Introduction

Meat and seafood products have a fibrous structure in which the myofibrils are aligned and visible after cooking. This type of structure provides a fibrous mouthfeel and texture.

Plant based versions of seafood products like crab, scallop, and calamari have become increasingly popular in recent years. High moisture extrusion generates extrudates with fibers that are high in protein content. The extrudate is usually brown or yellowish, whereas many seafoods are more gel-like and whitish.

Surimi is a crab imitation product made from egg, fish protein and starch. However, the fibers are not tightly connected and they tend to separate whilst the product is being cut.

Plant based seafood such as scallop is commercially available, but current offerings are characteristically poor in texture because they resemble a homogenous mass that lack the fiber bundle structure typical of animal based products.

Description of the Invention

The present teaching relates generally to an improved system for the production of meat and seafood analogues. It is a closed system capable of continuously generating meat and seafood analogues with visibly aligned fiber bundles that are highly connected.

The system of the invention comprises a die, wherein the die has an entrance plate and an exit plate. There are an array of tubes or pipes between the entrance plate and the exit plate. The plates are located at each end of the die. Each plate comprises holes. The entrance plate holes, the exit plate holes, and the tubes are configured to allow passage of a foodstuff through the die. The pipes generate fiber bundles in a foodstuff or dough as it passes through the pipes.

The system includes a means for applying an immiscible liquid to the foodstuff during its passage through the die, preferably during its passage through the exit plate holes.

In some embodiments, the system comprises i) a die, wherein the die comprises an entrance plate and an exit plate at each end, an array of tubes between the entrance plate and the exit plate, wherein each plate comprises holes, and wherein the entrance plate holes, the exit plate holes, and the array of tubes are configured to allow passage of a foodstuff through the die; and ii) means for applying an immiscible liquid to the foodstuff during its passage through the die, preferably during its passage through the exit plate holes. In some embodiments, the system comprises i) a die, wherein the die comprises an entrance plate and an exit plate at each end, an array of tubes between the entrance plate and the exit plate, wherein each plate comprises holes, and wherein the entrance plate holes, the exit plate holes, and the array of tubes are configured to allow passage of a foodstuff through the die; ii) means, preferably a pump, for delivering a dough mixture to the die and/or for its passage through the die to form a foodstuff; iii) means for coating a liquid onto the foodstuff during its passage through the die, preferably during its passage through the exit plate holes, wherein the liquid is thermodynamically immiscible to the foodstuff; and iv) means for controlling the temperature of the dough mixture, foodstuff and/or the immiscible liquid.

In some embodiments, the foodstuff is a gellifying preparation, and the thermodynamically immiscible liquid is applied to the foodstuff at or above the gellifying temperature of the foodstuff.

In some embodiments, the system further comprises a tubular structure which is connected to and located downstream of the die. Typically, the tubular structure has the same or substantially the same cross-sectional area as the sum of the plurality of cross-sectional areas of the holes on the exit plate. Preferably, the cross sectional area is kept substantially the same throughout the system. This helps to prevent pressure difference and so avoid product shear.

In some embodiments, the system further comprises a tubular structure which is connected to and located upstream of the die. The upstream tubular structure can be used for pre-heating, to regulate the dough thickness and to prepare for the gelation.

In some embodiments, the system further comprises means for independently controlling the temperature of one or more of the tubular structures.

In some embodiments, the entrance plate and exit plate have substantially the same diameter. In some embodiments, the entrance plate holes, the tubes, and the exit plate holes have substantially the same diameter.

In some embodiments, the entrance plate holes and exit plate holes cover substantially all of the entrance plate and exit plate surfaces, respectively.

In some embodiments, a cutting device is located at the end of the tubular structure located downstream of the die. This produces a product of the correct size for packing.

In some embodiments, the means for applying the immiscible liquid further comprises a distribution chamber of immiscible liquid and outlets located around the exit plate holes. The distribution chamber and outlets can be connected by an oil pipe. In some embodiments, the immiscible liquid is oil. In some embodiments, the immiscible liquid is or comprises fat, for example at least 50% fat. In some embodiments, the immiscible liquid is or comprises emulsion, for example at least 50% emulsion. In some embodiments, the immiscible liquid is or comprises wax, for example at least 50% wax. Typically, the emulsion has a lipid content greater than 50%.

