A protein composition and its use in restructured meat and food products

[0001] The present invention relates to a hydrated and ground protein composition and to the use of this hydrated and ground protein composition in vegetable products, fruit products and restructured meat products. Also described is a method for producing a hydrated and particulate protein composition. In addition, the present invention relates to a restructured meat product containing a hydrated and ground protein composition; also described is a method for producing this product by combining a hydrated and comminuted protein composition, minced meat and water, so that a meat product is obtained with a texture similar to intact muscles. The present invention also relates to a vegetable product comprising a hydrated and particulate protein composition; also described is a method for producing this product by combining a hydrated and comminuted protein composition, ground vegetable and water, so that a vegetable product is obtained. In addition, the present invention relates to a fruit product comprising a hydrated and particulate protein composition; also described is a method of making this product by combining a hydrated and comminuted protein composition, ground fruit and water, so that a fruit product is obtained. The hydrated and particulate protein composition may further contain starches, flour and fibers.

Background Art [0002] An important aspect of the present invention is the processing of the unstructured protein product into a structured protein product. Specifically, in one embodiment, the present invention provides a product and a method of processing an unstructured protein product without visible fibers or texture into a structured protein product of a certain shape having the consistency of a cooked muscle.

[0003] The term "structure" means many different physical properties of a food product. Acceptable product structure is usually synonymous with product quality. Structure is defined as' the attribute of a substance resulting from the combination of physical properties and perceived senses of touch, including kinesthesia and oral sensation, vision and hearing. The structure, according to the International Organization for Standardization, means "all rheological and structural (geometric and surface) attributes of food products that can be felt by mechanical, tactile and, where applicable, visual and auditory receptors." The following terms are used to describe the characteristics product covered by the term 'structure':

EP 2 020 868 B2

TABLE I

BRIEF LIST OF DEFINITIONS DESCRIBING THE FOOD STRUCTURE

<td>Sticky</td><td>Fleshy</td><td>Brejowaty</td><td>Soft</td>

<td>Resilient</td><td>flocculent</td><td>Oily</td><td>Soggy</td>

<td>Breakable</td><td>of foam</td><td>pasty</td><td>Shiny</td>

<td>Effervescent</td><td>Delicate</td><td>Plastic</td><td>cracked</td>

<td>Żujny</td><td>Full</td><td>Porous</td><td>Spongy</td>

<td>adhering</td><td>Sticky</td><td>powdered</td><td>Flexible</td>

<td>coating</td><td>Grainy</td><td>Fluffy</td><td>Sticky</td>

<td>Cohesive</td><td>Gritty</td><td>Pulpy</td><td>Wiry</td>

<td>Creamy</td><td>Sticky</td><td>Intense</td><td>Syropowy</td>

<td>Crisps</td><td>Hard</td><td>Sharp</td><td>Sensitive</td>

<td>Crumbling</td><td>Heavy</td><td>Rubbery</td><td>Thick</td>

<td>Crisp</td><td>Heterogeneous</td><td>Streaming</td><td>Rare</td>

<td>Gestures</td><td>Juicy</td><td>Sand</td><td>Biting</td>

<td>Pasty</td><td>Thin</td><td>Rough</td><td>Sharp</td>

<td>Dry</td><td>Light</td><td>Fragile</td><td>Uniform</td>

<td>Flexible</td><td>Limp</td><td>Silky</td><td>Sticky</td>

<td>Fat</td><td>Lumpy</td><td>Slippery</td><td>Watery</td>

<td>Compact</td><td>Humid</td><td>laminar</td><td>Waxy</td>

<td>flaky</td><td>Covering the mouth</td><td>Plain</td><td>Wavy</td>

[0004] Particular attention is paid to the structure when it relates to newer food substances including counterfeit products and imitations of original products, formed meat and fish products, where every effort is made to replicate the properties of the original substances or other natural food substances in the processes. The use of non-traditional raw materials, artificial flavors, fillers and carriers promotes the change of some texture properties of the final product. Often, duplication of texture properties is much more difficult than reproducing flavors, aromas and colors. Many manipulative processes, including extrusion structuring, have been developed to stimulate natural structural properties. It is prudent to replicate the properties of the original substances in these processes to the extent technically and economically feasible in order to promote rapid market acceptance. Although the structure has appearance-related attributes, it also has attributes associated with touch, as well as with oral sensation or interaction when food comes into contact with the mouth. Often these sensations during chewing can give either the desired or unwanted sensation.

[0005] Thus, structural terms include terms related to the behavior of a substance under pressure or stress, for example the following: compact, hard, soft, sharp, soft, tough, rubbery, flexible, plastic, sticky, sticky, sticky, crunchy, crunchy, etc. Secondly, structural terms may be associated with the structure of the substance: smooth, fine, powdered, chalky, lumpy, mealy, coarse, pebbly, etc. Thirdly, structural terms may refer to the shape and arrangement of structural elements such as flaky, fibrous, elastic, pulpy, follicular, crystalline, glassy, ​​spongy, etc. Finally

Structural properties may relate to features associated with sensation in the mouth, including oral sensation, fleshiness (dry, moist, wet, watery, waxy, muddy, slimy, etc.).

[0006] As used herein, the terms "unstructured" and "structured" describe the characteristics of a food product presented in Table II:

TABLE II

<td></td><td>unstructurised</td><td>structured</td>

<td>Behavior of the substance under pressure or stress</td><td>sticky greasy plastic</td><td>compact dragging on</td>

<td>The structure of the substance</td><td>plain</td><td>coarse-grained</td>

<td>Shape and arrangement of structural elements</td><td>gelatinous pulpy pasty</td><td>fibrous crisp</td>

<td>Mouth feel</td><td>creamy dry</td><td>humid</td>

slushy (with body)

US 2006/0051492 discloses a high protein snack product containing hydrated soy protein with a disintegrated structure.

Summary of the Invention [0007] The present invention relates to a hydrated and particulate protein composition of which at least about 75% by weight contains at least about 15% by weight of large pieces consisting of protein fibers at least about 4 centimeters long, protein bundles at least about 3 centimeters and protein nuggets at least about 2 centimeters long, and wherein at least about 75% by weight of the hydrated and particulate protein composition has a shear strength of at least about 1400 grams.

[0008] Also described is a method for producing a hydrated and particulate protein composition.

[0009] The present invention further relates to a meat or food product, comprising;

hydrated and crushed protein composition;

ground meat or ground vegetable or ground fruit, respectively; and water;

wherein at least about 75% by weight of the hydrated and particulate protein composition contains at least about 15% by weight of large pieces consisting of protein fibers of length

EP 2 020 868 B2 at least about 4 centimeters, protein bundles at least about 3 centimeters long and protein nuggets at least about 2 centimeters long, and wherein at least about 75% by weight of the hydrated and particulate protein composition has a shear strength of at least about 1400 grams.

Also described is a method of producing a meat or food product.

Detailed description of the invention [0010] Mechanically separated meat (MSM) is a meat paste obtained from beef, pork and chicken bones using commercially available equipment. MOM is a fragmented product that lacks the natural fibrous texture present in intact muscles. The lack of fiber limits the use of MSM, most often for the production of ground sausages such as frankfurters and Bologna sausage.

[0011] Ground vegetable means a puree from one single vegetable or a mixture of puree from more than one vegetable.

[0012] Ground fruit means a puree from one single fruit or a mixture of puree from more than one fruit.

Definitions [0013] The term "protein" herein means a protein selected from the group consisting of plant proteins, dairy proteins and mixtures thereof. Vegetable protein is selected from the group consisting of protein derived from legumes, soybeans, corn, peas, canola seeds, sunflower seeds, rice, amaranth, lupine, rapeseed, wheat, wheat gluten and mixtures thereof, whereas vegetable protein does not mean only gluten wheat. Thus, when wheat or wheat gluten is used as a source of protein, it must be mixed with a protein selected from the group consisting of protein derived from legumes, soybeans, corn, peas, canola seeds, sunflower seeds, rice, amaranth, lupine, rapeseed, casein, caseinates, milk whey protein and mixtures thereof. A preferred vegetable protein is soy protein. Milk proteins are selected from the group consisting of casein, caseinates, milk whey protein and mixtures thereof.

[0014] Corn protein substances that are useful in the present invention include feed corn gluten, and most preferably zein. Corn gluten feed is obtained from the traditional maize processing method and is commercially available. Corn gluten feed contains about 50% to about 60% corn protein and about 40% to about 50% starch. Zein is a commercially available purified corn protein that is produced by extracting feed corn gluten with dilute alcohol, preferably diluted isopropyl alcohol.

[0015] The term "soy protein" here means a substance derived from whole soybeans, which does not contain non-soybean additives. These additives can, of course, be added to soy protein to provide additional functionality or nutritional content in extruded4

EP 2 020 868 B2 a meat analogue containing a soy substance. The term "soybean" refers to the species Glycine max, Glycine soy and any species that is mutually compatible in terms of reproduction with Glycine max.

[0016] The term "protein content", as for example the term soy protein content, as used herein, refers to the relative content of a substance as stated in AOCS (American Oil Chemists Society) Official Methods Bc 4-91 (1997), Aa 5-91 (1997 ) or Ba 4d-90 (1997), which determine the total nitrogen content of a sample of a substance, such as ammonia, and the protein content as 6.25 times the total nitrogen content of that sample.

[0017] The modified Kjeldahl nitrogen-ammonia-protein method according to AOCS Bc 4-91 (1997), Aa 591 (1997) and Ba 4d-90 (1997) used to determine the protein content can be used as given below for a sample of soybean substance . 0.0250 - 1.750 grams of soy substance are weighed into a standard Kjeldahl flask. A commercially available mixture of catalysts 16.7 grams of potassium sulfate, 0.6 grams of titanium dioxide, 0.01 grams of copper (II) sulfate and 0.3 grams of pumice stone is added to the flask, then 0.3 grams of pumice stone is added to the flask, then added to the flask concentrated sulfuric acid. Porcelain is added to the mixture and the sample is extracted by heating it in a boiling water bath for about 45 minutes. The flask should be turned at least 3 times during extraction. Water (300 milliliters) is added to the sample and the sample is cooled to room temperature. A standardized 0.5 N hydrochloric acid solution and distilled water are added to the distillate in an amount sufficient to cover the end of the distillation conduit at the bottom of the receiving flask. A sufficient amount of sodium hydroxide solution is added to the extraction flask to strongly alkalize the extraction solution. Then the extraction flask is immediately connected to the distillation output line, the contents of the extraction flask are thoroughly mixed by shaking and the extraction flask is heated for about 7.5 min. under boiling until at least 150 milliliters of distillate are collected. The contents of the receiver flask are then titrated with a 0.25 N sodium hydroxide solution using 3 or 4 drops of a 0.1% solution of the indicator, methyl red in ethyl alcohol. A blank test on all reagents is carried out simultaneously with the sample, similarly in all respects, and a correction is made for the reagent blank. The moisture content of the ground sample is determined according to the procedure described below (AOCS Official Methods Ba 2a-38). The nitrogen content of the sample is determined by the formula: Nitrogen (%) = 1400.67 x [[(Normal acid solution standard) x (Volume of standard acid solution used for the sample (ml))] - [(Volume of standard base needed to titrate 1 ml of standard acid solution minus volume of standard base solution required for the titration of the blank used in the method and distilled to 1 ml of standard acid solution (ml)) x (Normality of standard base solution)] - [(Volume of standard base solution used for the sample (ml)) x (Normality of the standard solution of the base)]] / (Milligrams of the sample). The protein content is 6.25 times higher than the nitrogen content in the sample.

