GB1599195A

GB1599195A - Rapidly rehydrating meat analogue

Info

Publication number: GB1599195A
Application number: GB21363/78A
Authority: GB
Original assignee: Procter and Gamble Co
Current assignee: Procter and Gamble Co
Priority date: 1977-05-23
Filing date: 1978-05-23
Publication date: 1981-09-30
Also published as: DE2822154A1; FR2391654A1; JPS5417152A; IT7823661A0; NL7805554A; BE867322A

Description

(54) RAPIDLY REHYDRATING MEAT ANALOG (71) We, THE PROCTER & GAMBLE COMPANY, a company organised under the laws of State of Ohio, United States of America, of 301 East Sixth Street, Cincinnati, Ohio 45202, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed to be particularly described in and by the following statement: MEAT ANALOG PRODUCT Abstract of the Invention A process for preparing a dehydrated meat analog product, particularly a patty, which can absorb an equal weight of water quickly is disclosed. The dehydrated meat analog product is shelf-stable.

Background of the Invention With the rising cost of meats and poultry, and the growing concern with the cholesterol and fat contents of these foods, consumers are increasingly turning toward analog products made of vegetable protein materials.

An analog product designed to replace meat or poultry in the American consumer market must have all the attributes of the natural meat product. It must have the same mouth-feel, texture, mastication effect, flavor, juiciness and, importantly, the same convenience. Meat products are generally taken from the refrigerator, cooked and then eaten. To meet this same convenience, current meat analogs must be used as frozen food products.

Freezing also prevents the growth of bacteria and mold. This could also be accomplished by dehydration of the product; however, the consumer then must go through an additional step of hydrating the product before cooking and eating. With current dehydrated meat analogs, this rehydration step is unacceptably long, and takes from 30 minutes to 2 hours to accomplish.

In one aspect the present invention may produce a meat analog product which rehydrates quickly.

In another aspect the present invention may produce a rapidly-hydratable meat analog product which is shelf-stable.

In another aspect the present invention may provide a shelf-stable, dehydrated meat analog which rapidly rehydrates to a product having the appearance, texture and eating quality of meat or poultry, and the same convenience.

Summary of the Invention The invention encompasses a process for preparing a rapidly rehydratable meat analog compnsmg: a preparing a heat-set texturized protein/binder/water mixture having from 1.2 grams to 4 grams of water per gram of texturized protein; and (2) dehydrating the heat-set mixture.

Food grade flavors, coloring agents, and lipids, particularly immobilized lipids are optionally added during processing of the meat analog product.

The invention also encompasses the product prepared by said process.

The water in Step 1 of the process represents an amount in excess of that normally used in a meat analog product. This excess water produces a meat analog product which after heat-setting and dehydrating has increased porosity and surface area. The increased porosity and surface area contribute importantly to the rapid rehydration.

Immobilized lipids are preferred for use herein to give a shelf-stable readily rehydratable product and one which more closely resembles real meat. The immobilization prevents the lipid from coating the texturized protein, thereby retarding the rate of rehyration.

Detailed Description of the Invention This invention relates to a process for preparing a rapidly rehydrating meat analog product comprising a binder and texturized protein. Preferred products herein contain immobilized lipids.

By "binder" is meant a material which will hold the textured protein material together, but allows for easy separation of the textured protein particles during eating to duplicate the eating quality of authentic meat. The binder material may be a heat coagulable protein or starches, gums or combinations thereof.

By "textured" or "textured protein material" is meant protein which is edible. Preferred for use herein are vegetable proteins. The protein is texturized by forming it into fibers, granules, or particles or chunks which keep their shape and "chewy texture" when hydrated.

By "chewy texture" is meant that the protein material has a "mouth feel" during masticiation and shreds like meat when chewed.

By "immobilization" is meant that the lipid (fat) phase is stabilized by encapsulation or solidification so as to avoid coating the surface of the protein and thus retarding rehydration. This encapsulation or solidification process also allows release of the lipid during "in-home cooking" or during mastication.

