MUSHROOM-BASED FOOD PRODUCT

Abstract

The present invention relates to mushroom-based meat substitutes and methods of producing mushroom-based meat substitutes, wherein the method incorporates a retorting step. The invention has been developed to provide versatile vegetarian or vegan alternatives to meat that can mimic the visual, textural, and/or flavour characteristics of meat, and in particular, cooked meat products.

Claims

1. A method of preparing a mushroom-based meat substitute comprising a mushroom material, an emulsion and a binding agent, wherein the method comprises: preparing a raw mushroom-based meat substitute comprising the mushroom material, the binding agent and the emulsion; exposing the raw mushroom-based meat substitute to a forming process to produce a formed mushroom-based meat substitute; and exposing the formed mushroom material to a retorting process.

2. The method of claim 1, wherein the mushroom material comprises shredded mushroom stem.

3. The method of claim 1, wherein the mushroom material comprises mushroom of the genera selected from the group consisting of agaricus, lentinula, pleurotus, hericium, laetiporus, armillaria, pioppini, flammulina, hypsizygus, lyophyllum, canterellus, or combinations thereof.

4. The method of claim 1, wherein the emulsion comprises lecithin, water and a plant-derived oil.

5. The method of claim 1, wherein the binding agent is a plant derived starch, fat or protein.

6. The method of claim 1, wherein the mushroom-based meat substitute comprises about 30% (w/w) to about 95% (w/w) mushroom material, about 2% (w/w) to about 60% (w/w) emulsion and about 0.5% (w/w) to about 10% (w/w) binding agent.

7. A method of preparing a mushroom-based meat substitute comprising a mushroom material, an emulsion and a binding agent, wherein the method comprises: exposing the mushroom material to a forming process; preparing a raw mushroom-based meat substitute comprising the formed mushroom material, the binding agent and the emulsion; and exposing the raw mushroom-based meat substitute to a retorting process.

8. The method of claim 7, wherein the mushroom material comprises shredded mushroom stem.

9. The method of claim 7, wherein the mushroom material comprises mushroom of the genera selected from the group consisting of agaricus, lentinula, pleurotus, hericium, laetiporus, armillaria, pioppini, flammulina, hypsizygus, lyophyllum, canterellus, or combinations thereof.

10. The method of claim 7, wherein the emulsion comprises lecithin, water and a plant-derived oil.

11. The method of claim 7, wherein the binding agent is a plant derived starch, fat or protein.

12. The method of claim 7, wherein the mushroom-based meat substitute comprises about 30% (w/w) to about 95% (w/w) mushroom material, about 2% (w/w) to about 60% (w/w) emulsion and about 0.5% (w/w) to about 10% (w/w) binding agent.

13. A method of preparing a mushroom-based meat substitute comprising a mushroom material, an emulsion and a binding agent, wherein the method comprises: exposing the mushroom material to a retorting process; preparing a raw mushroom-based meat substitute comprising the retorted mushroom material, the binding agent and the emulsion; and exposing the raw mushroom-based meat substitute to a forming process.

14. The method of claim 13, wherein the mushroom material comprises shredded mushroom stem.

15. The method of claim 13, wherein the mushroom material comprises mushroom of the genera selected from the group consisting of agaricus, lentinula, pleurotus, hericium, laetiporus, armillaria, pioppini, flammulina, hypsizygus, lyophyllum, canterellus, or combinations thereof.

16. The method of claim 13, wherein the emulsion comprises lecithin, water and a plant-derived oil.

17. The method of claim 13, wherein the binding agent is a plant derived starch, fat or protein.

18. The method of claim 13, wherein the mushroom-based meat substitute comprises about 30% (w/w) to about 95% (w/w) mushroom material, about 2% (w/w) to about 60% (w/w) emulsion and about 0.5% (w/w) to about 10% (w/w) binding agent.

19. A mushroom based meat substitute produced by the method of claim 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0097] Preferred features, embodiments and variations of the invention may be discerned from the following detailed description which provides sufficient information for those skilled in the art to perform the invention. The detailed description is not to be regarded as limiting the scope of the preceding summary of the invention in any way.

Mushroom-Based Meat Substitute

[0098] In the below described example formulations, the emulsion comprises a 1:5:1 ratio of isolated soy protein (emulsifier): water (polar liquid): coconut oil (carrier oil). The mushroom material substantially comprises mushroom stem. Example 1 to 3 and 7 below comprise an emulsifier comprising about 14.3% (w/v) isolated soy protein, about 71.4% (w/v) water and about 14.3% (w/v) coconut oil.