[0018] The term "moisture content" here means the amount of moisture in the substance. The moisture content of the substance can be determined by the AOCS (American Oil Chemists Society) Method Ba 2a-38 (9997). According to this method, the moisture content of the substance can be measured by passing a 1000 gram sample of the ground substance through a 6 x 6 grate divider, available from Seedboro Equipment Co.,

EP 2 020 868 B2

Chicago, Illinois, and reducing the sample size to 100 grams. This 100 gram sample is then immediately placed in an airtight container and weighed. Five grams of the sample ("Sample Weight") is weighed into a tared humidity measuring vessel (minimum 30 gauge, approximately 50 x 20 millimeters, with a tightly fitting sliding lid for strong interference - available from Sargent-Welch Co.). The dish containing the sample is placed in a forced draft oven and dried at 130 ± 3 ° C for 2 hours. The vessel is then removed from the oven, immediately covered and cooled in a dispenser to room temperature. The dish is then weighed to obtain a dry matter. The moisture content is calculated according to the formula:

Moisture content (%) = 100 x [(Sample Weight - Dry Weight) / Sample Weight] [0019] The term "moisture free mass" (Dry Weight) here means the mass of the substance after complete drying, i.e. the moisture content of the substance is 0%. Specifically, a moisture-free substance mass can be obtained by weighing the substance after placing it in an oven at 45 ° C until it acquires a constant mass.

[0020] The term "soy protein isolate" is used herein in the conventional sense for the soy protein industry. Specifically, the soy protein isolate is a soy substance with a protein content of at least about 90% moisture free soy protein. The term "isolated soy protein" as used in the art has the same meaning as the term "soy protein isolate" as used herein and used in the art. Soy protein isolate is made from soybeans by removing shell and sprout from cotyledon, flaking or milling cotyledon and removing oil from flaked or ground cotyledon, separating soy protein and carbohydrates from cotyledon from cotyledon fiber, and then separating soy protein from carbohydrates.

[0021] The term "soy protein concentrate" is used herein in the conventional sense for the soy protein industry. Specifically, the soy protein concentrate is a soy substance having a protein content in the range of about 65% to less than about 90% soy protein calculated on a dry weight basis. The soy protein concentrate also contains soy cotyledon fiber, typically from about 3.5% to about 20% by weight based on the dry weight of the soy cotyledon fiber. Soy protein concentrate is made from soy bean by removing shell and sprout from cotyledon, flaking or milling cotyledon and removing oil from flaked or ground cotyledon, separating soy protein and cotyledon fiber from cotyledon carbohydrates.

[0022] The term "soy protein flour" here means a comminuted form of defatted soy substance, preferably containing less than about 1% oil, made from particles having a size that allows passage through a 0.149 mm sieve [mesh No. 100 in the American standard]. Soy dough, chips, flakes, soybean meal or a mixture of these substances are ground into soy flour using a conventional soy milling process. Soy flour has a protein content of from about 49% to about 60% without moisture. Preferably, this flour is ground very finely, most preferably such that less than 1% of the flour remains on a 0.048 mm sieve [mesh No. 800 in the American standard].

[0023] Rice is a starchy food containing from about 6% to about 10% protein. Here, the term "rice flour" means an inexpensive by-product of milling rice obtained by milling crushed rice. By milling rice with conventional methods, a flour consisting of approximately 80% carbohydrates is obtained. Due to the low protein concentration in rice and resulting from

Of this large amount required for satisfactory protein intake, infants and children cannot eat enough to meet their protein needs.

[0024] The term "starch" here means all starches derived from any natural source, all suitable for use herein. The term "native starch" here means starch in the form found in nature. Also useful are starches derived from plants obtained by standard breeding techniques including crossing, translocation, inversion, transformation, and any other gene or chromosome engineering technique to take account of their variants. In addition, starches derived from plants with artificial mutations and variants of the abovementioned are also suitable. generic compositions that can be prepared by known standard methods of mutation breeding.

[0025] Typical sources of starch are cereals, tubers, roots, legumes and fruit. The native source may be different waxy varieties selected from corn, peas, potato, sweet potato, banana, barley, wheat, rice, oats, sago, amaranth, tapioca (manioc), arrowroot, bead and sorghum, especially corn, potato, manioc and rice. The term "waxy" or "low amylose" includes starch containing no more than about 10% by weight of amylose. Starches that contain no more than about 5% by weight of amylose are particularly useful for the invention.

[0026] The term "gluten-free starch" means modified tapioca starch, the main ingredient in many different bakery products. Gluten-free or substantially gluten-free starches are made from wheat, corn and tapioca starches and are "gluten-free" because they do not contain wheat, oat, rye or barley gluten - a factor particularly important for people diagnosed with celiac disease and / or wheat allergy.

[0027] The term "wheat flour" means flour obtained by milling wheat. The particle size of wheat flour is usually from about 14-120 μm. Wheat flour usually contains from about 11.7 to about 14% protein and from about 3.7 to about 10.9% fiber.

[0028] The term "gluten" means a wheat flour protein fraction that has a high protein content as well as a unique structure and viscosity properties. In its freshly extracted wet state, it is known as gluten glue, and after drying becomes a free-flowing powder with a high protein content and a mild taste. Usually in this form it is used in food processing.

[0029] The term "fiber" here means any vegetable or fruit fiber known in the art, such as soy cotyledon fiber, soybean fiber, oat fiber and other cellulose fibers. The preferred fiber is soy cotyledon fiber. The fibrous portion of soy cotyledons contains at least about 70% insoluble fiber (polysaccharide). Soy cotyledon fiber usually contains some small amounts of soy protein, but may also contain 100% fiber. To avoid confusion, the term "fiber" here means (with the exception of this paragraph) the fiber obtained by the extrusion of a protein substance, usually by protein-protein interactions, not soy cotyledon fiber. In addition, to avoid confusion, the soy cotyledon fiber will be referred to here solely as "soy cotyledon fiber" and not "fiber". Soy cotyledon fiber is obtained from soybeans by removing shell and sprout from cotyledon, flaking or milling cotyledon and

EP 2 020 868 B2, removal of flaked or ground cotyledon oil, separation of soy cotyledon fiber from soy substance and carbohydrates from cotyledon.

[0030] The term "fiber" here means protein fiber, especially soy protein fiber, obtained by the extrusion of a protein substance, usually by protein-protein interactions. Protein-protein interactions are such that the proteins interact with each other or attach to each other mainly in a head-to-tail or head-to-head or tail-to-tail manner. Protein-protein interactions are such that proteins minimally interact with each other or combine side-to-side. The physical size of protein fibers is usually greater than about 4 centimeters in length. The width of soy protein fibers is usually from about 0.5 centimeters to about 1 centimeter. The thickness of protein fibers is usually less than 1 centimeter.

[0031] The term "bundles" here means protein bundles, especially soy protein bundles, also resulting from the extrusion of soy protein substance, again usually through protein-protein interactions. These protein-protein interactions are such that the proteins interact or combine with each other in a head-to-tail or head-to-tail or tail-to-tail manner, but to a lesser extent than in protein fibers. Protein-protein interactions are such that proteins interact or combine side-to-side, but to a greater extent than in protein fibers. The physical size of protein bundles is usually larger than about 3 centimeters in length. The width of protein bundles is usually from about 0.5 centimeters to about 1 centimeter. The thickness of protein bundles is usually less than about 1 centimeter.

[0032] The term "nuggets" herein means protein nuggets, especially soy protein nuggets, also formed by extruding a soy protein substance, again usually through protein-protein interactions. These protein-protein interactions are such that the proteins interact or combine with each other in a head-to-tail or head-to-tail or tail-to-tail manner, but to a lesser extent than in protein bundles. Protein-protein interactions are such that proteins interact or combine side-to-side, but to a greater extent than in protein bundles. The physical size of protein nuggets is usually greater than about 2 centimeters in length. The width of protein nuggets is usually greater than about 2 centimeters. The thickness of protein lumps is usually less than about 2 centimeters.

[0033] The term "large pieces" as used herein refers to the size of the protein composition, especially the soy protein composition. The large pieces contain protein fibers, protein bundles and protein nuggets. In the protein composition, 75% by weight of this protein composition contains at least about 15% by weight of large pieces. Large pieces are determined in a comminution test. The comminution test procedure is as follows: Weigh about 150 g of each example of the protein composition, using whole pieces only, into a heat-sealed plastic bag and add about 450 g of water at 25 ° C. Vacuum seal the bag at about 150 mm Hg and allow the contents to hydrate for about 60 minutes. Place the hydrated sample in a KitchenAid mixer bowl, model 14G0 equipped with a single blade spatula, and mix the contents at 130 rpm for 2 minutes. Scrape the spatula and the walls of the bowl by placing a scraped substance on the bottom of the bowl. Repeat mixing and scraping 2 times. Remove the mixture from the bowl and weigh it. Divide the mixture into groups 1 to 4. Group 1 is a group of fibers in which the fibers are at least 4 cm long and at least 0.5 cm wide. Group 2 is a group of beams in which the beams have at least

EP 2 020 868 B2 cm long and at least 1 cm wide. Group 3 is a group of nuggets in which the nuggets are more than 2 cm long and more than 2 cm wide. The remaining mixture is Group 4. The percentage of large pieces is determined by adding the total mass of Group 1 + Group 2 + Group 3, multiplying by 100 and dividing by the total mass of Group 1 + Group 2 + Group 3 + Group 4.

[0034] The term "shear strength" here means the ability of a textured protein to form a fibrous network with sufficient strength to give the resulting product a texture and a meat-like appearance. Shear strength is measured in grams. Shear strength is determined according to the following procedure: Weigh a sample of the protein composition, place it in a heat-sealed bag and hydrate it with tap water at room temperature, using 3 times the weight of the sample. Remove air from the bag and seal it and allow the sample to hydrate for about 12 to about 24 hours. Remove the hydrated sample and place it on the base plate of the texture tester in such a way that the knife of the device will cut through the diameter of the sample. Then, turn the sample under the device knife so that the knife will cut perpendicular to the long axis of the textured piece. The TA texture device used to conduct this experiment is the TA model. TXT2 manufactured by Stable Micro Systems Ltd. (England) and equipped with a 25, 50 or 100 kg load cell. Shear strength is the maximum force in grams needed to break through the sample. An example of each protein composition is tested 10 times and the average time is recorded.

[0035] The term "hydration test" here means measuring the time in minutes necessary to hydrate a known amount of the protein composition. The hydration test is carried out according to the following procedure: From each example of the protein composition, select 80 individual pieces and weigh the sum. Add pieces to the 5000 ml beaker and insert the smaller loaded beaker into this 5000 ml beaker so that all 80 pieces are immersed for 30 minutes. Remove 10 pieces of sample from the water and make a transverse cut of each piece near its center. If the cut pieces are dry at the cut, wait 10 minutes before removing the next 10 pieces. Make lateral cuts in subsequent pieces and check them for hydration. If they are completely or completely hydrated, the hydration time is 40 minutes. If dry, remove cuts, make transverse cuts, check for hydration every 10 minutes until hydration is complete, and record hydration time.

