Abstract
The present invention provides a novel combination of plant-based food groups in order to create a plant-based complete protein product that delivers an adequate proportion of all nine essential amino acids. A complete protein, often provided through animal-based food products, contains an adequate proportion of each of the nine essential amino acids. The present invention provides a novel combination of legumes and grains to create a plant-based complete protein product which can be further combined with additional ingredients to form a consumable dough containing plant-based complete protein.
Claims
1. A method for making a plant-based complete protein dough, said method comprising: formulating a dry mixture comprising grain protein, flour, and legume protein; combining said dry mixture with water; mixing said dry mixture and said water to form a dough; forming a desired shape with said dough; cooking said dough to form a cooked dough product; and drying said cooked dough product to form a dry dough product.
2. The method of claim 1, wherein said dough is formed into a noodle shape prior to said cooking.
3. The method of claim 1, wherein said flour further comprises at least a portion of whole grain flour.
4. The method of claim 1, wherein said legume protein comprises a pea protein.
5. The method of claim 1, wherein said method further comprises a method for commerce wherein said dry dough product is portioned, packaged, and sealed in shelf-stable containers distributed for commercial distribution.
6. The method of claim 1, wherein said flour is enriched wheat flour.
7. The method of claim 1, wherein said flour is gluten-free.
8. A plant-based complete protein dough product as made by a method comprising: formulating a dry mixture comprising grain protein, flour, and legume protein; combining said dry mixture with water; mixing said dry mixture with said water to form a dough; forming a desired shape with said dough; cooking said dough to form a cooked dough product; and drying said cooked dough product to form a dry dough product, wherein said plant-based complete protein dough product comprises: flour; grain protein; a plurality of salts; legume protein; and water.
9. The plant-based complete protein dough product of claim 8, wherein said flour is a gluten-free flour.
10. The plant-based complete protein dough product of claim 8, wherein said legume protein consists of pea protein.
11. The plant-based complete protein dough product of claim 8, wherein said dough is fried in an oil.
12. The plant-based complete protein dough product of claim 8, wherein said dough product is shelf-stable.
13. The plant-based complete protein dough product of claim 8, wherein said dough product is in the shape of a noodle.
14. The plant-based complete protein dough product of claim 8, wherein said flour further comprises a portion whole grain flour.
15. A system for making a plant-based complete protein dough, said system comprising: means for mixing a dry mixture comprising grain protein, flour, and legume protein; means for combining said dry mixture with water; combining said dry mixture with water to form a dough; means for forming said dough into a desired shape; means for cooking said dough; means for drying said dough; and means for packaging said dough in a shelf-stable container.
16. The system of claim 15, wherein said flour further comprises a portion of whole grain flour.
17. The system of claim 15, wherein said flour is gluten-free flour.
18. The system of claim 15, wherein said means for cooking said dough comprises means for boiling said dough.
19. The system of claim 15, wherein said means for cooking said dough comprises means for steaming said dough.
20. The system of claim 15, wherein said dough is combined with a plurality of dehydrated vegetables and a plurality of powdered spices prior to packaging and sealing in said shelf-stable container.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The various embodiments are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings. Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0026] FIG. 1 is a flow chart of the life cycle stages of the present invention.
[0027] FIG. 2 is a chart containing the environmental conditions required during the manufacturing process.
[0028] FIG. 3 is a chart containing the nutritional information of the present invention.
[0029] FIGS. 4A-B shows the steps of the method of the present invention.
[0030] FIG. 5 summarizes the basic elements of the invention.
[0031] FIG. 6 shows an exemplary legume protein data sheet.
[0032] FIG. 7 shows an exemplary first grain data sheet.
[0033] FIG. 8 shows an exemplary second grain data sheet.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] FIG. 1 is a flow chart of the life cycle stages of the present invention. In accordance with the preferred embodiment of the present invention, the manufacturing process begins with forming the dough. This dough may be used, in some embodiments, to form instant cooking noodles. The dry ingredients are mixed with water in order to form said dough, and once the dough has formed, the noodles are formed from the dough. Once the noodles are formed, they are cooked in a neutral oil, for example sunflower oil, and are steamed and fried. Once the noodles are cooked and portioned into individual servings, they are packaged in a food safe container along with spices and dehydrated vegetables specific to the flavor of the product. The term spices should be understood to encompass any edible aromatic vegetable or other substance used to provide flavor to food, for example and not by way of limitation, spices may include salt, pepper, cumin, paprika, garlic, and other similar dried, ground compounds. Once all ingredients have been added into the container, a lid is added and sealed, each container is placed on a pallet of several containers, the pallet is wrapped, and the product is distributed to retailers.