By "comprising" is meant that various other compatible ingredients may be present in the compositions in such proportions as will not adversely affect the processing of the food product. The term "comprising" thus encompasses and includes the more restrictive terms "consisting of" and "consisting essentially of" within its scope.

All percentages herein are by weight unless otherwise specified.

The texturized protein material can be made from protein derived from vegetable or animal sources. Soybeans, cottonseed, peanuts, corn and wheat are examples of vegetable protein materials. Whey protein concentrates, non-fat dry milk, egg albumin and fish protein concentrates are examples of animal derived proteins. No criticality exists as to the source of the texturized protein.

The texturized protein particles can be in the form of granules, extruded particles, spun fibers, other processed forms or mixtures thereof. These materials are characterized by having a structural integrity such that formed units will withstand hydration, retorting, mixing, cooking, cooling, and other procedures used in preparing food for consumption.

The protein products can be texturized by a number of known methods. One process involves fiber spinning. In this method, fibrous protein products are prepared from a protein, such as soy protein, by forming a spinning dope from alkali-treated protein and extruding the dope through a perforated die or membrane into an aqueous precipitating bath which contains an acid or an acid salt. The acid bath sets the filaments or fibers which are formed which are formed in the bath. The filaments may be bundled together and stretched to orient the molecular structure of the fibers.

Another method of forming texturized protein products is by extrusion. The extrusion process involves preparing a mixture of protein, water, flavor, and other minor components, and thereafter subjecting it to heat and pressure, and subsequently extruding the mixture. As it enters into the atmosphere, the extrudate expands to form what has been characterized as "meat-like" fibers.

Another method of preparing a texturized protein product involves forming a dry protein mix and then adjusting the moisture content of the dry mix to form a dough-like protein mix. This wet mix is creped to form a coherent workable creped protein dough sheet.

Subsequently the creped sheet can be aggregated into any desired configuration, or can be utilized itself. For details of this process, see U.S. 3,840,679, issued to Liepa and Slone, October 8, 1974.

No criticality exists with regard to the source of the binder material. The binder may be derived from animal protein, for example, egg white or gelatin, or from vegetable protein, for example, soy protein, the 7S fraction of soy, and cottonseed protein, among others. In addition, the binder may be a starch, such as corn-starch, potato starch, wheat starch, tapioca and the like, or a gum, such as guar gum, carrageenan gum or pectin. Methyl cellulose will also function as a binder.

The binder must have the following properties: it must be capable of heat setting under conditions such as autoclaving, frying, baking, and microwaving; it must remain in its gelled or heat-set form during dehydration; and it must not melt, i.e., it must remain heat-set, when it is rehydrated and cooked prior to consumption.

Highly preferred binders which meet these requirements are egg white, soy Protein isolate, and the 7S fraction of soy protein as disclosed in U.S. Patent 3,953,611 (1976).

Lipids are an important part of the proper gustatory quality of a meat analog, particularly a ground beef analog. If fats or oils (of animal or, preferably, vegetable origin) are not added to meat analog products, the products do not truly mimic meat in their physical and gustatory properties. However, it has now been discovered that adding oil to a meat analog product, before or after dehydration, results in a product which rehydrates quite slowly and in unacceptable to the average user. Apparently, the added fats/oils coat and "waterproof' the texturized protein particles or fiber, thereby retarding or preventing rehydration. If fats or oils are to be added to a meat analog mixture, then the most preferred method of dehydration is freeze-drying, which appears to reduce the coating effect.

It has now been found that, in order to optimally utilize fats or oils in rapidly rehydratable meat analogs, particularly in situations where dehydration requires the use of heat, the lipid materials must be stabilized to prevent their coating the texturized protein particles. It has now also been found that for use in rapidly rehydratable meat analogs of the present type, the lipid materials are preferably immobilized in such a way to stabilize them during heating and storage and yet make them available to the palate upon mastication of the meat analog. In short, the lipid materials are encapsulated or solidified. Any method of immobilization which meets these criteria can be used.