[0036] The term "density" here means the density determined by salt displacement. Salt density is determined according to the following procedure: All length measurements are in millimeters (mm), all volume measurements are in milliliters (ml), and all weight measurements are in grams (g). Salt is a granulated table salt having the following grain size distribution:

<td>mm</td><td>(US Mesh)</td><td>typical% retained on the sieve</td>

<td> 0,595</td><td> (30)</td><td>2 (10) max</td>

<td> 0,420</td><td> (40)</td><td> 37</td>

<td> 0,297</td><td> (50)</td><td> 52</td>

<td> 0,250</td><td> (60)</td><td> 3</td>

<td> 0,210</td><td> (70)</td><td> 1</td>

<td></td><td>receptacle</td><td>(10 max)</td>

EP 2 020 868 B2 [0037] Using a vessel having a known volume and known mass (tare), add table salt (density from about 1.29 g / cm³ up to about 1.40 g / cm³) up to a height of about 5 mm. Add a protein composition of known mass to the top of the salt, but so that it does not touch the walls of the vessel. Add table salt to the vessel to the overflow point, tap the filled vessel against the table to spread the salt around the protein composition and, using a spatula, align the salt flat with the edge of the vessel. Record the weight of the filled dish and subtract the weight of the vegetable protein composition and tare weight to obtain the mass of salt in the filled dish. Divide the mass of salt by its density, obtaining the volume of salt in the filled vessel. Subtract the volume of salt from the known volume of the vessel to obtain the volume of protein composition in the vessel. Divide the mass of the protein composition by the volume of the protein composition, obtaining its density in g / cm³.

[0038] The grain size distribution is determined using a RoTap sieve shaker manufactured by Tyler RoTap, Mentor Ohio. RoTap includes a shaker mechanism and is equipped with a stack of sieves as specified above.

[0039] The term "ground meat" here means meat paste collected from an animal skeleton. Meat, on the bone or boneless, is forced through the bone removal device so that the meat is separated from the bone and its size is reduced. The meat is separated from the meat / bone mixture by pressing through a cylinder with small diameter holes. The meat behaves like a liquid and is squeezed through the holes, while the bones stay behind the cylinder wall. The fat content of minced meat can be increased by adding animal fat.

[0040] The term "ground vegetable" here means vegetable puree.

[0041] The term "ground fruit" here means fruit puree.

Protein Composition [0042] The protein for the hydrated and particulate protein composition is selected from the group consisting of plant proteins, dairy proteins and mixtures thereof. The vegetable protein is selected from the group consisting of soybean, maize, pea, canola seed, sunflower seed, rice, amaranth, lupine, rape seed, wheat, wheat gluten and mixtures thereof, whereby vegetable protein does not only mean wheat gluten. Thus, when wheat or wheat gluten is used as a source of protein, it must be mixed with a protein selected from the group consisting of protein derived from legumes, soybeans, corn, peas, canola seeds, sunflower seeds, rice, amaranth, lupine, rapeseed, casein, caseinates, milk whey protein and mixtures thereof.

[0043] A preferred vegetable protein is soy protein. Milk proteins are selected from the group consisting of casein, caseinates, milk whey protein and mixtures thereof.

[0044] The hydrated and particulate protein composition may be a wheat gluten-free protein composition. The hydrated and ground protein composition may further comprise an ingredient selected from the group consisting of starch, gluten-free starch, rice flour, wheat flour, wheat gluten, soy cotyledon fiber and mixtures thereof. The protein is preferably derived from soybean, with

EP 2 020 868 B2 wherein the soy protein is selected from the group consisting of soy protein isolate, soy protein concentrate, soy protein flour and mixtures thereof.

[0045] It is further contemplated that the whole soybeans used in the method of the present invention may be standard, common soybeans, genetically modified soybeans (GM) in some way, or non-genetically modified soybeans.

[0046] When the soy protein used is selected from the group consisting of soy protein isolate, soy protein concentrate, soy protein flour and mixtures thereof, the soy protein may also contain soy cotyledon fiber which is present in soy protein in an amount of from about 1% to about 20% by weight as calculated on the dry matter, the rest being selected from the group consisting of soy protein isolate, soy protein concentrate, soy protein flour and mixtures thereof. [0047] When soy cotyledon fiber is used in an amount of from about 1% to about 20% by weight based on dry weight, the soy protein may also contain wheat gluten in an amount from about 10% to about 40% by weight based on dry weight, with the rest is selected from the group consisting of soy protein isolate, soy protein concentrate, soy protein flour and mixtures thereof. [0048] When soy cotyledon fiber is used in an amount of from about 1% to about 20% by weight based on dry matter and wheat gluten in an amount of from about 10% to about 40% by weight based on dry weight, soy protein may also include starch in an amount of from about 5% to about 15% by weight based on dry weight, the remainder selected from the group consisting of soy protein isolate, soy protein concentrate, soy protein flour and mixtures thereof.

[0049] It has surprisingly been found that by extruding one or more of soy protein isolate, soy protein concentrate and soy protein flour with or without the above-mentioned additional ingredients, a product is obtained with a number of large pieces of soy fiber, soy bundles and soybeans. It has also surprisingly been found that the soy protein composition prepared has a shear strength not found in the starting material. In addition, a difference in hydration time and density of the soy protein composition obtained by extrusion is visible compared to each of the starting materials.

[0050] The addition of hydrated soy isolate or hydrated soy concentrate to MSM, ground vegetable or ground fruit increases the total protein content of the product. However, the product thus obtained has only minimal structural integrity. In addition, this product cannot be given a form reminiscent of, for example, meat products. When the hydrated and ground soy protein composition of the present invention is combined with, for example, MOM, a protein product is formed having the appearance, texture and fiber of meat. What's more, this protein product has twice as much protein, less than half calories and less than a third of fat compared to the original MSM.

[0051] As stated above, at least about 75% by weight of the soy protein composition contains at least about 15% by weight large pieces after hydration and comminution. Preferably, at least about 75% by weight of the hydrated and ground soy protein composition, by weight, comprises at least about 20% by weight large pieces. Most preferably, at least about 75% by weight of the hydrated and comminuted soy protein composition by weight contains at least about 22 wt. large

EP 2 020 868 B2 pieces. There are three categories of large pieces: fibers, bundles and nuggets. For the fibers to be present in the substance in the form of hydrated and ground soy protein, the fibers must be at least about 4 centimeters long. The width of soy protein fibers is usually about 0.5 centimeters to about 1 centimeter. The thickness of soy protein fibers is usually from about 2 millimeters to about 5 millimeters. In order for the bundles to be present in the substance in the form of hydrated and ground soy protein, the bundles must be at least about 3 centimeters long. The width of soy protein bundles usually ranges from about 0.5 centimeters to about 1 centimeter. The thickness of soy protein bundles usually ranges from about 2 millimeters to about 5 millimeters. In order for the nuggets to be present in the form of hydrated and ground soy protein, the nuggets must be at least about 2 centimeters long. The width of the soy protein nuggets is usually greater than about 2 centimeters. The thickness of the soy protein nuggets usually ranges from about 2 millimeters to about 5 millimeters.

[0052] As stated above, at least about 75 wt. the hydrated and ground soy protein composition has a shear strength of at least about 1400 grams. Preferably, at least about 75 wt. the hydrated and ground soy protein composition has a shear strength of at least about 1800 grams. Most preferably, at least about 75 wt. the hydrated and ground soy protein composition has a shear strength of at least about 2000 grams.

[0053] The hydrated and particulate protein composition, such as a soy protein composition, is prepared by extruding one or more of soy protein isolate, soy protein concentrate and soy protein flour either alone or with one or more of the ingredients listed above from starch, gluten starch , rice flour, wheat flour and wheat gluten, and soy cotyledon fiber. The hydrated and particulate protein composition, such as the soy protein composition, has a moisture content of from about 5% to about 80%. Humidity conditions during the production of the soy protein composition are low moisture of the soy protein composition (about 5% to about 35%) and high humidity of the soy protein composition (about 50% to about 80%). In the production of a hydrated and comminuted soy protein composition, the above ingredients are heated together with water at increasing temperature, under increasing pressure and shear conditions in a heated extruder, and the mixture of ingredients is extruded through a matrix. After extrusion, the extruded product, entering the medium under reduced pressure (usually atmospheric), usually swells to form a fibrous cellular structure. Extrusion methods to produce fibrous cellular structures are well known and disclosed, for example, in US Patent No. 4099455.

[0054] The protein content of the hydrated and particulate protein composition, regardless of whether it is a low moisture protein composition or a high moisture protein composition, is from about 30% to about 90% by weight without moisture. For the hydrated and particulate protein composition with low moisture, the protein content, including moisture, is at least about 50% to about 90% by weight. For a hydrated and particulate high moisture protein composition, the protein content, including moisture, is at least about 30% to less than 50% by weight.

[0055] Furthermore, when soy protein isolate is used, it should not be a highly hydrolyzed soy protein isolate with low molecular weight distribution because the highly hydrolyzed soy protein isolate does not have long protein chains for proper formation of protein fibers in this process. However, the highly hydrolyzed soy protein isolate may be used in combination with other soy protein isolates when the condition that the content of highly hydrolyzed soy protein isolate in the combined soy protein isolates is less than about 40 wt.

[0056] The soy protein isolate used should have the ability to retain water sufficient to allow the formation of protein fibers after extrusion. Examples of soy protein isolates useful in the present invention are commercially available isolates, for example, from Solae, LLC (St. Louis, Missouri) and include SUPRO^® 500E, SUPRO^® EX 33, SUPRO^® 620, SUPRO^®630 and SUPRO^® 545.

[0057] Soy protein isolates useful in the soy protein composition can be prepared from soy by conventional methods in the soy protein industry. For example, in such a process, all commercially available soybeans are first cleaned of garbage, split, peeled, shelled and degreased by conventional means to produce soy flakes, soy flour, soy grits or soybean meal. Soybeans can be cleaned of rubbish using a magnetic separator to remove iron, steel and other magnetic objects, then shaking the beans on sieves with smaller and smaller meshes to remove soil residues, pods, stems, weed seeds, too small seeds and other debris. Soybean-cleaned soybeans can be split on splitting rollers. The rollers for splitting are cylinders with spirally cut folds that loosen shells when the grains pass through the rollers and break the grains into several pieces. The crushed pieces can then be shelled by suction. Shelled grains are de-germed by shaking on a sieve with small enough meshes to remove small-sized germs and to stop larger grain cotyledons. The cotyledons are then flaked by passing them through the flaking rollers. Cotyledon flakes are degreased by extracting oil from them by contacting them with hexane or another suitable lipophilic / hydrophobic solvent. The edible defatted flakes were then ground, usually in an open-circuit milling system, using a hammer mill, solids sorter, roller mill or impact mill, first on grit, and after further grinding, on soybean meal or soy flour of the desired particle size. Usually screening is used to divide the product into ranges of particles of uniform size, which can be done using a screen shaker or cylindrical rotating screens.

[0058] Defatted soy flakes, soy flour, soy grits or soybean meal are then extracted with an aqueous alkaline solution, usually a dilute aqueous sodium hydroxide solution having a pH of 7.5 to 11.0, to extract the soluble protein in the aqueous alkaline solution from the substance insoluble. Insoluble substances are soy cotyledon fibers, which consist mainly of insoluble carbohydrates. The aqueous alkaline extract containing soluble protein is then separated from insoluble substances and the extract is then treated with acid to lower the pH of the extract approximately to approximately

Isoelectric point of soy protein, preferably to a pH of 4.0 to 5.0, and most preferably to a pH of 4.4 to 4.6. Soy protein precipitates from the acidified extract due to a lack of solubility in the aqueous solution at or near its isoelectric point. The precipitated protein curd is then separated from the remaining extract (whey). The separated protein can be washed with water to remove residual soluble carbohydrates and ash from the proteinaceous matter. Water is added to the precipitated protein clot and the pH of the clot is adjusted to a value in the range of 6.5 to about 7.5. The separated protein is then dried using conventional drying methods such as spray drying or tunnel drying to produce soy protein isolate.