The invention further relates to a method of making a meat or seafood analogue.

In some embodiments, said method comprises preparing a dough mixture; passing the dough mixture through a die; and coating the foodstuff with an immiscible liquid during its passage through the die.

In some embodiments, said method comprises preparing a dough mixture; passing the dough mixture through a die to form a foodstuff; and coating the foodstuff with an immiscible liquid during its passage through the die.

In some embodiments, said method comprises preparing a dough mixture; passing the dough mixture through a die, wherein the die comprises an entrance plate and an exit plate at each end; and coating the foodstuff with an immiscible liquid during its passage through the die.

In some embodiments, said method comprises preparing a dough mixture; passing the dough mixture through a die to form a foodstuff, wherein the die comprises an entrance plate and an exit plate at each end, an array of tubes between the entrance plate and the exit plate, wherein each plate comprises holes, and wherein the entrance plate holes, the exit plate holes, and the array of tubes are configured to allow passage of a foodstuff through the die.

In some embodiments, said method comprises preparing a dough mixture; passing the dough mixture through a die, wherein the die comprises an entrance plate and an exit plate at each end, each plate comprising holes, wherein the entrance plate holes, the exit plate holes, and the tubes are configured to allow passage of a foodstuff through the die; and coating the foodstuff with an immiscible liquid during its passage through the die, preferably during its passage through the exit plate holes.

In some embodiments, said method comprises a) preparing a dough mixture; b) passing the dough mixture through a die, wherein the die comprises an entrance plate and an exit plate at each end, an array of tubes between the entrance plate and the exit plate, wherein each plate comprises holes, and wherein the entrance plate holes, the exit plate holes, and the array of tubes are configured to allow passage of a foodstuff through the die; and c) coating the foodstuff with a liquid during its passage through the die, preferably during its passage through the exit plate holes.

In some embodiments, the method comprises a) preparing a dough mixture; b) passing the dough mixture through a die to form a foodstuff, wherein the die comprises an entrance plate and an exit plate at each end, an array of tubes between the entrance plate and the exit plate, wherein each plate comprises holes, and wherein the entrance plate holes, the exit plate holes, and the array of tubes are configured to allow passage of a foodstuff through the die; and c) coating the foodstuff with a liquid during its passage through the die, preferably during its passage through the exit plate holes; and wherein the liquid is thermodynamically immiscible to the foodstuff, and the foodstuff is a gellifying preparation.

In some embodiments, a pump is used to deliver the dough mixture to the die and to pass the dough mixture through the die to form a foodstuff.

In some embodiments, the liquid is coated onto the foodstuff at a temperature which is at or above the gellifying temperature of the foodstuff.

In some embodiments, the meat or seafood analogue foodstuff is made using a system according to the invention.

In some embodiments, the dough mixture comprises konjac powder, pea fiber, tapioca starch and oil.

In some embodiments, the dough mixture comprises alginate, konjac glucomannan, soy protein, rice protein and encapsulated calcium.

The seafood analogue recipe may be substantially as described in the Examples.

For example, the seafood analogue may comprise pea fiber at a concentration of between 1 to 10 wt%, preferably between 3 to 6 wt%, or 4 to 6 wt%. Preferably, the seafood analogue comprises flavor, salt, sugar, and/or an insoluble mineral salt, for example calcium carbonate. Preferably, the seafood analogue comprises a starch source, for example between 1 to 10 wt% starch source, or between 3 to 8 wt% starch source, for example about 5 wt% starch source, preferably tapioca starch. Preferably, the seafood analogue comprises konjac, for example between 1 to 5 wt% konjac, for example konjac powder. Preferably, the seafood analogue comprises oil, for example between 1 to 5 wt% oil, for example sunflower oil.

For example, the seafood analogue may comprise alginate at a concentration of between 1 to 5 wt%, preferably between 2 to 4 wt%, or about 3 wt%. Preferably, the seafood analogue comprises flavor, salt, sugar, and/or an encapsulated calcium salt. Preferably, the seafood analogue comprises a protein source, for example between 1 to 10 wt% protein source, or between 1 to 5 wt% protein source, for example about 3 wt% protein source, for example soy protein. Preferably, the seafood analogue comprises konjac, for example between 1 to 5 wt% konjac, for example konjac glucomannan.

