A PROCESS FOR PREPARING A CRISPY COATED EXTRUDED PLANT-BASED FOOD PRODUCT

Abstract

The invention generally relates to a process for preparing a crispy coated extruded plant-based food product. More specifically the invention relates to a process for preparing a crispy coated extruded plant-based food product with a fibrous appearance and good juiciness and tenderness properties.

Claims

1. A process for preparing a crispy coated extruded plant-based food product, the process comprising the steps of: a) feeding an extruder barrel with a composition comprising 40-70 wt % water and 15-35 wt % plant protein; b) extruding the composition from step a) above the denaturation temperature of the plant protein; c) cooling the composition from step b) through a cooling die; d) injecting an aqueous solution into the extruded composition from step c); e) coating of the injected extruded composition of step d); and wherein the aqueous solution is injected by a needle injector or vacuum-tumbler.

2. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the extruded plant-based food product does not comprise protein from an animal source.

3. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the plant protein is selected from the group consisting of soy protein, pea protein, canola protein, hemp protein, oat protein, fava protein or wheat gluten, and a combination thereof.

4. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the plant protein is selected from a combination of at least two different plant proteins, wherein said plant proteins comprise wheat gluten and at least one other plant protein selected from the group consisting of pea protein, soy protein, fava bean protein, and canola protein and wherein wheat gluten comprises between 20 to 70% of total plant protein in the plant protein mixture.

5. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the extruder barrels are heated to a temperature between 80-300 C.

6. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the extruded mixture has an exit temperature at the end of the cooling die between 50-110 C.

7. The process for preparing a crispy coated extruded plant-based food product according to claim 1 further comprises a cutting of the extruded composition after step c) or step d).

8. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein 5-35 wt % (based on total composition) of the aqueous solution is injected into the extruded composition.

9. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the needle injector is a multiple-needle injector.

10. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the aqueous solution has a temperature between 5 to 38 C.

11. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the aqueous solution comprises water or a water-based solution.

12. The process for preparing a crispy coated extruded plant-based food product according to claim 1, wherein the coating is selected from the group consisting of crumb coating, flour coating, tempura coating, cornflakes coating or a combination thereof.

13. The process for preparing a crispy coated extruded plant-based food product according to claim 11, wherein the water-based solution comprises at least one of the ingredients selected from the group consisting of flavouring, hydrocolloid, starch, fiber, protein, vitamin, mineral, colorant, lipid and a combination thereof.

14. The process for preparing a crispy coated extruded plant-based food product according to claim 11, wherein the aqueous solution comprises at least one further ingredient selected from the group consisting of 0.1-40 wt % of flavouring (based on the aqueous solution), 0.01-5 wt % of hydrocolloid (based on the aqueous solution), 0.1-7 wt % of starch (based on the aqueous solution), 0.01-5 wt % of protein (based on the aqueous solution), 0.01-5 wt % of fiber (based on the aqueous solution), 0.01-30 wt % of lipid (based on the aqueous solution), 0.0001-5 wt % of vitamin (based on the aqueous solution), 0.0001-5 wt % of mineral (based on the aqueous solution), 0.01-10 wt % of colorant (based on the aqueous solution) and a combination thereof.

Description

EXAMPLES

Example 1-2

[0055] The examples are describing the preparation of a crispy coated extruded plant-based food product by the process of this invention. A dry mix of the plant protein was added through a hopper into the extruder barrel and water is separately injected into the extruder. The extruder barrels are heated within a curve between 80-180 C. The cooling die is cooling the extruded mixture to an exit temperature of 80 C. The extruded product is cut, and an aqueous solution is injected using a needle injector (Henneken; HPI650Servo). The coating of the injected plant-based extrudate has been done using GEA Batter Mixer 200P, GEA Wet Coater 600, GEA Crumb Master 600 or GEA Tempu Dipper. The extrudate was made on a Bhler B93 twin screw extruder from the following materials:

TABLE-US-00001 Comp. ex 1 Example 2 Extrusion Water [wt %] 63 63 process to Soy Protein 33 33 obtain concentrate [wt %] extrudate Flavouring [wt %] 4 4 Injection Water [wt %] 0 8 into extrudate

[0056] Comparison example 1 shows no injection of water into the extrudate. In an additional processing step 8 wt % of water has been injected into example 2. All examples are treated with a batter comprising 64 wt % of water, 3.5 wt % of corn starch and 32.5 wt % of wheat flour and afterwards coated with breadcrumbs.