[0059] Soy protein concentrate can be mixed with soy protein isolate to replace a portion of soy protein isolate as a source of soy protein. Preferably, if the soy protein concentrate replaces a portion of the soy protein isolate, the soy protein concentrate replaces at most up to about 40 wt. soy protein isolate, and more preferably it replaces up to about 30 wt. soy protein isolate.

[0060] Soy protein concentrates useful in soy protein composition are commercially available. For example, Promine soy protein concentrates^® DSPC, Response^® , Procon^®, Alpha^™ 12 and Alpha^™ 5800 are available from Solae, LLC (St. Louis, Missouri). Soy protein concentrates useful in the present invention can also be produced from commercially available soy beans by conventional methods in the soy protein industry. For example, defatted soy flakes, soy flour, soy grits or soy meal prepared as described above can be washed with an aqueous ethanol solution (preferably about 60% to about 80% ethanol solution) to remove soluble carbohydrates from soy protein and soy fiber. The soy protein and soy fiber containing material is then dried to produce a soy protein concentrate. Alternatively, defatted soy flakes, soy flour, soy grits or soybean meal may be washed with an aqueous acid solution having a pH from about 4.3 to about 4.8 to remove soluble carbohydrates from soy protein and soy fiber. After removing the soluble carbohydrates, water is added and the pH adjusted to a range from about 6.5 to about 7.5. The soy protein and soy fiber containing material is then dried to produce a soy protein concentrate.

[0061] Soy cotyledon fiber used in the hydrated and comminuted protein composition should effectively bind water when co-extruding a mixture of soy protein and soy cotyledon fiber. By binding water, soy cotyledon fiber gives a viscosity gradient to the extrudate when it is extruded through the cooling matrix, thereby promoting the formation of protein fibers. To effectively bind water for the purposes of the process of the present invention, soy cotyledon fiber should be able to retain at least 5.50 grams of water per gram of soy cotyledon fiber, and preferably soy cotyledon fiber have the ability to retain at least about 6.0 grams of water per gram of fiber soy cotyledon. It is also preferred that the soy cotyledon fiber has a water retention capacity of at most 8.0 grams of water per gram of soy cotyledon fiber.

[0062] Soy cotyledon fiber is a complex carbohydrate and is commercially available. For example, FIBRIM^® 1260 and FIBRIM^® 2000 are substances in the form of soy cotyledon fiber that are available

EP 2 020 868 B2 commercially available from Solae, LLC (St. Louis, Missouri), which are well suited for use in the method of the present invention. Soy cotyledon fiber useful in the method of the present invention can also be produced by conventional methods in the soybean processing industry. For example, defatted soy flakes, soy flour, soy grits or soy meal, prepared as described above, can be extracted with an aqueous alkaline solution as described above in connection with the production of soy protein isolate to separate insoluble soy cotyledon fiber from aqueous alkaline soluble soy protein and carbohydrates. The separated soy cotyledon fiber is then dried, preferably by spray drying, to obtain the product in the form of soy cotyledon fiber. Soy cotyledon fiber is usually present in the soy protein composition in an amount of from about 1% to about 20%, preferably from about 1.5% to about 20%, and most preferably from about 2% to about 5% by weight based on dry weight .

[0063] A low concentration of soybean fiber is believed to be effective in hindering the crosslinking of protein molecules, thereby preventing too high gel strength in the extruded cooked mass exiting the matrix. Unlike protein, which also absorbs moisture, soy fiber easily releases moisture when released from pressure at the matrix exit temperature. [0064] Wheat gluten can be used as an ingredient to be mixed and extruded together with hydrated and ground protein. Wheat gluten is an economical source of protein and can be combined with a portion of protein in a hydrated and ground protein composition. Protein in wheat gluten has very little ability to retain water and as such is ineffective in forming important protein fibers during extrusion. Wheat gluten is a commercially available ingredient. Commercially available wheat gluten useful in the present invention is Gem of the Star Gluten available from Manildra Milling.

[0065] Also, the starch material can be used as an ingredient to be mixed and extruded together with the hydrated and particulate protein composition. Starch may be used to provide texture to the hydrated and particulate protein composition produced by extrusion. The starch substance used is preferably a naturally occurring starch. The starch substance can be isolated from many plants, such as corn, wheat, potato, rice, arrowroot and manioc, by well-known conventional methods. Starch substances useful in the process of the present invention include the following commercially available starches: corn, wheat, rice, high amylose corn, waxy maize, arrowroot and tapioca. Preferably, the starch material used is corn starch or wheat starch, and most preferably, commercially available fodder corn starch or native wheat starch. Fodder corn starch is commercially available from AE Staley Mfg., Co. sold as Dent Corn Starch, Type IV, Pearl.

[0066] In addition, the flavor ingredients can be mixed with the hydrated and particulate protein composition and extruded together with it. Preferred flavor ingredients are those that provide a meat-like flavor to the hydrated and ground protein material produced by extrusion. Preferred ingredients include beef flavor, chicken flavor, grill flavor

EP 2 020 868 B2 and malt extract, all commercially available from flavor ingredient manufacturers. Mixtures of these ingredients may also be used.

[0067] The hydrated and particulate protein composition may also contain one or more optional ingredients, such as an antioxidant or antimicrobial agent. Antioxidant additives include BHA, BHT, TBHQ, vitamins A, C and E as well as derivatives and various plant extracts such as containing carotenoids, tocopherols and flavonoids having antioxidant properties and can be included to extend shelf life of food and meat products . The hydrated and ground protein composition may also contain an additional dye selected from the group consisting of titanium dioxide, caramel and mixtures thereof.

[0068] Antimicrobial agents are selected from the group consisting of sodium lactate, potassium lactate, sodium diacetate, potassium diacetate, sorbic acid and its potassium salt, and mixtures thereof.

[0069] Antioxidants and antimicrobials may together be present at a level from about 0.01% to about 10%, preferably from about 0.05% to about 5%, and more preferably from about 0.1% to about 2% wt. restructured meat product.

[0070] A suitable extrusion process to produce a hydrated and shredded low moisture protein composition, such as a low value hydrated and shredded soy protein composition involves the introduction of specific ingredients that constitute the hydrated and shredded soy protein composition into a mixing tank (i.e. to a loose material mixer) to combine the ingredients and produce a soy protein powder pre-mix. The loose soy protein pre-mix is ​​then transferred to a hopper, from which the powdered mixed ingredients are added together with moisture to the preconditioner to produce a conditioned soy protein mixture. The conditioned soy protein is then fed to an extrusion device (i.e. extruder), in which the soy protein mixture is processed under mechanical pressure generated by the extruder screws to produce a molten extruded mass. This molten extruded mass exits the extruder through an extrusion die.

[0071] In the preconditioner, the blend of loose bulk components is mixed with water to allow moisture to penetrate individual particles and soften them. The preconditioning step increases the bulk density of the bulk fiber mixture. The preconditioner has one or more paddles enabling uniform mixing of the protein and movement of the protein mixture through the preconditioner.

[0072] Typically, the soy protein mixture is preconditioned prior to entering the extrusion device by contacting the premix with moisture (i.e. steam and / or water) at a temperature of at least 45 ° C (110 ° F). However, higher temperatures (i.e. temperatures above about 85 ° C (185 ° F)) in the preconditioner may cause the starch to gel, which in turn may result in the formation of lumps that may interfere with the flow of the protein mixture from the preconditioner into the extruder sleeve.

[0073] Typically, the soy protein pre-mix is ​​conditioned for a period of about 30 to about 60 seconds, depending on the speed and size of the conditioner. Pre-mix of the composition

EP 2 020 868 B2 soy protein is contacted with steam and / or water and heated in a preconductor at a generally constant steam flow to reach the desired temperatures. Water and / or steam conditions (i.e. hydrates) the soy protein mixture, increases its density, and facilitates the flow of the dried mixture without interference before entering the extruder barrel, where the proteins acquire structure.

[0074] The conditioned pre-mix may contain from about 5% to about 30% (by weight) of water. The conditioned pre-mix usually has a bulk density of about 0.25 g / cm3³ up to about 0.6 g / cm³. Usually, as the bulk density of the preconditioned protein mixture increases in this range, this protein mixture is easier to process.

[0075] The conditioned pre-mix is ​​usually introduced into the extruder at a rate of not more than about 30 (kg) / min. (no more than about 65 pounds / min). Generally, it has been observed that the density of the extrudate decreases as the protein content of the premix supplied to the extruder increases.

[0076] Extruders have long been used in the production of a wide variety of food products. One suitable extruder is a twin-cylinder twin-screw extruder described, for example, in US Patent No. 4,600,311. Examples of commercially available twin-cylinder twin-screw extruders include the CLEXTRAL extruder^® Model BC-72 manufactured by Clextral, Inc. (Tampa, FL); WENGER Model TX-57 extruder manufactured by Wenger (Sabetha, KS); and the WENGER Model TX-52 extruder manufactured by Wenger (Sabetha, KS). Other conventional extruders suitable for use in the present invention are described, for example, in US Patent Nos. 4763569, 4118164 and 3117006, which are incorporated by reference.

[0077] The screws of a twin-screw extruder may rotate in the cylinder in the same or opposite directions. The rotation of the screws in the same direction is called a single flow, while the rotation of the screws in the opposite directions is called a double flow. The speed of the screw or snails in the extruder may vary depending on the specific device. However, the screw speed is usually from about 250 to about 350 rpm. Usually, as the screw speed increases, the density of the extruded article decreases.

[0078] The extruder typically includes a plurality of temperature controlled zones through which the mixture is transferred under mechanical pressure before it exits the extruder through the extrusion die. The temperature in each subsequent temperature controlled zone typically exceeds the temperature in the previous temperature controlled zone in the range of from about 10 ° C to about 70 ° C (in the range of from about 15 ° F and about 125 ° F). In one embodiment, the conditioned premix is ​​conveyed through four temperature controlled zones in the extruder, with the soy protein mixture heated to a temperature from about 100 ° C to about 150 ° C (from about 212 ° F to about 302 ° F), yes that the molten extrusion mass enters the extrusion die at a temperature from about 100 ° C to about 150 ° C (from about 212 ° F to about 302 ° F).

[0079] The pressure in the extruder cylinder is not exactly critical. Typically, the extrusion mass is pressurized at least about 400 psig (about 28 bar) and typically the pressure in the last two heating zones is from about 1000 psig to about 3000 psig (from about 70 bar to about 210 bar). The pressure in the cylinder depends on many factors including, for example, speed

EP 2 020 868 B2 extruder screw, mixture feed cylinder speed, water feed cylinder speed and molten mass viscosity in the cylinder.

[0080] Water is injected into the extruder cylinder to hydrate the soy protein mixture and cause the proteins to obtain the texture. As an aid in forming the melt extrusion mass, water can act as a plasticizing agent. Water can be introduced into the extruder cylinder through one or more nozzles or injection holes. Typically, the mixture in the cylinder contains from about 15% to about 35% by weight. water. The rate of introduction of water into the cylinder is usually controlled to obtain the desired characteristics of the extruded product.

[0081] The molten extrusion mass in an extrusion device is extruded through a die to obtain an extruded product which can then be dried in a dryer.

[0082] The extrusion conditions are usually such that the product coming out of the extruder cylinder usually has a moisture content of from about 20% to about 45% (by weight). The moisture content is derived from the water present in the mixture introduced into the extruder, the moisture added during preconditioning and / or any water injected into the extruder cylinder during processing.