The invention further relates to a packaged food product comprising the meat or seafood analogue according to the invention. The food product may be, for example, a pasta, a pizza, a salad, a sandwich, a breaded, or a deep fried shrimp. Preferably, the food product is a vegan food product.

Detailed description of the embodiments

The system of the invention comprises a die, wherein said die comprises an entrance plate comprising holes and an exit plate comprising holes. The die can be made of stainless steel. Preferably, the entrance plate holes and the exit plate holes are connected by tubes. The exit plate preferably comprises outlets surrounding the exit plate holes for the application of immiscible liquid to the foodstuff during its passage through the exit plate holes. Preferably, the diameter of the entrance plate holes, the exit plate holes, and the pipes connecting the entrance plate holes and the exit plate holes are substantially similar. Preferably, the holes on the exit plate cover substantially all of the surface area of the exit plate. This helps to avoid significant disturbance of the flow of the foodstuff and to obtain straighter fiber bundles. The shape of the entrance plate and exit plates can be round, rectangular, or an alternative shape. The shape can be round, or substantially round. The shape of the entrance plate and exit plate can be the same as the tubular structure connected to the exit plate.

There can be about 35 holes on the entrance plate and about 35 holes on the exit plate. The typical inside diameter of each plate is about 28 mm. The typical outside diameter of each plate is about 30 mm. There can be about 11 holes per square centimetre on the entrance plate and on the exit plate. Each hole can be substantially the same shape and size. The diameter of each hole can be about 2.2 mm. Alternatively, the pipes can be replaced by a series of plates with holes configured so that a foodstuff can pass from one side of the die to the other through the holes.

The means for applying an immiscible liquid is configured so that the immiscible liquid is applied to the surface of the foodstuff during its passage through the die, preferably during its passage through the exit plate holes. The means for applying an immiscible liquid may comprise a distribution chamber and a pump, configured in use so that the immiscible liquid is moved from the distribution chamber to the die, for example to the exit plate holes.

The immiscible liquid keeps the foodstuff fiber bundles separate and helps to prevent them remerging with one another after passage of the foodstuff fiber bundles through the exit plate holes. Typically, the immiscible liquid is pumpable at room temperature or when heated and is capable of being injected in small volumes onto the foodstuff during passage of the foodstuff through the die, preferably during passage of the foodstuff through the exit plate holes.

Typically, a tubular structure, which can in some embodiments be an alternative geometrical structure, is located downstream of the exit plate. The tubular structure does not typically exert significant pressure on the foodstuff during its passage. This would have the unwanted side effect of disrupting fiber alignment. Typically, the minimum inner diameter of the tubular structure is be the sum of the surface area of the holes on the exit plate. The maximum inner diameter of the tubular structure should be the sum of the surface area of the exit plate. The tubular structure may have an internal diameter of about 20 mm. The tubular structure may have an alternative, non-cylindrical shape. For example, it could be a square shape. The tubular structure located downstream of the exit plate may have a length of about 2 meters. This can be further extended to provide greater residence time for the foodstuff. The tubular structure located upstream of the exit plate may have a length of about 1.5 meters, although this is usually less critical than the length of the tubular structure located downstream of the die. The tubular structure located upstream may also have a pressure guage. The die and the downstream tubular structures can be arranged so that the foodstuff travels in the same downward plane.

Typically, heating is applied through the tubular structure to set and stabilize the foodstuff fiber bundles in the closed device. Expansion during heating may create a slight pressure and help to form compact aligned fiber bundles. The tubular structure is typically arranged so that the foodstuff travels in the same direction after its exit from the die. Where the tubular structure is heated, the temperature is typically set to about 100°C (100 degrees Celsius) to ensure that the minimum temperature of the foodstuff is about 80°C as it passes through the tubular structure. Heating of the tubular structure may use a double jacket heating mechanism. The tubular structure located downstream of the die may be divided in more than one part. For example, a first part adjacent to the die can be heated to about 90°C, and a further part located adjacent to and downstream to the first part can be heated to about 100°C. Suitable temperatures that can be used are demonstrated in the examples section. Where the tubular structure is cooled, the temperature is set at a suitable level in order to settle the gel. A suitable cooling temperature is about 4°C.