Three preferred methods of immobilizing fats and oils which meet the above criteria include: immobilization with ethyl cellulose; immobilization with a thermally set protein emulsion; and immobilization with propylene glycol monostearate, propylene glycol monobehenate and other higher melting propylene glycol monofatty acid esters. The immobilization using ethyl cellulose is described in U.S. Patent 3,935,319, issued to N. B.

Howard, (1976) which is incorporated herein by reference. The thermally set protein emulsion immobilization process is described in U.S. 3,729,325, issued to N. B. Howard, (1973) which is also incorporated therein by reference. The immobilization using a propylene glycol monofatty acid ester is described in U.S. Patent 3,145,108, issued to N. B.

Howard, (1964) the disclosure of which is incorporated herein by reference.

All three of the above lipid immobilization procedures increase the heat tolerance of the meat analog containing a fat, oil or other lipid, prevent the "water proofing effect", and provide a rapidly rehydratable product with true meat-like eating qualities.

In a preferred meat analog product from 0.01 to 2.0 grams of immobilized lipid materials are added per gram of texturized protein. More preferably, 0.05 to 1.0 grams are used.

Lipids which can be conveniently used herein are both animal and vegetable fats or oils.

These lipids may be hydrogenated or "hardened". Fats or oils which are particularly useful for preparing meat analogs are corn oil, lard, beef tallow, and hydrogenated soybean oil, corn oil or cottonseed oil. These oils are also easy to immobilize as described above.

In the first step of the process for preparing a rapidly rehydrating meat analog product, a mixture of texturized protein (particles, fibers, etc.) binder and water is prepared. Most preferably, immobilized fats or oils are added. The amount of water used is critical to the preparation of the rapidly rehydrating meat analog product.

From about 1.2 to 4 grams of water per gram of texturized protein material is needed in the present process. This amount of water represents an excess of about 0.2 to 3.0 times the amount of water desired in the final rehydrated, ready-to-use meat analog. Preferably, about 1.3-2.0 grams of water per gram of protein material is used.

The water can be added during preparation of the texturized protein/binder/water mixture, or it can be added to the texturized protein before mixing with the binder and water, or it can be added during the heat-setting step.

The binder is generally prepared for use by adding sufficient water to the binder material to form a moist tacky binder composition. This binder composition is generally from 30% to 90%, by weight, water and preferably from 50% to 80%, by weight, water.

The binder is employed in an amount sufficient to provide a food product bound together to the desired extent after the heat-setting step. The particular amount of binder most suitably employed will, of necessity, vary somewhat with the particular food product formulated and with the particular binder. In general a ratio (dry weight basis) of binder to texturized protein will be in the range of from about 1:1 to 1:20 and more preferably from about 1:2 to 1:10.

A variety of known techniques can be employed to coat the particulate textured protein material with the binder. For example, the binder can be sprayed or metered on to the textured protein particles, or the binder and particles can be combined and mixed, for example, by tumbling the combination in an inclined rotating drum.

Preferably, the particulate textured protein material to be coated with the binder is hydrated with 1 to 3 times its dry weight with water. While it is preferred that both the particulate protein and the binder be moistened prior to mixing, the materials can be mixed together dry prior to adding the required amount of water.

To prepare a meat analog, the texturized protein granule/binder/water mixture is prepared, shaped into the desired form, for example, patty, meat loaf, chunk, etc., and then heat-set. Preferred methods of heat-setting are autoclaving, microwaving and oven heating.

In one method of adding the additional water, the meat analog product is autoclaved in the presence of wet or dry steam. This process combines the heat-setting step and the introduction of extra water since the meat analog can absorb water under these conditions.

The length of time the meat analog must be exposed to the wet or dry steam to absorb the extra water depends upon the shape of the meat analog, the amount of water used during the preparation, and the weight of the product. For a meat analog patty containing about 50 o water and about 4 inches in diameter by 0.25 inch in. depth, about 4 to 8 minutes exposure is necessary for the patty to absorb 30% to 50% more water.