[0083] After the pressure is released, the molten extruded mass exits the extruder cylinder through the matrix, the superheated water present in the mass evaporates as vapor, causing simultaneous expansion (i.e. swelling) of the substance. The level of expansion of the extrudate after the mixture exits the extruder, in terms of the ratio of the extrudate cross-sectional area to the die opening cross-sectional area, is usually less than about 15: 1. Typically, the ratio of the extrudate cross-sectional area to the cross-sectional area of ​​the die opening is from about 3: 1 to about 11: 1.

[0084] After leaving the matrix, the extrudate is cut. Suitable extrudate cutting equipment includes flexible knives manufactured by Wenger (Sabetha, KS) and Clextral^® (Tampa, FL). [0085] A dryer, when used for low moisture soy protein compositions to dry the extrudate, typically includes many drying zones in which air temperature may vary. Typically, the air temperature in one or more of these zones will range from about 135 ° C to about 185 ° C (from about 280 ° F to about 370 ° F). Usually, the extrudate is present in the dryer for a time sufficient to provide the desired moisture content. This desired moisture content may vary considerably depending on the intended use of the extrudate, and usually ranges from about 5% to about 35% by weight, more preferably from about 6% to about 13% by weight. Usually the extrudate is dried for at least 5 minutes , more generally for at least about 10 minutes. Suitable dryers include those manufactured by Wolverine Proctor &amp; Schwartz (Merrimac, MA), National Drying Machinery Co. (Philadelphia, PA), Wenger (Sabetha, KS), Clextral^®(Tampa, FL) and Buehler (Lake Bluff, IL).

[0086] The dried extrudates can then be comminuted to reduce the average particle size. Suitable milling equipment include hammer mills such as Mikro Hammer Mills manufactured by Hosokawa Micron^® Ltd. (England).

[0087] Before combining the low-moisture dried extrudate with ground meat or ground vegetable or ground fruit, the extract with moisture content from about 6% to about 13% by weight, if dried, must be hydrated with water until it is absorbed and crushed until

EP 2 020 868 B2 for the separation of fibers. If the extrudate is not dried or is not completely dried, its moisture content is higher, usually from about 16% to about 30% by weight. in terms of dry matter. The un-dried or not completely dried extrudate must be hydrated before combining with ground meat or with ground vegetable or with ground fruit before grinding. However, when an un-dried or not completely dried extrudate is used, less water is needed to hydrate it and hydration occurs much faster.

[0088] Ingredients used to prepare a hydrated and particulate low moisture protein composition having from about 5% to about 35% by weight moisture, it is also used to prepare the hydrated and particulate high moisture protein composition having from about 50% to about 80% by weight moisture. Soy protein, soy cotyledon fiber and other ingredients are dry mixed in a mixing tank to combine the ingredients and form a free-flowing soy protein pre-mix. Alternatively, soy protein, soy cotyledon fiber and other ingredients can be mixed directly with water to form a dough mixture, without first dry blending, preferably in a preconditioner.

[0089] Preferably, the doughy mixture comprising dry ingredients and water is conditioned prior to extrusion in a preconductor by heating it. Preferably, the pasty mixture is heated in a preconditioner to a temperature in the range of from about 50 ° C (122 ° F) to about 80 ° C (176 ° F), more preferably from about 60 ° C (140 ° F) to about 75 ° C ( 167 ° F).

[0090] Then, the pasty mixture is introduced into the extruder to heat, cut and, finally, give it plasticity. The extruder can be selected from commercially available extruders. Preferably, the heated extruder is a single-screw extruder, more preferably a twin-screw extruder, which mechanically cuts the dough by means of snails. Commercially available extruders useful for practicing the present invention include Clextral extruders^® commercially available from Clextral, Inc., Tampa, Florida; Wenger extruders, commercially available from Wenger, Inc., Sabetha, Kansas; and Evolum extruders^® extruders, commercially available from Clextral, Inc. A particularly preferred extruder for practicing the present invention is the Clextral extruder^® BC72, available from Clexrtal, Inc. Another preferred extruder for practicing the present invention is the EV32 twin screw extruder from Evolum^®.

[0091] The dough mixture is cut and pressurized in an extruder to plasticize it. The extruder elements in the form of snails cut the mixture in the form of dough, and also create pressure in the extruder pushing the dough mixture through the extruder and through the matrix. The speed of the screw motor determines how many times the dough will be cut and what pressure the dough mixture will be subjected to by the screw (s). Preferably, the screw motor speed is set to be in the range of from about 200 rpm to about 500 rpm, and more preferably from about 300 rpm to about 400 rpm, which causes the dough mixture to pass through the extruder at a rate of at least about 20 kilograms per hour, and more preferably at least 40 kilograms per hour. Preferably, the extruder generates a pressure of about 3.4 x 10 at the cylinder outlet⁶ up to about 10 x 10⁶ Pa (from about 500 to about 1500 psig), and more preferably from about 4.1 x 10⁶ up to about 6.9 x 10⁶ Pa (from about 600 to about 1000 psig).

EP 2 020 868 B2 [0092] The dough mixture passing through this extruder is heated. Heating denatures the protein in the pasty mixture, allowing the mixture to plasticize. The extruder contains means for heating the mixture to a temperature in the range of about 100 ° C (212 ° F) to about 180 ° C (356 ° F). Preferably, the means for heating the mixture in the extruder include cylinder jackets into which heating or cooling agents, such as steam or water, can be introduced to control the temperature of the pasty mixture passing through the extruder. For direct injection of steam into the mixture in the extruder, it may also be equipped with steam injection openings. The extruder preferably comprises a plurality of heating zones whose temperature can be independently controlled, wherein the temperatures of these heating zones are preferably set to increase the temperature of the dough mixture as it passes through the extruder. For example, the extruder can be arranged in a system with four temperature zones, where the first zone (at the extruder inlet) is set to a temperature from about 80 ° C (176 ° F) to about 100 ° C (212 ° F), the second zone is set to a temperature from about 100 ° C (212 ° F) to about 135 ° C (275 ° F), the third zone is set to a temperature from 135 ° C (275 ° F) to about 150 ° C (302 ° F) . and the fourth zone (at the extruder outlet) is set to a temperature from 150 ° C (302 ° F) to 180 ° C (356 ° F). The extruder can be set, if necessary, in a different temperature zone system. For example, the extruder can be set in a system with five temperature zones, where the first zone is set to a temperature of about 25 ° C (77 ° F), the second zone is set to a temperature of about 50 ° C (122 ° F), the third zone is set to a temperature of about 95 ° C (203 ° F), the fourth zone is set to a temperature of about 130 ° C (266 ° F), and the fifth zone is set to a temperature of about 150 ° C (302 ° F).

[0093] A long cooling matrix is ​​attached to the extruder, such that the plasticized dough mixture flows from the extruder through the cooling matrix after leaving the extruder outlet port. The dough mixture forms in the extruder a molten plastic mass that flows from the heated extruder to this matrix. The cooling matrix cools and shapes the mixture as a hot dough as it exits the extruder. The formation of fibers in the mixture constituting the plasticized dough is caused by the cooling effect of the cooling matrix, resulting in a fibrous meat analogue product. The fibrous substance exits the cooling matrix through at least one slot in the face of the matrix, which may be a matrix plate attached to the matrix. The extruded fibrous substance is cut to the desired length with a cutting knife placed at the die gap (s) to cut the extrudate as it exits the die gap (s).

[0094] The cooling matrix is ​​kept at a temperature much lower than the temperature in the extruder, in the end zone of the extruder at the matrix. The cooling matrix contains means for maintaining a temperature significantly lower than the exit temperature of the extruder. Preferably, in order to maintain the temperature of the cooling matrix, it comprises an inlet port and an outlet port for circulating means. Most preferably, constant temperature water is pumped in a closed circuit to maintain the desired temperature of the cooling matrix within the cooling matrix. Preferably, the cooling matrix is ​​maintained at a temperature from about 80 ° C (176 ° F) to about 110 ° C (230 ° F),

EP 2 020 868 B2 more preferably from about 85 ° C (185 ° F) to about 105 ° C (221 ° F), and most preferably from about 90 ° C (194 ° F) to about 100 ° C (212 ° F ).

[0095] In order to provide sufficient cooling as the plasticized dough passes through the matrix and cause proper fiber formation, preferably the cooling matrix is ​​a long cooling matrix. In a preferred embodiment, the matrix is ​​at least 200 millimeters long, and more preferably at least about 500 millimeters long. Long cooling matrices useful for practicing the method of the present invention are commercially available, for example from Clextral^®, Inc., EI duPont de Nemours and Company and Kobe Steel, Ltd.

[0096] The width and height of the cooling matrix gap (s) are selected and set before extruding the pasty mixture to obtain an extruded fibrous product of the desired dimensions. The width of the gap (gaps) can be set such that the extrudate resembles a product from a cubic piece of meat to a steak meat fillet, while increasing the gap (slots) of the matrix reduces the properties resembling a cube block of the extruded product and increases the extrudate-like properties. Preferably, the width of the cooling matrix gap (s) is set in the range of about 10 millimeters to about 40 millimeters, and most preferably in the range of about 25 millimeters to about 30 millimeters.

[0097] The height of the slit (s) of the cooling matrix can be adjusted to obtain the desired thickness of the extrudate. The height of the slit (s) can be set to obtain a very thin extrudate or thick extrudate. A new feature of the present invention is that the height of the gap (s) can be set to at least about 12 millimeters, and the extrudate obtained is fibrous in any arbitrary cross-section. Prior to the present invention, extruded articles with high humidity, having a thickness of at least about 12 millimeters (determined by the height of the cooling matrix gap (s)) gelatinized in the middle and were not fibrous throughout the entire cross-section. Preferably, the height of the slit (s) of the cooling matrix can be set in the range of from about 1 millimeter to about 30 millimeters, more preferably from about 12 millimeters to about 25 millimeters, and most preferably from about 15 millimeters to about 20 millimeters.

[0098] Due to the high moisture content of the pasty mixture, there is little dissipation of energy and expansion of the extruded soy protein composition as it exits from the matrix slit (s). As a result, this soy protein composition is relatively dense compared to the expanded low moisture product, since few air bubbles get into the expanded soy protein composition when expanding when leaving the matrix.

[0099] One example of an extrudate containing soy protein and soy cotyledon fiber for use in the restructured meat product described herein is FXP MO339, available from Solae LLC (St. Louis, MO). FXP MO339 is an extruded dry textured soy protein with the right fiber and texture and the right amount of soy protein. Specifically, FXP MO339 contains about 59 wt. soy protein, about 2 wt. fiber, about 25 wt. wheat gluten, about 10 wt. starch, about 0.1% L-cysteine, about 0.5% dicalcium phosphate and about 5.2% by weight moisture. Another example of an extrudate containing soy protein and

EP 2 020 868 B2 soy cotyledon fiber for use in the restructured meat product described here is VETEX^® 1000, available from Stentorian Industries Company Limited (Taiwan).

[0100] The following examples relate to the production of low moisture extrudate, which after hydration and comminution gives a hydrated and crumbled low moisture soy protein composition.

Example 1 [0101] The following ingredients are added to the tank for mixing loose compositions: 1000 kg Supro 620, 440 kg wheat gluten, 171 kg wheat starch, 34 kg soy cotyledon fiber, 9 kg dicalcium phosphate and 1 kg L-cysteine . The contents are mixed to produce a loose soy protein mixture. The loose composition is then transferred to a hopper, from which it is introduced into the preconditioner together with 480 kg of water, forming a conditioned soy protein pre-mixture. The conditioned soy protein pre-mixture is then fed into a twin-screw extruder at a rate of not more than 25 kg / min. The extrusion device comprises six temperature controlled sections, wherein the controlled temperature of the protein mixture ranges from about 100 ° C (212 ° F) in the first section to about 150 ° C (302 ° F) in the sixth section. The extruded mass is subjected to a pressure of at least about 28 bar in the first section to about 210 bar in the fourth section. Water, 60 kg, is injected into the extruder cylinder through one or more injection nozzles connected to the heating section. The molten mass from the extruder exits the extruder cylinder through the matrix, and the moisture present in the mass evaporates in the form of steam, causing the substance to expand. When the mass exits the matrix, it is cut by rotary knives and then the cut mass is dried until a moisture content of about 10 wt.