The invention further relates to a method of making a meat or seafood analogue. The seafood analogue may be a texturized seafood product.

The method comprises preparing a dough mixture. Preferably, the mixture is formed by hydrating and mixing raw materials to form a dough, wherein the raw materials include fibres, protein, oil, sugar, salt, water. Preferably, the temperature of the mixture is below the gelling temperature of the formulation. The thickness of the dough should be sufficient to avoid re-merging. The storage modulus G' should be greater than the loss modulus G" in oscillation measurement.

The mixture is passed through a die according to the invention. The flow rate of dough through the die may be, for example, up to about 20 kg per hour, for example about 4 kg dough per hour or between 8 to 10 kg dough per hour, or between 8 to 20 kg dough per hour. Preferably, a texturized product with aligned fiber bundles is formed by pressing the dough through the die. Preferably, an immiscible liquid, for example an oil, is injected through outlets surrounding the hole in the exit plate, thereby the surface of the fiber bundles. The oil quantity should be controlled to generate a thin layer for separation of the fiber bundles but still allowing the fiber bundles to connect with each other as a whole mass.

The aligned fiber bundles coated with oil will be pushed into a tubular structure or heating pipe to set and stabilize the structure. The expansion during heating will create pressure and form compact aligned fiber bundles. The gelation depends on the heating temperature and residence time, and further defined by the flow rate and the length of the pipe. These parameters are defined to solidify the gel for further cutting and achieve the final texture.

Typically, the final thickness of the product is about 3 cm. The residence time of the dough in the tubular structure is important for heat exchange. The dough needs to be thick enough or partially gelled when entering device to prevent merging. There is a close relationship between flow rate, length of tubular structure, and temperature of the tubular structure. In general, if a fast flow rate is used, then a longer heating tube will be needed to maintain the residence time and ensure the setting of the gel. Increasing the temperature can accelerate the gelation.

The foodstuff product may comprise between 1 to 10 wt% immiscible liquid, or between 2 to 5 wt% immiscible liquid, which has been contributed during passage of the foodstuff through the die, particularly during its passage through the exit plate. Too much immiscible liquid causes over lubrication and loss of the connection completely between the fiber bundles. The bundles should still be connected when cutting.

When a composition is described herein in terms of wt%, this means a mixture of the ingredients on a moisture free basis, unless indicated otherwise.

As used herein, the term "about" or "substantially" is understood to refer to numbers in a range of numerals, for example the range of -30% to +30% of the referenced number, or -20% to +20% of the referenced number, or -10% to +10% of the referenced number, or -5% to +5% of the referenced number, or -1% to +1% of the referenced number. All numerical ranges herein should be understood to include all integers, whole or fractions, within the range.

As used herein, a gellifying preparation is a liquid or viscous mixture composed of biopolymers. The biopolymers are able to associate or cross link to form a three-dimensional continuous network. The three-dimensional continuous network can trap and immobilize water or liquid within it to form a rigid and cohesive structure.

Those skilled in the art will understand that they can freely combine all features of the present invention disclosed herein. In particular, features described for the compositions of the present invention may be combined with the method or uses of the present invention and vice versa. Further, features described for different embodiments of the present invention may be combined. Where known equivalents exist to specific features, such equivalents are incorporated as if specifically referred to in this specification.

Description of figures

While the disclosure is susceptible to various modifications and alternative forms, specific example approaches are shown by way of example in the drawings and are herein described in detail. It should be understood however that the drawings and detailed description attached hereto are not intended to limit the disclosure to the particular form disclosed but rather the disclosure is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the claimed invention.

As used in this specification, the words "comprises", "comprising", and similar words, are not to be interpreted in an exclusive or exhaustive sense. In other words, they are intended to mean "including, but not limited to".

It will be recognized that the features of the above-described examples of the disclosure can conveniently and interchangeably be used in any suitable combination. It will also be recognized that the invention covers not only individual embodiments but also combinations of the embodiments that have been discussed herein.

