EGG PROTEIN PRODUCT

This invention relates to food and in particular to a versatile and healthy food product

made from egg protein.

BACKGROUND

Protein requirements for humans are supplied by a wide variety of foods, both from vegetable sources such as nuts, beans, and peas, and from animal sources such as meat, milk, and eggs. Various well known foods such as cheese, peanut butter, and tofu are derived from raw foods to provide high protein foods. Protein is also commonly concentrated from various food sources, such as milk, egg, and soybeans, to make protein supplement products for use by athletes.

For health and economic reasons, considerable effort has been made to develop concentrated protein products that have the full taste and texture of meat or cheese or peanuts or any other food but are made from vegetable protein.

Texturized vegetable protein (TVP) is a product made from soybeans. It is produced from soy flour after the soybean oil has been extracted, then cooked under pressure,

extruded, and dried. TVP typically comes in small dry chunks, granules, or in a finely-

ground form. It's flavorless, but when rehydrated it and with added flavorings, it provides

a protein-filled addition to dishes calling for ground meat. Because of its varying texture, it's versatile, and can take on the texture of many meats, and substituted for meat as an ingredient in many dishes. Once rehydrated, TVP granules can be used as a substitute for ground beef in recipes such as chili, spaghetti sauce, and tacos. The chunks can be used to replace meat in stews and soups. It can be flavored to taste like beef, sausage, or chicken.

Soybean products have a definite taste that must be overcome by adding significant flavoring if it is desired to disguise the conventional TVP product in certain dishes. As with most foods, a portion of the population cannot derive the health and economic benefits of TVP because of allergies.

Textured whey protein products are also known for use as meat substitutes or extenders, for example as disclosed in United States Patent Application Number 20040161519.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a texturized high protein food product derived from eggs that overcomes problems in the prior art.

Egg whites comprise essentially protein and water, and are readily and commonly

separated from the whole eggs for various food uses. The amino acid distribution of the

protein in egg whites almost identically follows the amino acid distribution of the human body, and thus is more readily assimilated than the protein of other foods. The amino acid distribution of egg white protein is about a 97% match to humans. In contrast, soybean protein for example, such as is found in TVP, is only about a 48% match.

Egg whites have virtually no flavor, so that masking with large quantities of flavorings is not required. They also are very low in fats, have no cholesterol or sugar, are easily digested and satisfy hunger cravings. Moreover, the vitamin and nutrient content of eggs, as well as the taste, can be enhanced by adjusting the feeding regime of the layers - for example, eggs can be produced to contain heightened levels of lutein and omega 3 fatty acids.

Texturized egg protein can be made by separating egg whites and then cooking, drying, rehydrating, extruding, or otherwise processing in different ways to obtain different textures and flavours. Typically the texturized egg protein product will be supplied in a dry form in chunks, granules, or powder, and then rehydrated for use. For example, texturized egg protein may be used to develop substitute forms of each of beef chili, ricotta cheese and noodles, thus creating a new form of lasagna. Texturized egg protein can also be used to develop entirely new food products, such as meal replacement bars.

Texturized egg protein enables consumers to access either familiar foods (such as

lasagna, or burgers) or new foods (such as snacks, power bars, or breakfast cereals) in

healthy ways that have the taste and texture of meat or cheese or peanuts or any other food, but that offer the superior health benefits of egg protein.

DETAILED DESCRIPTION

Eggs, or derivatives of eggs (in dried or liquid form), as a whole or as components (white as opposed to yolk) will be used in the manufacture of extruded texturized egg protein products. Dried egg whites can be manufactured by drum drying, spray drying or freeze drying. Selection of processing aids is determined based on the process of extrusion and end-use food application. The steps required for processing egg whites into a texturized egg protein product will vary with the nature of the desired end product.