[0102] Examples 2-92 are repeats of Example 1.

[0103] Table III below shows the results of the analysis of the above Examples.

Table III

<td>Example No.</td><td>% Big pieces</td><td>Shear Texture (g)</td><td>Hydration (min.)</td><td>Density (g / cm³)</td>

<td> 1</td><td> 30,2</td><td> 2150</td><td> 80</td><td> 0,27</td>

<td> 2</td><td> 24,2</td><td> 2366</td><td> 80</td><td> 0,24</td>

<td> 3</td><td> 29,4</td><td> 2341</td><td> 60</td><td> 0,30</td>

<td> 4</td><td> 26,0</td><td> 2142</td><td> 70</td><td> 0,29</td>

<td> 5</td><td> 27,1</td><td> 2291</td><td> 70</td><td> 0,28</td>

<td> 6</td><td> 32,7</td><td> 2442</td><td> 70</td><td> 0,23</td>

<td> 7</td><td> 17,4</td><td> 2668</td><td> 70</td><td> 0,27</td>

<td> 8</td><td> 26,1</td><td> 2511</td><td> 90</td><td> 0,26</td>

<td> 9</td><td> 21,1</td><td> 2260</td><td> 80 .</td><td> 0,28</td>

<td> 10</td><td> 22,3</td><td> 2421</td><td> 80</td><td> 0,24</td>

EP 2 020 868 B2

<td>Example No.</td><td>% Big pieces</td><td>Shear Texture (g)</td><td>Hydration (min.)</td><td>Density (g / cm³)</td>

<td> 11</td><td> 21,9</td><td> 2490</td><td> 75</td><td> 0,28</td>

<td> 12</td><td> 22,4</td><td> 2438</td><td> 104</td><td> 0,28</td>

<td> 13</td><td> 17,8</td><td> 2159</td><td> 81</td><td> 0,30</td>

<td> 14</td><td> 27,3</td><td> 2675</td><td> 83</td><td> 0,28</td>

<td> 15</td><td> 29,3</td><td> 2553</td><td> 100</td><td> 0,24</td>

<td> 16</td><td> 27,3</td><td> 2226</td><td> 90</td><td> 0,23</td>

<td> 17</td><td> 23,5</td><td> 2412</td><td> 72</td><td> 0,24</td>

<td> 18</td><td> 40,0</td><td> 2055</td><td> 100</td><td> 0,23</td>

<td> 19</td><td> 32,6</td><td> 2511</td><td> 75</td><td> 0,25</td>

<td> 20</td><td> 22,7</td><td> 2168</td><td> 100</td><td> 0,25</td>

<td> 21</td><td> 22,0</td><td> 2207</td><td> 102</td><td> 0,25</td>

<td> 22</td><td> 27,7</td><td> 2247</td><td> 62</td><td> 0,29</td>

<td> 23</td><td> 31,2</td><td> 2151</td><td> 73</td><td> 0,28</td>

<td> 24</td><td> 30,2</td><td> 2164</td><td> 63</td><td> 0,27</td>

<td> 25</td><td> 26,6</td><td> 1966</td><td> 68</td><td> 0,28</td>

<td> 26</td><td> 24,9</td><td> 2164</td><td> 50</td><td> 0,31</td>

<td> 27</td><td> 25,0</td><td> 1812</td><td> 58</td><td> 0,28</td>

<td> 28</td><td> 19,6</td><td> 2108</td><td> 60</td><td> 0,31</td>

<td> 29</td><td> 15,8</td><td> 1864</td><td> 70</td><td> 0,27</td>

<td> 30</td><td> 26,5</td><td> 2473</td><td> 58</td><td> 0,25</td>

<td> 31</td><td> 20,7</td><td> 1879</td><td> 65</td><td> 0,28</td>

<td> 32</td><td> 25,4</td><td> 1688</td><td> 70</td><td> 0,29</td>

<td> 33</td><td> 20,3</td><td> 2038</td><td> 74</td><td> 0,26</td>

<td> 34</td><td> 39,3</td><td> 2074</td><td> 73</td><td> 0,28</td>

<td> 35</td><td> 11,5</td><td> 1937</td><td> 70</td><td> 0,39</td>

<td> 36</td><td> 32,5</td><td> 1462</td><td> 77</td><td> 0,40</td>

<td> 37</td><td> 30,1</td><td> 2051</td><td> 66</td><td> 0,28</td>

<td> 38</td><td> 27,9</td><td> 2384</td><td> 54</td><td> 0,31</td>

<td> 39</td><td> 28,1</td><td> 2064</td><td> 58</td><td> 0,28</td>

<td> 40</td><td> 29,2</td><td> 2158</td><td> 60</td><td> 0,27</td>

<td> 41</td><td> 20,0</td><td> 1834</td><td> 58</td><td> 0,28</td>

<td> 42</td><td> 26,8</td><td> 2202</td><td> 58</td><td> 0,28</td>

<td> 43</td><td> 32,8</td><td> 2363</td><td> 57</td><td> 0,26</td>

<td> 44</td><td> 33,9</td><td> 2361</td><td> 57</td><td> 0,28</td>

<td> 45</td><td> 36,9</td><td> 2293</td><td> 103</td><td> 0,25</td>

<td> 46</td><td> 26,3</td><td> 2205</td><td> 73</td><td> 0,28</td>

<td> 47</td><td> 19,0</td><td> 2286</td><td> 53</td><td> 0,29</td>

EP 2 020 868 B2

<td>Example No.</td><td>% Big pieces</td><td>Shear Texture (g)</td><td>Hydration (min.)</td><td>Density (g / cm³)</td>

<td> 48</td><td> 22,6</td><td> 2206</td><td> 63</td><td> 0,25</td>

<td> 49</td><td> 30,5</td><td> 2125</td><td> 63</td><td> 0,31</td>

<td> 50</td><td> 25,5</td><td> 2290</td><td> 55</td><td> 0,29</td>

<td> 51</td><td> 38,2</td><td> 2274</td><td> 55</td><td> 0,26</td>

<td> 52</td><td> 31,5</td><td> 2205</td><td> 42</td><td> 0,33</td>

<td> 53</td><td> 31,3</td><td> 2185</td><td> 55</td><td> 0,31</td>

<td> 54</td><td> 31,8</td><td> 1969</td><td> 40</td><td> 0,30</td>

<td> 55</td><td> 19,1</td><td> 2028</td><td> 55</td><td> 0,31</td>

<td> 56</td><td> 17,2</td><td> 1598</td><td> 63</td><td> 0,37</td>

<td> 57</td><td> 28,3</td><td> 1869</td><td> 60</td><td> 0,31</td>

<td> 58</td><td> 29,7</td><td> 2044</td><td> 50</td><td> 0,29</td>

<td> 59</td><td> 27,6</td><td> 2216</td><td> 52</td><td> 0,28</td>

<td> 60</td><td> 25,0</td><td> 2001</td><td> 53</td><td> 0,28</td>

<td> 61</td><td> 28,1</td><td> 2096</td><td> 45</td><td> 0,27</td>

<td> 62</td><td> 19,0</td><td> 1796</td><td> 53</td><td> 0,27</td>

<td> 63</td><td> 20,0</td><td> 1924</td><td> 51</td><td> 0,27</td>

<td> 64</td><td> 23,7</td><td> 2295</td><td> 51</td><td> 0,28</td>

<td> 65</td><td> 17,4</td><td> 2259</td><td> 50</td><td> 0,29</td>

<td> 66</td><td> 29,2</td><td> 2204</td><td> 43</td><td> 0,28</td>

<td> 67</td><td> 25,3</td><td> 2059</td><td> 38</td><td> 0,31</td>

<td> 68</td><td> 26,1</td><td> 2284</td><td> 70</td><td> 0,32</td>

<td> 69</td><td> 23,6</td><td> 2085</td><td> 70</td><td> 0,30</td>

<td> 70</td><td> 25,6</td><td> 2279</td><td> 44</td><td> 0,28</td>

<td> 71</td><td> 23,7</td><td> 2170</td><td> 44</td><td> 0,32</td>

<td> 72</td><td> 31,2</td><td> 2128</td><td> 49</td><td> 0,29</td>

<td> 73</td><td> 32,4</td><td> 2068</td><td> 50</td><td> 0,29</td>

<td> 74</td><td> 40,1</td><td> 1939</td><td> 40</td><td> 0,30</td>

<td> 75</td><td> 28,7</td><td> 1592</td><td> 50</td><td> 0,30</td>

<td> 76</td><td> 29,6</td><td> 1812</td><td> 68</td><td> 0,28</td>

<td> 77</td><td> 25,2</td><td> 1848</td><td> 64</td><td> 0,28</td>

<td> 78</td><td> 23,6</td><td> 1973</td><td> 70</td><td> 0,30</td>

<td> 79</td><td> 23,7</td><td> 2078</td><td> 66</td><td> 0,36</td>

<td> 80</td><td> 35,6</td><td> 1940</td><td> 44</td><td> 0,31</td>

<td> 81</td><td> 18,5</td><td> 2339</td><td> 33</td><td> 0,29</td>

<td> 82</td><td> 30,2</td><td> 2366</td><td> 50</td><td> 0,24</td>

<td> 83</td><td> 28,1</td><td> 2425</td><td> 40</td><td> 0,29</td>

<td> 84</td><td> 29,6</td><td> 2122</td><td> 59</td><td> 0,27</td>

EP 2 020 868 B2

<td>Example No.</td><td>% Big pieces</td><td>Shear Texture (g)</td><td>Hydration (min.)</td><td>Density (g / cm³)</td>

<td> 85</td><td> 27,5</td><td> 2193</td><td> 56</td><td> 0,16</td>

<td> 86</td><td> 21,1</td><td> 2186</td><td> 56</td><td> 0,28</td>

<td> 87</td><td> 22,4</td><td> 2061</td><td> 56</td><td> 0,27</td>

<td> 88</td><td> 31,3</td><td> 2143</td><td> 50</td><td> 0,27</td>

<td> 89</td><td> 24,4</td><td> 2108</td><td> 54</td><td> 0,26</td>

<td> 90</td><td> 39,9</td><td> 2101</td><td> 53</td><td> 0,30</td>

<td> 91</td><td> 32,3</td><td> 2551</td><td> 55</td><td> 0,25</td>

<td> 92</td><td> 24,3</td><td> 2164</td><td> 57</td><td> 0,28</td>

<td>1st quartile</td><td> 22,6</td><td> 2045</td><td> 53</td><td> 0,27</td>

<td>Median</td><td> 26,5</td><td> 2164</td><td> 60</td><td> 0,28</td>

<td>3rd Quartile</td><td> 30,2</td><td> 2291</td><td> 70</td><td> 0,30</td>

<td>Average</td><td> 26,6</td><td> 2156</td><td> 63</td><td> 0,28</td>

Ground meat [0104] It is well known to produce mechanically deboned raw meat using high pressure mechanical devices that separate the bone from animal tissue, first crushing the bone and adjacent tissue, and then squeezing the tissue, but not the bone, through a sieve or similar device for screening. The animal tissue in the present invention includes muscle tissue, organ tissue, connective tissue and skin. As a result of this process, a non-structured, paste-like mixture of soft animal tissue with a butter consistency is created and is commonly called mechanically separated meat or MSM. This paste-like mixture has a particle size of from about 0.25 to about 15 millimeters, preferably up to about 5 millimeters, and most preferably up to about 3 millimeters.