Figure 1 shows a schematic of the system of the invention. In operation, a foodstuff is placed in a receptacle 14 and fed or pumped along direction 18 in a pipe 16 to the die 20. It is not shown in the figure, but the pipe 16 may be heated, for example by use of a double jacket mechanism. The pipe 16 could be heated by electric heating. The pipe 16 transports the foodstuff to the die 20 at which point an immiscible liquid in receptacle 32 is applied to the foodstuff through pipe 33. After exit from the die 20 the foodstuff enters a tubular structure 60 which can be heated, for example by means of a double jacket arrangement 72 which includes an inlet 70 for hot liquid and a corresponding outlet 74. The product is transported along pipe 60 in downstream direction 62 and can be cut using a cutting device 100 to form product 120. Significant pressure differences along the length of the pipes 16 and 60 should be avoided. The pipes 16 and 60 should have substantially the same cross section area along their whole length.

Figure 2 shows a schematic view of the die 20 and tubular structure 60. The die 20 comprises an entrance plate 24 comprising an array of holes 25 which receive a foodstuff. The foodstuff passes through an array of pipes 30 before exiting through holes 29 on the exit plate 28. Tubular structure 60 receives the foodstuff after it exits through the exit plate 28.

Figure 3 shows a cutaway view of the die and the tubular structure 60 located adjacent and downstream of the die. A pipe 33 to transport immiscible liquid to the die is shown. Typically, immiscible liquid does not make contact with the entrance plate. The downstream tubular structure can be heated by double jacket mechanism comprising an inlet 70 for hot liquid and a corresponding outlet 74. The structure is shown in two parts which can be maintained at different temperatures.

Figure 4 shows a view of the exit plate 28 and exit plate holes 29 and pipe 33 to transport immiscible liquid to the die.

Figure 5 shows an alternative exit plate which has a square shape with square holes 29a.

Figure 6 shows the die of the invention with the entrance plate 24 at the top. Immiscible liquid is transported to the die through pipe 33. The general arrangement shows the die secured by attachment 19 and clip 17. A further clip 15 helps to secure the arrangement to the downstream tubular structure.

Figure 7 shows a comparison of cooked animal scallop with products which have been made by methods of the invention using a constant flow rate. The effects of varying the temperature of the tubular structures upstream and downstream of the die are shown.

Figure 8 shows the results of Hardness tests on the products shown in figure 7.

Figure 9 shows the gel properties of the product. The graph demonstrates that the product gels upon cooking and that G' increases sharply when the temperature is greater than 70°C.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the spirit and scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, and means, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Examples

Example 1

Recipe and process for plant based scallop production

The system and method of the invention was used to generate plant based cooked scallop with aligned fiber bundles to mimic animal scallop. A recipe based on konjac powder, pea fiber, tapioca starch and oil was used to prepare a homogenous dough. A vegan seafood flavor from a commercial source was added. The dough was prepared by hydrating the raw material with water in a bowl chopper at 3000 rpm for 5 min (5 minutes) and 500 rpm for another 35 min, initially without sodium carbonate. After 35 min hydration, sodium carbonate was mixed at 500 rpm in the dough for 5-10min. The hydrated dough was thick and not very flowable. The dough was then conveyed by a vacuum filler along a pipe to the die. The pipe was heated to 40 - 65°C with double jacket in order to preheat the dough and prepare for the gelation. An oil pump was connected to the die, and oil was injected through the exit holes of the die while pressing the dough through the die. The purpose of injecting the oil was to keep the formed noodle-like structure from remerging. After the generation of noodle-like structure, the mass was pressed through a heating tube (80-100°C) to set the gel. Gelation was accelerated, and the texture became hard. The noodle-like structures stuck together in long continuous strands with a harder outer surface created due to increased temperature in the tube-like pipe. The gel exited the tube-like pipe in a long continuous gel tube which was cut into individual scallop-like pieces. The scallop-like pieces were chilled by refrigeration.

