into a first single scraped surface heat exchanger (SSHE) heating unit with a volume of approx. 17.8 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The first SSHE heating unit was continuously supplied with steam at a temperature between 155-158° C. and the shaft was operated at 300 rpm. The outlet temperature of the material from the first SSHE heating unit was between 109 ° C. and 110° C. The material was immediately directed into a second SSHE heating unit with a volume of approx. 11.3 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure.

[0076] The second SSHE heating unit was continuously supplied with steam at a temperature between 167-169° C. and the shaft was operated at 360 rpm. The outlet temperature of the material from the second SSHE heating unit was between 158-160° C. The residence time in the two heating units was distributed as about 61.2% in the first heating unit and about 38.8% in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80° C. The solid material obtained was cut to produce meat analogues with internal fibrosity.

Example 2

[0077] The present Example provides processes for the production of meat analogues in accordance with certain embodiments of the present disclosure.

[0078] Three parts of a slurry containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing min. 75% protein (vital wheat gluten) to form a semi-solid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semi-solid mixture are based on the total weight of the semi-solid mixture). The mixture was fed into a first SSHE heating unit with a volume of approx. 17 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The first SSHE heating unit was continuously supplied with steam at a temperature between 134-136° C. and the shaft was operated at 200 rpm. The outlet temperature of the material from the first SSHE heating unit was between 109° C. and 111° C. The material was immediately directed into a second SSHE heating unit with a volume of approx. 9.7 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The second SSHE heating unit was continuously supplied with steam at a temperature between 166-168° C. and the shaft was operated at 300 rpm. The outlet temperature of the material from the second SSHE heating unit was between 158-160° C. The residence time in the two heating units was distributed as two-thirds in the first heating unit and one third in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80° C. The solid material obtained was cut to produce meat analogues with internal fibrosity.

Comparative Example 3

[0079] The present Example provides a comparative process for the production of meat analogues using one heating unit.

[0080] Three parts of meat emulsion containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing min. 75% protein (vital wheat gluten) to form a semi-solid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semi-solid mixture are based on the total weight of the semi-solid mixture). The mixture was fed into a SSHE heating unit with a volume of approx. 14.6 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The SSHE heating unit was continuously supplied with steam at a temperature between 166-168° C. and the shaft was operated at 300 rpm. The outlet temperature of the material from the SSHE heating unit was between 158-160° C. The material was then directed to a cooling area through which its temperature was brought down to below 80° C. The solid material obtained was cut to produce meat analogues with internal fibrosity.

[0081] A comparison of food intake by cats between the product manufactured using two SSHE heating units and the product manufactured using one SSHE heating unit showed cats eating on average 21% less (by weight) from the product manufactured using a single SSHE heating unit, a statistically significant loss under conditions tested.

Comparative Example 4

[0082] The present Example provides a comparative process for the production of meat analogues in which the outlet temperature of a first heating unit is below coagulation temperature and the outlet temperature of a second heating unit is below melting temperature.

[0083] Three parts of meat emulsion containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing min. 75% protein (vital wheat gluten) to form a semi-solid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semi-solid mixture are based on the total weight of the semi-solid mixture). The mixture was fed into a first SSHE heating unit with a volume of approx. 17 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The first SSHE heating unit was continuously supplied with steam at a temperature between 120-125° C. and the shaft was operated at 200 rpm. The outlet temperature of the material from the first SSHE heating unit was below coagulation temperature and between 60-70° C. The material was immediately directed into a second SSHE heating unit with a volume of approx. 9.7 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The second SSHE heating unit was continuously supplied with steam at a temperature between 120-125° C. and the shaft was operated at 200 rpm. The outlet temperature of the material from this heating unit was below melting temperature and between 80-85° C. The residence time in the two heating units was distributed as two-thirds in the first heating unit and one third in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80° C. No internal fibrosity was observed in the outlet material, only protein coagulation.

Comparative Example 5

[0084] The present Example provides a comparative process for the production of meat analogues in which the outlet temperature of a second heating unit is below melting temperature.

[0085] Three parts of meat emulsion containing 90.8% meat and animal derivatives, 4.7% water, and 4.5% of at least one of vitamins, minerals, palatants, colorants, etc. (all percentages are weight percentages based on the total weight of the slurry) as to achieve a nutritionally complete cat food finished product were mixed with one part vegetable protein powder containing min. 75% protein (vital wheat gluten) to form a semi-solid mixture containing 30.5% crude protein, 59% moisture and 4.5% fat (all percentages of the semi-solid mixture are based on the total weight of the semi-solid mixture). The mixture was fed into a first SSHE unit with a volume of approx. 17 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The first SSHE unit was continuously supplied with steam at a temperature between 134-136° C. and the shaft was operated at 200 rpm. The outlet temperature of the material from first SSHE heating unit was between 90-95° C. The material was immediately directed into a second SSHE heating unit with a volume of approx. 9.7 L and a surface to volume ratio of 60 m2/m3 under 1,200 kPa product pressure. The second SSHE heating unit was continuously supplied with steam at a temperature between 166-168° C. and the shaft was operated at 250 rpm. The outlet temperature of the material from the second SSHE heating unit was below melting temperature and between 120-125° C. The residence time in the two heating units was distributed as two-thirds in the first heating unit and one third in the second heating unit. The material was then directed to a cooling area through which its temperature was brought down to below 80° C. No internal fibrosity was observed in the outlet material, only protein coagulation.

[0086] Although the presently disclosed subject matter and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the application as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the presently disclosed subject matter, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein can be utilized according to the presently disclosed subject matter. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

[0087] For any patents, patent applications, publications, product descriptions, and protocols are cited throughout this application, the disclosures of all of which are incorporated herein by reference in their entireties for all purposes.