[0035] FIG. 2 is a chart containing the specific environmental conditions required during the manufacturing process. In accordance with the preferred embodiment of the present invention, several aspects must be considered in order to produce the exact composition desired. These aspects include but are not limited to the temperature in the room during production, the temperature of the oil used to cook the noodles, the humidity of the room during production, the amount of water used, the amount of steam used, the speed at which the components are combined, and the time it takes to cook the noodles before drying and packaging. In one example, but not by way of limitation, per 100 kg batch, 15-25% of oil used for frying the dough will be absorbed by the dough product as it fries. Between 3.0-4.0 kg of a plurality of salts (referred to as the salt mix) may be added. the environment humidity is maintained between 40-60%, the environment temperature is maintained between 65-75 degrees Fahrenheit, the added water is between 70-80% by weight, the steam used is maintained between 0.07-0.09 bar, the oil temperature used for frying is maintained between 140-160 degrees Celsius, the speed is between 120-150 seconds, and the thickness of the dough noodle product is between 0.040-0.050 inches.
[0036] FIG. 3 is a chart containing the nutritional information of the present invention. In accordance with the preferred embodiment of the present invention, the composition of the final product contains 20 g of complete protein, 14 g of fat total, wherein 1.5 g of the total fat is saturated fat, 0 g cholesterol, 29 g of total carbohydrates wherein 2 g of the total carbohydrates includes 2 g of dietary fiber and 3 g total sugars, 3 mg of iron, and 21 mg of calcium. One serving of the product contains approximately 330 calories. The protein content of the present invention makes up 36% of the daily value, the total fat content makes up 18% of the daily value, and the total carbohydrate makes up 11% of the daily value. Furthermore, iron makes up 15% of the daily value and calcium makes up 2% of the daily value. These percentages are based on the daily value calculated from a 2,000 calorie per day diet.
[0037] FIGS. 4A-B show the steps of the method of the present invention. Specifically, FIG. 4A shows a summary of the process. In accordance with the preferred embodiment of the present invention, the process may be summarized as follows. Ingredients for the plant-based complete protein dough are combined to form said dough, which is then kneaded and shaped. These steps are performed in a controlled environment wherein the temperature, humidity, and other environmental factors are monitored and maintained at ideal levels. The dough is then cooked and dried. The dough may be dried in small portions to increase speed of drying and to increase speed of packages post-drying. After the dough has dried, it may be packaged and shipped for retail or other purposes.
[0038] FIG. 4B shows a more detailed step by step process. In accordance with the preferred embodiment of the present invention, the process begins by combining a flour, which may be an enriched wheat flour, a gluten-free flour, a low GI flour, or other starch, and plant-based protein powders, for example a legume protein, a grain protein, or some combination thereof. In one embodiment, at least a portion of the plant-based protein is sourced from a legume, for example, green or yellow peas (any peas, etc.) and at least another portion of the plant-based protein is sourced from a grain, for example, wheat. In one embodiment, at least a portion of the flour used is whole grain flour. This dry mixture is then combined with water to form a dough. This dough is then formed into a desired shape, for example, a noodle, and cooked. The cooking process may include steaming, frying, boiling, baking, or some combination thereof. The cooked product is then portioned and dried before being packaged. Additional ingredients including but not limited to dehydrated vegetables and spices may be packaged along with the dried dough product before the package is sealed.
[0039] FIG. 5 summarizes the basic elements of the invention. In accordance with the preferred embodiment of the present invention, a plant-based complete protein product is formed from a first protein, a second protein, and a third protein. The first protein may be sourced from a legume. In one embodiment, the legume is a variety of pea including green, yellow peas, and any peas etc. The second and third proteins may be sourced from a grain. In one embodiment, the grain is a variety of wheat. In alternative embodiments, additional plant-based protein sources may be added to ensure adequate values of each of the nine essential amino acids are present in the final plant-based complete protein product. The plant-based complete protein product may then be combined with a starch and a liquid to form a dough containing plant-based complete protein. In the preferred embodiment, the starch may be flour and the liquid may be water. In an alternative embodiment, the starch may be a gluten-free flour and the plant-based complete protein may be developed in a way that when combined with the gluten-free flour and water, forms a gluten-free, plant-based, complete protein dough product. In another alternative embodiment, a portion of the starch may be composed of a whole grain flour. In another alternative embodiment, the starch is a flour having a low GI value.