The following recipe was used:

, Content

Ingredient

L/oj

Vegan seafood flavor

Konjac powder 1.8

Pea fiber 5

Tapioca starch 2

Sunflower oil 2

NaCI 1.1

Sucrose 1.5

CaCO ₃ 0.4

Na ₂ CO ₃ 0.4

Water 85.3

SUM 100.0

Example 2

Role of oil injection in texture generation

Plant based scallop was prepared as described in example 1. Samples were collected with and without oil injection. The final samples were analyzed by a cutting test using a texture analyzer. Each sample of plant based scallop had a diameter of 2cm, and the length was cut to 2cm. The analysis was done by cutting against the fiber and along the fiber direction. Frozen animal scallop was purchased from supermarket and thawed before analysis. The animal scallop was cooked by pan frying two minutes on each side with medium heat. The animal scallop was cooled down to room temperature and cut into the same shape as the plant based scallop. The Hardness which represents the force needed to break the gel was used to compare the plant based scallop with the animal scallop.

The sample without oil injection did not have any fiber formation, only a homogenous mass was obtained. The sample with oil injection had visible fiber bundles using different conditions. A first pipe (Tl) was used to pre-heat the dough mixture before it entered the die, and a second pipe (T2) was used to set the gel downstream of the die. The best fiber bundle formation was obtained when the dough was preheated to between 50 to 65°C, and then set at temperature above 90°C.

Figure 7 shows samples with aligned fiber bundles produced from the device and cooked animal scallop (right bottom picture). T1 was the temperature used in the first pipe prior to the fiber formation geometry for pre-heating the gel, and T2 was the temperature used in the second pipe after the fiber formation geometry for setting the gel.

Animal scallop has soft texture before cooking and becomes harder after cooking (see graph in Figure 8). Without oil injection, the gel was hard because it has homogenous and had a compact texture. When oil was injected, the texture became softer and closer to the animal cooked scallop. Because oil breaks the dough or gel consistency leaving a barrier between fiber bundles and making it softer, therefore, a significant decrease of the hardness was seen when cutting along the fiber. Higher temperature led to a more stronger fiber formation. The structural differences and extent of gelation at different temperature may contribute to the textural differences.

Figure 8 shows the hardness measured by cutting test of plant-based scallop and animal benchmark. Left figure was measured by cutting along the fiber (motion of blade is the same as the fiber bundle direction), and right figure (*) was measured against the fiber direction. T1 - 1st heating pipe (before fiber formation geometry), T2 - 2nd heating pipe (after fiber formation geometry). The table below describes the temperatures used in degrees Celsius in each heating pipe T1 and T2 Example 3

Gel property of the dough before and after heating

The dough from the recipe in example 1 was analyzed with a rheometer. The gel properties while heating at heating rate of 8°C/min with a temperature sweep from 20°C to 90°C were evaluated. The strain used was 0.2%. The time between alkali addition and start of measurement was kept constant at 15 min. The dough was a solid-like material because G' was larger than G". The increase of G' while the temperature increased to 70°C indicated gelation of the mass, and the material become more solid. Figure 9 shows the gelation kinetics of scallop dough during temperature sweep.

Example 4

Alginate recipe and process for plant based scallop

A thick dough was prepared comprising of alginate, konjac glucomannan, soy protein, rice protein and encapsulated calcium, salt and flavor. The ingredients were hydrated by mixing them with water at room temperature for 20min. The dough was passed through the system of the invention and then set after heating. Heating served to release the calcium and induce alginate gelation. The thickness of the dough was found to be important to keep the generated bundles from remerging. The dough was composed of alginate as the main gelling agent. Konjac was found to increase the dough viscosity, thereby preventing merging of the fibers.

In the absence of konjac glucomannan, the noodles quickly merged and gave a homogeneous texture even with oil injection.

The following recipe was used: The oil used also impacted on the texture. Liquid wax had better separation of the fiber bundles compared to an emulsion comprising 50% sunflower oil and 1% soy protein isolate (coarse emulsion). Emulsion with higher percentage of lipid content could show better results. The konjac and alginate noodles after cooking and sprayed with coarse emulsion were found to have merged during cooking and gave a homogeneous gel. Noodles that were extruded and coated with wax had fibers that were clearly visible and could be detected in the mouth.