The shaped, hydrated heat-set meat analog product prepared in the foregoing manner is then dehydrated to produce a substantially dry product, preferably having a water activity, a", of less than 0.5, which is shelf-stable. Any conventional method of dehydration may be used. The preferred method is freeze-drying.

As previously noted, if a method of dehydration which requires heat is used, the lipid matenals are preferably immobilized. A process for preparing this type of meat analog follows.

A mixture of texturized protein, binder and water, the water being from 1.2 to 4.0 grams/per gram of texturized protein is prepared. To this mixture is added the desired amount of an immobilized lipid. The resultant mixture is shaped into the desired form, patty, loaf, chunk, etc., and then heat-set by any conventional method. As previously noted, some of the excess water may be added by heat-setting in the presence of wet or dry steam. The meat analog is then dehydrated by conventional means.

In addition to the texturized protein granules, binder, and water, flavoring agents and color may be added to the meat analog product to make it more meat-like.

The following examples are meant to be illustrative of the invention and not limiting thereof.

Example I Ingredients Parts by Weight Extruded soy concentrate 29.6 particles Soy isolate (binder) 4.2 Meat flavors 3.4 Water 48.3 Melted "Crisco" (Trade 14.4 Mark) shortening The soy isolate is mixed in a blender with some of the water (about 5-10 ml). The isolate water mixture is then hand-mixed with the texturized protein particles and allowed to stand for 10 minutes. The flavoring, part of the water, and the "Crisco" oil are mixed in a blender. The flavoring mixture is then mixed with the water/texturized protein particle mix.

The remaining water is added at this point.

The entire mixture is then used to fill a 1-1/8" x 12" sausage casing using a sausage stuffer.

The entire product is then autoclaved for two minutes in a sterilizing autoclave at 1300C, 15 pounds steam.

The sausage is then sliced to 3/8 inch thickness and freeze-dried overnight.

Patty rehydration is measured by placing the patties prepared in Example I between tared wire screens held together with copper wire. This frame containing the patty is then dipped in excess water for an appropriate time, removed, and the surface blotted with a paper towel before weighing.

The patties as prepared in Example I absorbed their own weight of water in about 30 seconds. When these rehydrated patties are then cooked, complete uniform rehydration results and the product resembles a "hamburger".

Example II Ingredients Texturized protein particles 412 grams (extruded soy concentrate) Soy isolate (binder) 58 grams Flavoring agents 47 grams Water 672 milliliters "Crisco" shortening 180 grams Ethyl cellulose 20 grams The soy isolate is mixed in a blender with less than 50 milliliters of water and is mixed by hand with the texturized protein and 500 milliliters of water. The mixture is allowed to sit for 10 minutes.

The "Crisco" shortening is heated to 1800C under a nitrogen atmosphere and mixed with 20 grams of ethyl cellulose. The ethyl cellulose dissolves in the "Crisco" shortening. Upon cooling to 90"C, the mixture is emulsified in a blender with 200 ml water. The flavoring agent is added during the emulsification of the "Crisco" shortening and the ethyl cellulose.

The texturized protein particles/binder/water mixture is mixed with the shortening, ethyl cellulose, flavoring, and water mixture. The entire mixture is then stuffed into 1 1/4 inch sausage casing. The sausage is then autoclaved for two minutes in a sterilizing autoclave at 121"C at 15 pounds steam. The sausage is then sliced into 3/8 inch slices forming patties.

These patties are freeze-dried to yield a substantially dry, shelf-stable product. In use, the patties are dipped in water, whereupon complete hydration of the patties occurs after 1 minute. The rehydration rate of the patties does not change when they are stored for 47 days.

When the shortening-ethyl cellulose mix of Example II is replaced by 100 grams of "Crisco" oil, 10 grams propylene glycol monostearate, 2 grams palmitic acid blended with 200 ml of water containing 0.2 grams of calcium chloride, correcting for the water content, similar results are achieved.

