A METHOD OF PRODUCING A STACKED, SLICED FOOD ANALOGUE

Abstract

The present invention relates to a method of producing a stacked, sliced food analogue. The invention finds utility in the field of food production, in particular in the field of production of plant-based food analogues, and specifically plant-based cheese analogues.

Claims

1. A method of producing a stacked, sliced food analogue; the method comprising the steps of: (a) providing a food analogue mass comprising propionic acid; (b) forming at least a first and a subsequent slice from the food analogue mass; and (c) contacting the first and subsequent slices to form a stack.

2. A method according to claim 1, wherein the food analogue mass comprises protein, fat, thickener, and gelling agent.

3. A method according to claim 2, wherein the food analogue mass further comprises at least 45.5% (w/w) liquid water and at least 8.5% (w/w) gaseous water.

4. A method according to claim 1, wherein the food analogue mass comprises at least 5.0% (w/w) protein.

5. A method according to claim 1, wherein the food analogue mass comprises at least 25% (w/w) fat.

6. A method according to claim 1, wherein the food analogue mass comprises a thickener, which is a starch and/or a modified starch.

7. A method according to claim 6, wherein the modified starch is a combination of modified tapioca starch and modified potato starch.

8. A method according to claim 1, wherein the food analogue mass comprises at least 10% (w/w) thickener.

9. A method according to claim 1, wherein the food analogue mass comprises at least 1.5% (w/w) gelling agent.

10. A method according to claim 1, wherein the step of providing a food analogue mass comprises admixing at least two of 5.0% (w/w) pea protein, 25.0% (w/w) coconut oil, 7.5% (w/w) modified tapioca starch and 3.0% (w/w) modified potato starch, and 1.6% carrageenan with water to form an emulsion.

11. A method according to claim 1, wherein the step of providing a food analogue mass comprises heating at least two of protein, fat, thickener, and gelling agent to a temperature of greater than 80 C. to form an emulsion.

12. A method according to claim 1, wherein the step of providing a food analogue mass further comprises cooling the food analogue mass to a temperature of less than 20 C.

13. A method according to claim 1, wherein the step of contacting the first and subsequent slices forms a contiguous stack of separable first and subsequent slices.

14. A method according to claim 1, wherein the stack comprises at least 50 slices.

15. A method according to claim 1, wherein each slice weighs at least 14 g.

16. A method according to claim 2, wherein the protein is a plant protein, optionally at least 2.5% (w/w) plant protein.

17. A method according to claim 2, wherein the fat is a plant oil, optionally at least 10% (w/w) plant oil.

18. A method according to claim 2, wherein the thickener is a starch or modified starch, optionally at least 2.0% (w/w) starch or modified starch.

19. A method according to claim 18, wherein the thickener is at least 10.0% (w/w) starch or modified starch.

20. A method according to claim 2, wherein the gel at least one hydrocolloid, optionally at least 0.5% (w/w) at least one hydrocolloid.

21. A method according to claim 1, wherein the food analogue mass comprises at least 0.05% (w/w) of the propionic acid.

22. A method according to claim 1, wherein the food analogue mass comprises a starch, and the starch comprises tapioca.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0187] The invention will be described with reference to the accompanying drawings in which:

[0188] FIG. 1 illustrates slices separable by hand without breaking or tearing; and

[0189] FIG. 2 illustrates comparative samples, which do not form a contiguous stack and are not separable by hand, readily breaking and tearing.

EXAMPLES

[0190] The invention will now be described with reference to the following non-limiting examples.

Example 1

[0191] A cheese analogue mass was prepared by admixing 5.0% (w/w) pea protein (Ingredion UK Limited), 25.7% (w/w) coconut oil (Cargill GmbH, Hamburg), 7.5% (w/w) modified tapioca starch (Ingredion UK Limited) and 3.0% (w/w) modified potato starch (Ingredion UK Limited), and 1.6% (w/w) carrageenan (Kerry (NL) B.V.) with 45.5% (w/w) water in a large (5,000 kg) pre-blender where they are mixed using twin screw augers (such as Karl Schnell, DE).

[0192] The mixture was heated to a temperature of 90 C. using direct or indirect heating means with high shear mixing at 900 rpm using a batch or continuous cooking system until an emulsion formed.

[0193] The emulsion was extruded as a cheese analogue sheet by depositing the cooled emulsion onto a continuous casting belt. The emulsion was deposited on to a casting belt using industry standard technology comprising two stainless steel conveyor belts, cooling pans, food manifold, set of slitters, and twist and stack unit (such as HART Design & Manufacturing, Inc). The cheese analogue sheet thickness is obtained by adjusting manifold valves and thickness bar, and weight control is accomplished by varying the cheese pump speed.

[0194] The emulsion was cooled to a temperature of less than 20 C. Cooling of the casting line is accomplished with cooling pans. As the stainless steel conveyor belt passes over the cooling pans, coolant or chilled water is pumped into the pans and cools the belt, which in turn cools the cheese.

[0195] The extruded cheese analogue sheet was cut into slices/ribbons; each slice weighing approximately 14 g. Once the cheese analogue sheet reaches the opposite end of the conveyor, the cheese analogue sheet is directed around the end drum, over the doctor blade and onto the lower stainless steel belt. After the cheese analogue sheet passes over the lower belt and is slit into ribbons, the ribbons are directed over transfer rolls and through the twist and stack section.

[0196] Each of the cut slices was stacked to form a contiguous stack of desired number, which is then packed using an automatic packing machine which may be modified atmosphere depending on requirements Each of the cut slices was stacked to form a contiguous stack of 56 separable slices.

[0197] The stored slices were easily separable by hand without breaking or tearing (see FIG. 1).

Example 2

[0198] A comparative cheese analogue mass was prepared in accordance with Example 1 by admixing 10.0% (w/w) pea protein, 25.0% (w/w) coconut oil, 1.5% (w/w) modified potato starch, and 1.0% (w/w) hydrocolloids with 45.7% (w/w) water. The mixture was heated with high shear mixing until an emulsion formed. The emulsion was extruded as a cheese analogue sheet by depositing the cooled emulsion onto a continuous casting belt. The extruded cheese analogue sheet was cut into slices/ribbons. Each of the cut slices was stacked to form a contiguous stack of desired number.

[0199] The stored slices did not form a contiguous stack and were not separable by hand, readily breaking and tearing (see FIG. 2).

[0200] The present invention accordingly provides a method of producing a stacked, sliced plant-based food product analogue in a convenient and practical way, which reduces the requirement for superfluous packaging and thereby reduces the complexity of the method of preparation, associated costs, and ultimately the environmental impact. The present invention also provides a method that can be readily implemented at industrial scale.