[0099] Mushroom-based meat substitute Example 1—Mince patty mushroom-based meat substitute

TABLE-US-00001 Ingredient Category Percentage(w/w) Emulsion Emulsion 48.73% Mushroom Mushroom material 42.70% Isolated soy protein Binding agent 2.33% Yeast Extract Flavour 0.69% Cocoa Butter Binding agent 1.93% Soy Sauce Flavour 0.32% Onion Powder Flavour 0.50% Garlic Powder Flavour 0.26% Tomato Paste Flavour 2.34% Liquid Smoke Flavour 0.20%

[0100] Mushroom-based meat substitute Example 2—Brisket style patty mushroom-based meat substitute

TABLE-US-00002 Ingredient Category Percentage (w/w) Emulsion Emulsion 50.07% Mushroom Mushroom material 43.87% Isolated soy protein Binding agent 2.39% Yeast Extract Flavour 0.71% Cocoa Butter Binding agent 0.00% Soy Sauce Flavour 0.34% Onion Powder Flavour 0.51% Garlic Powder Flavour 0.26% Tomato Paste Flavour 1.45% Liquid Smoke Flavour 0.406%

[0101] Mushroom-based meat substitute Example 3—Minced mushroom-based meat substitute

TABLE-US-00003 Ingredient Category Percentage (w/w) Emulsion Emulsion 44.55% Mushroom Mushroom material 39.09% Isolated soy protein Binding agent 2.13% Yeast Extract Flavour 0.64% Soy Sauce Flavour 0.31% Onion Powder Flavour 0.46% Garlic Powder Flavour 0.22% Tomato Paste Flavour 2.11% Liquid Smoke Flavour 0.20% Water Liquid 10.29%

[0102] Mushroom-based meat substitute Example 4—Slow cooked mushroom-based meat substitute

TABLE-US-00004 Ingredient Category Percentage (w/w) Yeast Extract Flavour 0.56 Sugar Flavour 2.06 Tapioca starch Binding agent 1.88 Salt Flavour 0.19 White pepper Flavour 0.11 Black pepper Flavour 0.09 Isolated soy protein Binding agent 5.87 Gluten Free Soy Sauce Flavour 0.94 Hydrated Mushroom Mushroom material 44.3 RBD Coconut oil Flavour 5.64 Emulsion Emulsion 26.62 Water Liquid 11.74 EMULSION of Example 4 % of emulsion % of total Isolated soy protein 13.6 3.62 Salt 0.5 0.13 Sugar 0.4 0.11 Coconut oil 16.3 4.34 Water 69.2 18.42 Total 100% 26.62%

[0103] Mushroom-based meat substitute Example 5—Mince burger patty mushroom-based meat substitute

TABLE-US-00005 Ingredient Category Percentage (w/w) Emulsion Emulsion 47.90% Hydrated Mushroom Mushroom 42.00% Material 60-75% MC material Isolated soy protein Binding agent 2.70% soy sauce Flavour 0.40% Salt Flavour 0.50% Onion Flavour 0.60% Garlic Flavour 0.30% Smoke Flavour 0.20% yeast extract Flavour 0.80% Tomato Flavour 0.20% Fat Moisture 4.40% EMULSION of Example 5 % of emulsion % of total Isolated soy protein 14.30% 6.80% Mushroom Liquid 2.5-8Brix 71.40% 34.20% Fat 14.30% 6.80% Total .sup. 100% 47.90%

[0104] Mushroom-based meat substitute example 6—Fresh mince mushroom-based meat substitute

TABLE-US-00006 Ingredient Category Percentage (w/w) Hydrated Shiitake Mushroom material 58.66% Hydrated Agaricus Mushroom material 6.52% Salt Flavour 0.51% Onion Flavour 0.57% Garlic Flavour 0.30% Yeast x Flavour 0.80% tomato powder Flavour 0.31% Emulsion + Binding Emulsion 32.33% Emulsion of Example 6 % of emulsion % of total Agaricus liquid 48.96% 15.83% Isolated soy protein 12.02% 3.89% Fat 35.18% 11.37% Flax 2.32% 0.75% Smoke 0.37% 0.12% Soy 1.14% 0.37%