A method for making texturized egg protein product using extrusion, either through single screw or twin screw extruders comprises:

(i) preparing an egg protein mixture, for example powdered egg white and a starch,

(ii) thermoplastic extrusion under controlled temperature and pressure to form an extrudate,

(iii) optionally puffing the extrudate prior to cooling to form an expanded

product, such would be suitable for snack food,

(iv) cooling at atmospheric pressure, (v) drying to form a texturized egg protein product.

The physical appearance can be altered through sizing, colouring, and like processes. The physical properties can be altered by secondary processes. The chemical composition, textural and functional properties vary depending on composition of ingredients, configuration and process parameters of the extruder.

A method for making a texturized egg protein product comprises:

(a) preparing a mixture comprising about 20-80% by weight of dried egg white powder and about 20-80% by weight of an edible starch;

(b) thermoplastically extruding the composition under conditions of temperature and pressure such that the composition is melted and cooked to result in an extrudate; and

(c) drying the extrudate to result in the texturized egg protein product.

Cooling the extrudate prior to returning it to atmospheric pressure inhibits expansion or puffing of the extrudate and results in a texturized egg protein product having a fibrous

meat-like texture bound together by fibres that is suitable for use as a meat extender or

meat analog. If the extrudate is not cooled prior to being returned to atmospheric

pressure, then the extrudate expands or puffs, resulting in an expanded texturized egg protein product suitable for use as a snack food.

EXAMPLE 1

Texturized egg protein products were made according to the present invention by extruding the following blends of dried egg white powder EW, rice flour RF, and pea flour PF:

a) 50% EW 50% PF - resulted in product with substantially no texture

b) 70% EW 30% RF - resulted in a highly textured product - the most favourable product - very suitable for use as a meat extender or substitute

c) 80% EW 20% RF - less texture, less suitable

The product from b) was the most suitable of the products for meat substitutes.

EXAMPLE 2

Expanded texturized egg protein products were made according to the present invention by extruding the following blends of egg white powder EW and corn starch CS:

a) 50% EW 50% CS - resulted in poor expansion b) 30% EW 70% CS - very good expansion, very suitable for snack food c) 20% EW 80% CS - very good expansion, very suitable for snack food

The product from b) has a higher protein content than that of c) with similar physical characteristics, and will generally be preferred.

Thus it appears from the examples that increasing the egg white content above 50% and cooling the extrudate prior to returning it to atmospheric pressure to inhibit expansion results in a highly textured product with high protein that is suitable for meat substitutes and extenders, while reducing the egg white content below 50% and allowing the extrudate to expands or puff results in an expanded texturized egg protein product suitable for use as a snack food.

It is contemplated that other starches could be combined with the egg whites as well in varying proportions to form suitable texturized egg protein products.

It is contemplated as well that other food grade protein source material could be added to

the egg white powder in some circumstances, however given the economy and particular suitability of egg white protein for human consumption, it is contemplated that the food grade protein blended with starch to form the composition to be extruded will comprise at least about 50% egg white powder.

The protein in the texturized egg protein product is more readily assimilated than the protein of other foods because amino acid distribution of the egg white protein is very close to the amino acid distribution of the human body

The texturized egg protein product is versatile and has a wide range of food applications. It is contemplated that flavoring and other treatments known in the art can be applied to the product to produce a wide variety of foods including:

• Bakery e.g. cookies, cakes, cake mixes

• Noodles

• Meat replacements & extenders e.g. pizza, hamburgers, chili, meat loaf, meat sauces, soups, stews, meat pies, dry soup mixes

• Food analogs

• Pet food application

• Functional foods

• Food adjuncts

• Meal replacements e.g. energy bars, protein bars

• Snack foods e.g. chips, crackers

• Breakfast cereal

It is contemplated that non-food applications would include:

• Medical applications

• Packaging materials

• Polymers for use in manufacture

• Processing aids

• Anti-caking agents

• Carriers and delivery systems of chemicals and compounds

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous changes and modifications will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all such suitable changes or modifications in structure or operation which may be resorted to are intended to fall within the scope of the claimed invention.