[0057] 8 internal experienced panelists were used to rate the sensory attributes of the examples. Therefore, the examples have been fried in oil before tasting. The fibrous structure of both examples is the same. All panelists appreciated the juicier and more tender mouthfeel of example 2 compared to comparison example 1.

Example 3

[0058] Following the process and coating of example 1 an extruded product has been obtained from the following materials:

TABLE-US-00002 Example 3 Extrusion Water [wt %] 65 process to Soy Protein concentrate 33 obtain [wt %] extrudate Flavouring [wt %] 2 Injection Aqueous solution with 2% of 8 into flavours (based on aqueous extrudate solution) [wt %]

[0059] 8 internal experienced panelists were used to rate the sensory attributes of example 2 compared to example 1. The fibrous and juiciness perception of the products is the same, but example 2 has a better taste compared to example 1. To be not bound by theory it is expected, that the flavour (NaCl and meat flavor) is not entrapped in the protein matrix as it would be by the extrusion process. Therefore, the flavour is perceived more intense in the mouth and the amount of flavour can be lowered in case the flavour is injected within the aqueous solution.

Example 4-6

[0060] Following the process and coating of example 1 an extruded product has been obtained from the following materials:

TABLE-US-00003 Exam- Exam- Exam- ple 4 ple 5 ple 6 Extrusion Water [wt %] 59 59 59 process to Soy Protein concentrate 18 18 18 obtain [wt %] extrudate Wheat Gluten [wt %] 18 18 18 Flavouring [wt %] 5 5 5 Injection Aqueous solution with 10 into 2 wt % of flavours (based extrudate on aqueous solution) [wt %] Injection Aqueous solution with 10 into 2 wt % of flavours and extrudate 2 wt % of starch (based on aqueous solution) [wt %] Injection Aqueous solution with 14 into 2 wt % of flavours and extrudate 2 wt % of starch and 0.6 wt % of xanthan (based on aqueous solution) [wt %]

[0061] The aqueous solution of example 5 comprises in addition to example 4 also a starch. The aqueous solution of example 6 comprises in addition a hydrocolloid, which increase the viscosity of the aqueous solution and the amount of the injected aqueous solution.

[0062] 8 internal experienced panelists were used to rate the sensory attributes of examples 4 to 6. The fibrous perception has been rated equal. Example 5 has been perceived juicier and more tender compared to example 4. The starch in example 5 and 6 increases the water holding capacity of the final product after cooking or frying. After frying in oil example 4 lost 19% wt of water, wherein example 5 only lost 9 wt % of water after frying. The best perceived example regarding juiciness and tenderness was example 6.

Comparison Example 7: Boiling of Extrudate in Water Compared to Injection

[0063] Comparison example 1 has been used to boil the extrudate for in 90 C. hot water and compare it against example 2. The extrudate has been weighted before and after the cooking to measure the water up-take. The boiled extrudate only had a water up-take of 4 wt % (based on total composition). This shows, that by injecting an aqueous solution into the extrudate according to the invention a higher amount of water into the product can be achieved, which gives a juicier and tender sensorial attribute. In addition, a further advantage is, that the injection of the extrudate with a multiple-needle injector is much faster and only takes a few seconds, whereas the boiling process takes at least several minutes. After boiling the boiled extrudate needs to be cooled, wherein the injection can be done with a cold aqueous solution. This increase again the processing time. In addition, no heat sensitive ingredients (for example starch and/or colorants) can be used during a boiling step compared to the process of injection.