Example III Ingredient Texturized protein particles made 800 grams from 60neo soy isolate, 40% concentrate 7S soy protein (binder) 115 grams Beef flavor 90 grams Water 1500 ml Egg white 10 grams Calcium chloride 0.2 grams "C-risco" oil 100 grams Palmitic acid 2 grams The egg white is blended with 200 ml of distilled water and adjusted to a pH of 8.1 using the calcium chloride. This mixture is then blended into 100 grams of melted "Crisco" shortening containing 2 grams of palmitic acid to immobilize the lipids.

The flavoring mixture and the 100 ml of water is mixed with the egg white emulsion.

The 7S soy isolate is blended with about 500 ml of water and then mixed with the extruded protein particles and the remaining water. The fractions are then mixed together.

This mixture is not molded, but is simply spread out on a pan in granular form. The product is heat-set and then freeze-dried overnight.

The granules absorb their own weight in water in about 30 seconds. The rehydrated granules resemble "ground and can be used to make a meat loaf, chili, hamburger or barbecue product.

WHAT WE CLAIM IS: 1. A process for preparing a rapidly rehydratable meat analog comprising: (1) heat-setting a texturized protein material/binder/water mixture having from 1.2 to 4 grams of water per gram of texturized protein material; and (2) dehydrating the heat-set mixture.

2. A process according to Claim 1 wherein from 1.3 grams to 2.0 grams of water per gram of texturized protein material is used.

3. A process according to Claim 2 wherein said texturized protein is selected from the group of vegetable protein and animal protein.

4. A process according to Claim 3 wherein said texturized protein is vegetable protein selected from the group of soybean protein, cottonseed protein, and peanut protein.

5. A process according to Claim 4 wherein the binder is selected from the group of egg albumin, vegetable protein binder, and the mixtures thereof.

6. A process according to Claim 5 wherein said vegetable protein binder is selected from the group consisting of soy protein isolate, 7S soy protein and cottonseed protein binder.

7. A process according to Claim 1 wherein lipid and flavoring are added to the mixture of step (1).

8. A process according to Claim 1 wherein an immobilized lipid is added to said texturized protein/binder/water mixture.

9. A process according to Claim 8 wherein said immobilizing agent is selected from the group of ethyl cellulose, thermally set protein emulsion, or propylene glycol monofatty acid esters.

10. A process according to Claim 9 wherein said texturized protein is selected from the group of vegetable protein and animal protein.

11. A process according to Claim 18 wherein said texturized protein is vegetable protein selected from the group consisting of soybean protein, cottonseed protein and peanut protein.

12. A process according to Claim 11 wherein said binder is selected from the group consisting of soy protein isolate, 7S soybean protein and cottonseed protein binder.

13. The product produced by the process of Claim 1.

14. The product produced by the process of Claim 7.

15. A rapidly rehydratable meat analog product comprising texturized protein material, binder, water and from 0.01 to 2.0 grams of immobilized lipid per gram of texturized protein as prepared by the process of Claim 8.

.16. A process for preparing a rapidly rehydratable meat analog when carried out substantially as described in Example 1 or 2.

17. A rapidly rehydrating meat analog product when produced by the process of Claim 16.

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. The granules absorb their own weight in water in about 30 seconds. The rehydrated granules resemble "ground and can be used to make a meat loaf, chili, hamburger or barbecue product. WHAT WE CLAIM IS:

1. A process for preparing a rapidly rehydratable meat analog comprising: (1) heat-setting a texturized protein material/binder/water mixture having from 1.2 to 4 grams of water per gram of texturized protein material; and (2) dehydrating the heat-set mixture.

13. The product produced by the process of Claim 1.

14. The product produced by the process of Claim 7.

.

16. A process for preparing a rapidly rehydratable meat analog when carried out substantially as described in Example 1 or 2.