[0105] Although animal tissue, also known as raw meat, is preferably provided in at least partially frozen form, so as to avoid contamination with microorganisms prior to processing, after grinding the meat, it is not necessary to freeze it to make it cut into individual strips or pieces. Unlike meat meal, the meat raw material has a natural moisture content above about 50% and the protein is not denatured.

[0106] The raw meat used in the present invention can be any edible meat suitable for human consumption. This meat may be non-utilized meat, dehydrated meat, raw meat, raw meat products, raw meat by-products and mixtures thereof. Meat or meat products are ground and usually delivered daily in a state of complete or at least partial freezing so as to avoid contamination with microorganisms. Typically, the ground meat temperature is below about 40 ° C (104 ° F), preferably below about 10 ° C (50 ° F), more preferably in the range of about -4 ° C (25 ° F) to about 6 ° C ( 43 ° F), and most preferably from about -2 ° C (28 ° F) to about 2 ° C (36 ° F). Although chilled meat can be used, it is usually not practical to store large amounts of non-frozen meat for long

EP 2 020 868 B2 period at the plant. Frozen products provide a longer shelf life than chilled products. Beef, pork, chicken and turkey are preferred meat products for human consumption. Specific examples of animal food products that can be used in the process of the present invention include a pork shoulder, beef shoulder, beef patch, turkey leg, beef liver, beef heart, pork heart, pork head, diaphragm muscle, mechanically separated beef, pork mechanically separated meat and mechanically separated chicken meat. Mechanically boned beef, mechanically boned pork and mechanically boned chicken meat are preferred.

[0107] Instead of using frozen ground meat, freshly ground meat may be used to prepare the restructured meat product, provided that the freshly ground meat meets temperature conditions, not higher than about 40 ° C (104 ° F).

[0108] The moisture content of frozen or non-frozen raw meat is usually at least about 50 wt.%, And most often from about 60 wt.%. up to about 75% by weight, based on the weight of the raw meat. In embodiments of the present invention, the fat content of frozen or non-frozen raw meat may be at least 2 wt%, usually from about 15 wt% up to about 30 wt. In other embodiments of the present invention, meat products having a fat content less than about 10 wt. and skimmed meat products.

[0109] Frozen or chilled meat can be stored at a temperature from about -18 ° C (4 ° F) to about 0 ° C (32 ° F). Usually delivered in 20 kg blocks. Before use, these blocks are allowed to warm to about 10 ° C (50 ° F), i.e., to thaw, but in a moderate environment. Thus, the outer layer of the blocks, for example to a depth of about 6.4 mm (1/4 ”) can be thawed, but still at a temperature of about 0 ° C (32 ° F), while the remaining inner part of the blocks, although still frozen, still heating and thus maintaining the outside at temperatures below about 10 ° C (50 ° F).

[0110] The term "meat" refers not only to cattle, pigs, sheep and goats, but also to horses, whales and other mammals, poultry and fish. The term "meat by-products" means not derived from the utilization of parts of the carcases of slaughtered animals including, but not limited to, mammals, poultry and the like, and is covered by the term "meat by-products" in the definitions of feed ingredients promulgated by the Association of American Food Control Officers ( Association of American Feed Control Officials, Incorporated, AAFCO) The terms "meat" and "meat by-products" are understood to refer to all of the animal, poultry and sea products defined by this association.

[0111] Examples of meats that can be used include mammalian meat such as beef, veal, pork and horse and meat tissue from bison, cows, roe deer, elk, and the like. Poultry meat that can be used includes chicken, turkey, duck and goose, and the like. Fish and shellfish meat may also be used in embodiments of the present invention. The meat includes the striated muscles, i.e. the skeletal or muscles located, for example, in the tongue, diaphragm, heart and esophagus together with the accompanying fat and portions of skin, tendons, nerves and blood vessels that normally accompany meat. Examples of meat products

Side effects are organs and tissues such as the lungs, spleen, kidneys, brain, liver, blood, bone, partially defatted fat, stomachs, intestines without content, and the like. Poultry by-products include non-utilized clean parts of the carcasses of slaughtered domestic birds, such as heads, paws and guts, free from faeces and foreign matter.

Water [0112] As water, tap water, distilled water or deionized water is used. Water is added to hydrate the ingredients in the form of soy protein, soy cotyledon fiber, wheat gluten and starches contained in the soy protein composition such that these ingredients absorb water and the soy cotyledon fiber contained in the soy protein composition are separated. Typically, the ratio of non-moisture soy protein composition to hydration water is from about 1: 1.75 to about 1:10, preferably from about 1: 2 to about 1: 7, and most preferably from about 1: 2.5 to about 1 5. More hydration water is used when a low moisture soy protein composition is used in the restructured meat product. Less hydration water is used when a high moisture soy protein composition is used in the restructured meat product. The water temperature can range from 0 ° C (32 ° F) to about 30 ° C (86 ° F). The hydration time can be from about 30 minutes to several hours, depending on the moisture content of the soy protein composition, the amount of water used, and the temperature of the water.

[0113] The restructured meat product is prepared by a process comprising the steps of: combining a hydrated and ground protein composition, preferably a hydrated and ground soy protein composition; at least about 75 wt. contains at least 15% by weight of fragments consisting of protein fibers at least about 4 centimeters long, protein bundles at least about 3 centimeters long, and protein nuggets at least about 2 centimeters long and of which at least about 75 percent by weight has a strength of shearing at least about 1400 grams, with ground meat, wherein the temperature of the ground meat is below about 40 ° C (104 ° F); and mixing the preferred hydrated and ground soy protein composition and ground meat to produce a homogeneous, fibrous restructured meat product with a moisture content of at least about 50%.

[0114] Before hydrating the preferred soy protein composition, the weight ratio of non-moisture soy protein composition to ground meat without moisture is usually from about 1: 0.25 to about 1:50, preferably from about 1: 1 to about 1:40, and most preferably from about 1: 2 to about 1:20. The hydrated soy protein composition, after shredding into a fibrous substance, and ground meat are combined in a mixing apparatus to obtain a homogeneous restructured meat product.

[0115] The product and process of the present invention ends by combining the hydrated and ground soy protein composition, ground meat and water in the disclosed ratios of protein composition to ground meat and protein composition to water. The soy protein composition is first hydrated with water and then comminuted to expose the fibers. When hydration is completed, ground meat is added and the contents are mixed until a homogeneous mass of the restructured meat product is obtained. At this stage, a homogeneous restructured meat product can be used

EP 2 020 868 B2 formed into strips, steaks, cutlets, patties, milled or usually shaped into cubes for kebabs, manually or by machine. The homogeneous restructured meat product can also be packaged in permeable or impermeable casings.

[0116] The restructured meat product may also contain at least one other ingredient selected from the group consisting of gelling protein, animal fat, sodium chloride, sodium tripolyphosphate, disodium dihydrogen pyrophosphate, dye, binding agent, antioxidant, antimicrobial, flavoring agent and mixtures thereof.

[0117] The gelling protein is selected from the group consisting of soy protein flour, soy protein isolate and soy protein concentrate. These are the same soy proteins that are used in making the soy protein composition. Soy protein isolate useful as a gelling protein is high viscosity isolated soy protein and / or medium / high gelation. Gelling protein provides a gel base in the restructured meat product. Suitable sources of isolated high-viscosity soy protein and / or medium / high gelation (i.e. non-hydrolyzed protein) for use as a gelling protein include SUPRO^® 620, SUPRO^® 500E, SUPRO^®630 and SUPRO^® EX33 available from Solae LLC (St. Louis, MO); PROFAM 981 available from Archer Daniels Midland (Decatur, IL); and PROLISSE soy protein isolate^® available from Cargill Soy Protein Solutions, Inc. (Minneapolis, MN). The gelling protein is present in an amount of from about 2% to about 10% by weight. in terms of dry matter.

[0118] Animal fats are highly saturated triglycerides. Animal fats at room temperature are usually solid or waxy. The purpose of animal fats in a restructured meat product is to act as a gelling agent in the unboiled state and as an auxiliary flavor in the cooked state. Animal fats are usually present in an amount of from about 1% to about 30% by weight. based on dry weight, and preferably from about 2% to about 10% by weight. in terms of dry matter.

[0119] Sodium chloride and sodium phosphates are salts that are mixed with a restructured meat product to extract / dissolve myofibril protein in ground meat. These salts, used alone or in combination, in addition to improving the flavor, also help bind ground meat in a restructured meat product. These salts typically are present in an amount of from about 0.1% to about 4.0% by weight, respectively. based on dry weight and from about 0.1% to about 1.0% by weight in terms of dry matter. Preferably, these salts are present in an amount of from about 0.5% to about 2.0% by weight, respectively. based on dry weight and from about 0.2% to about 0.5% by weight in terms of dry matter.

[0120] Dyes provide a "pleasing to the eye" appearance of the restructured meat product. Dyes provide the red color of the restructured meat product in raw state, as well as the brown color when cooked. Examples of dyes include edible dyes such as caramel, paprika, cinnamon and FD &amp; C Red No. 3 (aka Food Red 14 and Erythrosine BS), FD &amp; C Yellow No. 5 (aka Food Yellow 4 and Tartrazine), FD &amp; C Yellow 6 (aka Food Yellow 3 and Sunset Yellow FCF), FD &amp; C Green No. 3 (aka Food Green 3 and FCF Permanent Green), Blue FD &amp; C No. 2 (Food Blue 1 and Indigo Carmine), Blue FD &amp; C No. 1 (aka food blue 2 and brilliant blue FCF) and violet FD &amp; C No. 1 (aka violet

EP 2 020 868 B2 food 2 and violet B6) as well as sodium nitrate; the latter also acts as a curing agent. Caramel is preferred, which can occur in various shades of color.

[0121] Caramel means an amorphous, dark brown, deliquescent or thick liquid with a bitter taste, aroma of burnt sugar and a specific density of about 1.35. It is soluble in water and diluted alcohol. Caramel is produced by careful, controlled heat treatment of carbohydrate or saccharide substances, such as dextrose, invert sugar, lactose, malt syrup, molasses, sucrose, starch hydrolysates and their fractions. Other substances that can be used during heat treatment to facilitate caramelization include acids (e.g., acetic acid, citric acid, (ortho) phosphoric acid, sulfuric acid, and sulfuric acid) and salts (e.g., ammonium, sodium or potassium carbonate, bicarbonates, hydrogen (ortho) phosphates or dihydrogen (ortho) phosphates).

[0122] In one method of making caramel, described in US Patent No. 3,733,405, liquid sugar, cane or corn, is pumped into the reaction vessel along with one or a combination of reagents approved by the US Food and Drug Administration, and then the mixture is heated. During the polymerization, the temperature is maintained in the range of from about 121 ° C (250 ° F) to about 260 ° C (500 ° F), and the product is maintained under pressure from about 0.1x10⁶ to about 1.7x10⁶ Pa (pressure about 15 and about 250 psig (psi)). When the process is completed, the product is poured into an instant cooler, which lowers the temperature to about 65 ° C (150 ° F). Then it is filtered, cooled and then pumped into a storage container.

[0123] It is preferred that, when a liquid is used, the dye is present in the restructured meat product in the range from about 0.1% to about 2%, preferably in the range from 0.2% to about 1%, and most preferably in the range from about 0.25% to about 0.75% by weight of the restructured meat product.