[0105] Mushroom-based meat substitute Example 7—Roasted shaved mushroom-based meat substitute

TABLE-US-00007 Ingredient Category Percentage (w/w) RBD coconut oil Emulsion   2% colloidal emulsion Flattened shitake Mushroom material 66.36%  Rice Flour Binding agent 2.13% RDB coconut oil Flavour/Moisture 3.98% Onion Powder Flavour 0.40% Black pepper Flavour 0.33% Salt Flavour  0.2% Liquid Smoke Flavour 0.20% Agaricus liquid Liquid 22.56% 

Method of Making Different Embodiments of Mushroom-Based Meat Substitutes of Example 1-6

[0106] To make the mushroom-based meat substitutes 1 through 7 the emulsion was first prepared using a high sheer emulsifier until the mixture combined to a smooth mass.

[0107] The mushroom material, which was primarily mushroom stem, or whole mushrooms, is washed first to removed foreign matter. The mushroom materials then were hydrated by a 30-minute par-cooking process before being dehydrated. The dehydration steps to remove the excess water was performed by a centrifugal dryer, for about 3-5 min.

[0108] For Example 4, the hydrated mushroom material was placed in a bowl cutter fitted with blunt knives, and shredded for 5-7 minutes, depending on the desired fibre to be formed in the process. For all other Examples 1-3 and 5-6, the hydrated mushroom material was processed through a screw driven meat mincer, with the cutting plate ranging between 3-6 mm. In some preferred embodiments of the invention, the desired ratio of 3 mm to 6 mm dice is 20% 3 mm and 80% 6 mm, wherein the 6 mm diced mushroom material was exposed to a retorting process to change the colour, texture and flavour of the ingredient beneficially prior to combing with the binding agent and emulsion.

[0109] For each of Examples 1 to 7, the hydrated, shredded, minced and/or retorted mushroom material was combined with emulsion and mixed for 1-2 minutes, prior to adding the binding agent, any water and remaining ingredients and mixing for another 2 minutes to produce the raw mushroom-based meat substitute. The mixing process is performed at temperatures below 35° C.

[0110] For the forming process of the burger patty versions of mushroom-based meat substitutes of Example 1, 2 and 5, the raw mushroom-based meat substitute was formed into uniform burger patty shapes with uniform masses in the first stage of the forming process. For the second stage of the forming process, a continuous frying application was used, with the oil temperature being at least 180° C. (±5° C.), to flash fry the patties for about 50 seconds to achieved the desired surface texture, flavour and colour for the patties.

[0111] For the forming process of the ball or chunk version of mushroom-based meat substitute of Example 4, the raw mushroom-based meat substitute was formed into uniform ball or chunk shapes with masses ranging from 7-20 g in the first stage of the forming process. For the second stage of the forming process, a continuous frying application was used, with the oil temperature being at least 180° C. (±5° C.), to flash fry the pieces for about 50 seconds to achieve the desired surface texture, flavour and colour.

[0112] For the forming process of mushroom-based meat substitute of Example 3, the raw mushroom-based meat substitute was fed through a meat mincer directly in the continuous fryer set at 180° C. (±5° C.) and fired for about 30-40 seconds, such that the first and second stage of the forming process were essentially performed at the same time.

[0113] For the forming process of mushroom-based meat substitute of Example 6, the raw mushroom-based meat substitute was fed through a meat mincer with plate size 5-8 mm to resemble freshly minced meat in the first stage of the forming process. This product was not subjected to the second stage of the forming process, though the mushroom material was retorted prior to being combined with the emulsion. The product was packaged into Modified Atmosphere Packaging, under a Gas flush to maintain food safety.

[0114] For the forming process of mushroom-based meat substitute of Example 6, the raw mushroom-based meat substitute was formed into flatten sheets in the first stage of the forming process. This product was not subjected to the second stage of the forming process, and the product was packaged into Modified Atmosphere Packaging, under a Gas flush to maintain food safety.

[0115] The formed mushroom-based meat substitutes of examples 1-7 were then allowed to drain and/or cool, before packaging into retort pouches, bags or trays. The formed, packaged mushroom-based meat substitutes were then retorted in a steam retort with a core temperature of 121° C. for 15 minutes to ensure sterility produce additional flavours via the initiation of the Millard reaction.

[0116] The mushroom-based meat substitutes were then processed and packaged for sale.