[0040] FIG. 6 shows an exemplary legume protein data sheet. In accordance with the preferred embodiment of the present invention, a first protein is sourced from a legume which meets the specification criteria shown. Specifically, a first protein source should have a maximum of 6% moisture, at least 75% protein-moisture free basis (MFB), at most 50,000 cfu/g aerobic plate count, less than 10 cfu/g coliform, less than 10 cfu/g E. Coli, test negative for Salmonella per 375 g, less than 100 cfu/g yeast, less than 100 cfu/g mold, less than 2.5 ppm soy, less than 20 ppm gluten, and a pH between 6.5-7.5.
[0041] FIG. 7 shows an exemplary first grain data sheet. In accordance with the preferred embodiment of the present invention, a second protein is sourced from grain. An example of data from a suitable grain is shown. In one embodiment, the grain may have a moisture near-infrared (NIR) of 13.5, an ash NIR at 14% MB of 0.55, a protein NIR at 14% MB of 11.5, a falling number at 14% MB of 388, a farinograph absorption at 14% MB of 60.5, a farinograph mixing tolerance index (MTI) of 35, a farinograph peak of 6, and a farinograph stability of 11. These values are by way of example and are not intended to limit the scope of the present invention.
[0042] FIG. 8 shows an exemplary second grain data sheet. In accordance with the preferred embodiment of the present invention, a second grain is used which meets the acceptance criteria as shown. Specifically, the second grain should have a protein content greater than or equal to 75.0%, a moisture content less than or equal to 9.0%, an ash content of less than or equal to 1.5%, and a water absorption of greater than or equal to 150%. The results shown are by way of example and are not intended to limit the scope of the present invention. A microbiological analysis may also be completed to show that the grain used meets the accepted criteria shown. Specifically, a total aerobic plate count should be less than 10,000 cfu/g, a yeast and mold count should be less than 500 cfu/g, E. Coli and Salmonella should be absent. The results shown are by way of example and are not intended to limit the scope of the present invention.
[0043] In one embodiment, a noodle is formed from the dough product of the present invention. The noodle composition is formed by combining the dry ingredients with water and kneading the resulting dough until firm. Once the dough is prepared, it may be shaped via cutting, forming, or other methods. Once the dough is shaped as desired, for example into the shape of noodles, the noodles are cooked via frying in oil, steaming, or boiling, portioned into single servings, and then dried or frozen and packaged. An instant cooking effect (which generally refers to the noodles ability to cook to an al dente texture in approximately three minutes) may be achieved by perfecting the moisture content of the noodles. A perfect moisture content ensures that the noodles will cook quickly without losing texture, remaining too firm or disintegrating, and maintaining the ideal slurpability of the noodle.
[0044] While various embodiments of the disclosed technology have been described above, it should be understood that they have been presented by way of example only, and not of limitation. Likewise, the various diagrams may depict an example architectural or other configuration for the disclosed technology, which is done to aid in understanding the features and functionality that may be included in the disclosed technology. The disclosed technology is not restricted to the illustrated example architectures or configurations, but the desired features may be implemented using a variety of alternative architectures and configurations. Indeed, it will be apparent to one of skill in the art how alternative functional, logical or physical partitioning and configurations may be implemented to implement the desired features of the technology disclosed herein. Also, a multitude of different constituent module names other than those depicted herein may be applied to the various partitions. Additionally, with regard to flow diagrams, operational descriptions and method claims, the order in which the steps are presented herein shall not mandate that various embodiments be implemented to perform the recited functionality in the same order unless the context dictates otherwise.
[0045] Although the disclosed technology is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead may be applied, alone or in various combinations, to one or more of the other embodiments of the disclosed technology, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the technology disclosed herein should not be limited by any of the above-described exemplary embodiments.
[0046] Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term including should be read as meaning including, without limitation or the like; the term example is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms a or an should be read as meaning at least one, one or more or the like; and adjectives such as conventional, traditional, normal, standard, known and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.