[0124] Although the restructured meat product comes from a meat source, it is preferred to add flavor to this product to improve its aroma and taste. Flavors are natural or artificial. Flavorings are selected from the group consisting of beef flavor, pork flavor and chicken flavor. Beef flavor is preferred. Flavorings are typically present in an amount of from about 0.1% to about 5.0% by weight. based on dry weight, preferably from about 0.5% to about 3.0% by weight in terms of dry matter.

[0125] When the restructured meat product further comprises at least one component selected from the group consisting of gelling protein, animal fat, sodium chloride, sodium tripolyphosphate, dye, binder, antioxidant, antimicrobial, flavoring and mixed ingredients thereof the product and process ends following a procedure similar to that of the product and process using only a vegetable protein composition, ground meat and water. The vegetable protein composition is first hydrated with water and comminuted to expose and separate the fibers. When hydration and comminution are completed, a colorant is added. Ground meat and water are added and the contents are mixed until a homogeneous mass is obtained. This will be followed by29

The addition of animal fat, flavors, sodium chloride, sodium tripolyphosphate and gelling proteins is added to EP 2 020 868 B2.

[0126] A homogeneous restructured meat product can be formed into strips, steaks, cutlets, patties or generally formed into kebab cubes, manually or by machine. A homogeneous restructured meat product can be formed into meat sticks. A homogeneous restructured meat product can also be packed into permeable or impermeable casings to produce sausages.

[0127] The restructured meat product, with or without gelling protein, may be dried, for example, as jerky, or partially dried, for example, as salami. Preferably, the restructured meat product has a moisture content of at least about 50% prior to drying. If it is dry or partially dried, the restructured meat product has a moisture content of from about 15 to about 45%. An example of a dry meat product is a jerky product.

[0128] After forming, the restructured meat product is either cooked, partly cooked for final preparation later, or frozen in an uncooked, partially cooked or cooked state. Cooking includes frying, both saute and deep frying, baking, smoking and processing using an impingement. The fully cooked restructured meat product can then be cut into slices, ground or ground.

[0129] In addition, the restructured meat product may be fermented. Meat products are fermented by adjusting the pH of the meat from about 4.0 to about 5.2. Fermentation is terminated by adding at least one of the ingredients from the following group: lactic acid bacteria culture, citric acid, delta-gluconolactone and mixtures thereof.

[0130] The jerky products of the present invention can be made in a variety of shapes, such as bone shape, cutlet, round, triangular, chicken bone shape, square, rectangular, strap shape, etc. Various shapes can be made simultaneously using differently shaped molds or dies on one cylinder. In addition, logos or patterns can be embossed or imprinted on the products using molds or dies on this roller.

[0131] The shelf life of the jerky products of the present invention, when stored outside the refrigerator / refrigerator, is at least about six months and preferably at least about twelve months in a suitable moisture-proof package, such as foil sealed bags. In addition, the restructured meat product can also be formulated to store minced meat and crumble. They are usually made with spices and flavors and have a water activity of from about 0.65 to about 0.8. They can be consumed as protein-rich rice dishes, as meat snacks, and as a substitute for the Mexican machaca dish.

[0132] The restructured meat product (before drying, partially dried, dry, cooked or uncooked) can be packaged without further processing. Further processing of the restructured meat product (before drying, partially dried, dry, cooked or uncooked) may be shock freezing, for example in a freezing tunnel, followed by automatic packaging in portions into appropriate packaging, e.g. plastic

EP 2 020 868 B2 bags etc. The type of further processing and packaging mentioned is suitable if the product is to be used in fast-food restaurants or in catering, where it is usually deep fried or baked before consumption.

[0133] Alternatively, after producing a restructured meat product (before drying, partially desiccated, dry, cooked or uncooked), the product surface may also be sprayed with solutions of carbohydrates or related substances to obtain homogeneous browning for deep frying or baking. Then the product can be subjected to shock freezing and sold packed in portions (i.e. in bags). The consumer can also bake or process the restructured product in a convection oven instead of deep frying. In addition, the restructured meat product can also be coated with breadcrumbs or other coatings, before or after cooking. In addition, the restructured meat product can be heated in the retort to kill any microbes.

[0134] The restructured meat product, cooked or uncooked, can also be packaged and sealed in cans in a conventional manner and using standard sealing procedures. Typically, cans at this stage are kept at a temperature between 65 ° C and 77 ° C and, as soon as possible, the retort or cooking stage begins to prevent the risk of microbial spoilage in between the canning and sterilization period during the retort or cooking stage.

[0135] To ensure that the restructured meat product has an intact muscle texture after production, it is required that at least about 75 wt. the protein composition contained at least about 15 wt. large pieces consisting of vegetable protein fibers at least about 4 cm long, vegetable protein bundles at least about 3 cm long and vegetable protein nuggets at least about 2 cm long and at least about 75 wt. the protein composition had a shear strength of at least about 1400 g.

[0136] The fruit product is produced by a process comprising the following steps: combining a cured and ground protein composition, preferably a hydrated and ground soy protein composition; of which about 75 wt. contains at least about 15 wt. fragments consisting of protein fibers at least about 4 cm long, protein bundles at least about 3 cm long and protein nuggets at least about 2 cm long, with at least about 75% by weight of the protein composition having a shear strength of at least about 1400 g; with ground vegetable; mixing the beneficial hydrated and ground soy protein composition and ground vegetable to form a homogeneous, fibrous and structured product. [0137] Examples of plant products produced by the above process are vegetarian patty chops, vegetarian hot dogs, vegetarian sausages and vegetarian crumble.

[0138] Another example of vegetarian food is cheeses enriched with hardened and ground protein composition.

[0139] The fruit product is produced by a process comprising the following steps: combining a cured and ground protein composition, preferably a hydrated and ground soy protein composition; of which about 75 wt. contains at least about 15 wt. fragments consisting of protein fibers at least about 4 cm long, protein bundles with a length of every

At least about 3 cm and protein nuggets at least about 2 cm in length, wherein at least about 75% by weight of the protein composition has a shear strength of at least about 1400 g; with ground fruit; mixing the beneficial hydrated and ground soy protein composition and ground fruit to form a homogeneous, fibrous and structured product.

[0140] Examples of fruit products produced in the above process are snacks, including fruit roll-ups, cereal products and fruit crumble.

[0141] The invention, described generally above, is better understood with reference to the following examples. The following examples are specific, but not limiting, embodiments of the present invention.

Example 93 [0142] 3625 g of tap water was poured into the stirrer at a temperature of about 10 ° C (50 ° F) and 1160 g of dried soy protein composition with low humidity (from about 7% to about 12%) called FXP was added with stirring MO339, manufactured by Solae, LLC, St. Louis, MO containing soy protein isolate, soy cotyledon fiber, wheat gluten and starch until the soy protein composition was hydrated and the fibers separated. 5216 g of mechanically deboned chicken meat with a moisture content of at least about 50% was added to the stirrer. The mechanically deboned chicken was at a temperature from about 2 ° C (36 ° F) to about 4 ° C (39 ° F). The contents were mixed until a homogeneous restructured meat product was obtained. The restructured meat product was placed in a Hollymatic molding machine, where it was processed into steaks or cutlets, which were then frozen.

Example 94 [0143] The procedure of Example 1 was repeated except that 1500 g of non-dried low moisture soy protein composition (about 28- about 35%) containing soy protein isolate, soy cotyledon fiber, wheat gluten and starch was hydrated with 3175 g of water. The restructured meat product was contained in a stuffer in which it was introduced into impermeable casings and frozen. Stuffers are available from many manufacturers, including (but not limited to) HITEC Food Equipment, Inc., located in Elk Grove Village, III., Townsend Engineering Co., located in Des Moines, Iowa, Robert Reiser &amp; Co., Inc. , located in Canton, Mass. and Handtmann, Inc., located in Buffalo Grove, III.

Example 95 [0144] To the first agitator, 2127 g of tap water was poured at a temperature of about 12 ° C (54 ° F) and 1000 g of dried (from about 7% to about 12%) soy protein composition with low humidity was added until stirring. hydration and fiber separation. 43 g of caramel dye were then added to the hydrated soy protein composition. 4500 g of mechanically deboned chicken meat with a moisture content of about 50% at a temperature of about 2 ° C (36 ° F) was added. Then, 100 g sodium chloride and 30 g sodium tripolyphosphate were added to extract 32

EP 2 020 868 B2 digest / dissolve myofibrillary protein in ground meat for binding. While stirring, 500 g of beef fat and 100 g of beef aroma were added and mixing continued. In a second mixer, 600 g Supro gelling protein^® 620 was hydrated in 1000 g of water and added to the first stirrer. The contents were mixed until a homogeneous restructured meat product was obtained. The restructured meat product was placed in a Hollymatic molding machine (Hollymatic Corp., Park Forest IL), where it was processed into a patty cutlet, which was then frozen.

Example 96 [0145] 3000 g tap water was poured into the stirrer at a temperature of about 10 ° C (50 ° F) and 1500 g extruded Supro soy protein product was added with stirring.^® 620 until hydration of the soy protein composition and fibers were separated by comminution. 5000 g ground meat from mechanically boned chicken with a moisture content of about 50% was added to the stirrer. The mechanically deboned chicken was at a temperature from about 2 ° C (36 ° F) to about 4 ° C (39 ° F). The contents were mixed until a homogeneous restructured meat product was obtained. The restructured meat product was placed in a Hollymatic molding machine, where it was processed into steaks or cutlets, which were then frozen.

Example 97 [0146] The procedure of Example 96 was repeated except that the hydrated and ground soy protein composition contained soy protein isolate, rice flour and gluten-free starch.

Example 98 [0147] The procedure of Example 96 was repeated except that the hydrated and ground soy protein composition contained soy protein isolate and rice flour.

Example 99 [0148] The procedure of Example 96 was repeated except that the hydrated and ground soy protein composition contained soy protein isolate and gluten-free starch.

Example 100 [0149] The procedure of Example 96 was repeated except that the hydrated and ground soy protein composition contained soy protein isolate, wheat flour and starch.

Example 101 [0150] The procedure of Example 96 was repeated except that the hydrated and ground soy protein composition contained soy protein isolate and soy cotyledon fiber.

EP 2 020 868 B2

Example 102 [0151] The procedure of Example 96 was repeated except that the hydrated and ground soy protein composition contained soy protein isolate, soy cotyledon fiber and wheat gluten.

Example 103 [0152] 3383 g of tap water was poured into the stirrer at a temperature of about 10 ° C (50 ° F) and 1208 g of dry low-moisture soy protein extrudate (from about 7% to about 12%) called FXP MO339 was added with stirring. until its hydration, the fibers were separated by comminution. 3340 g of mechanically boned chicken meat with a moisture content of at least about 50% and 3383 g of beef with a grinding of 1.3 cm (, inch), with a fat content of about 10% were added to the stirrer. Mechanically boned chicken and ground beef were at a temperature from about 2 ° C (36 ° F) to about 4 ° C (39 ° F). Various dyes and flavors have also been added - salt, isoascorbate, sodium nitrate, dextrose, crushed black pepper, nutmeg, nutmeg shell, granulated garlic, coriander, red pepper and hydrated seed culture of LHP cells. The contents were mixed until a homogeneous restructured meat product was obtained. Then, the restructured meat product was processed into meat sticks.

Example 104 [0153] Although the invention has been explained with reference to its preferred embodiments, it should be understood that one skilled in the art, upon reading the description, will be able to use various modifications of these embodiments. It is therefore to be understood that the invention disclosed herein is intended to include such modifications in accordance with the scope of the appended claims.