Low Moisture Extrusion of Plant Proteins

A method for processing plant-based protein sources to produce meat analogs with enhanced nutritional profile and texture. The method involves converting plant-based protein sources into a semi-moist, fibrous protein matrix through extrusion or expander processing. The matrix is then extracted using an aqueous solvent at pH 4 or higher, followed by separation of the soluble components. This process preserves the protein's natural texture and structure while selectively extracting soluble proteins, resulting in a protein-rich meat analog with improved taste, texture, and nutritional profile.

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A method for making low-energy vegetarian meat strips that can be eaten directly without rehydration or further processing. The method involves extruding a mixture of soy protein, yeast extract, and hydrolyzed vegetable protein. This creates a ready-to-eat vegetarian meat strip product with a meat-like texture and flavor. The soy protein is mixed with the flavor agents before extrusion to fully incorporate them. The extruded product is then cooked to complete the process.

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Extruded plant-based meat substitutes made from pea protein that have improved texture, consistency, and appearance compared to soy-based substitutes. The key is selecting pea proteins with specific properties like high water holding capacity, high water binding, and viscosity, along with low potassium and high sodium content. This allows extrusion at lower temperatures and pressures to form cohesive, meat-like whole cuts.

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A two-stage extrusion process for plant-based meat protein that enhances texture and appearance. The method involves first processing the plant protein to increase oil content, followed by a second stage of extrusion that incorporates the protein with added fats. This multi-stage approach significantly improves the protein's surface characteristics, texture, and overall mouthfeel, particularly in plant-based meat products that require a meat-like texture.

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A process to improve the texture and hydration properties of plant-based meat alternatives by using rapeseed protein, legume protein, and calcium carbonate. The process involves extruding a mixture of rapeseed protein, legume protein, and calcium carbonate to make texturized vegetable protein (TVP). The calcium improves hydration speed, water holding capacity, and density of the TVP compared to using just legume protein. This allows making meat alternatives with better texture and mouthfeel.

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A method for texturizing and tenderizing plant-based meat alternatives to make them taste more like meat. It involves using enzymes during the food processing to break down the plant protein fibers and create space between them. This reduces density and gives a meat-like texture and mouthfeel. The enzymatic treatment is applied dynamically during extrusion based on a recipe to optimize the plant protein meat analog texture and tenderness.

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A method for producing a low-moisture texturized plant protein from brewer's spent grain (BSG) and other vegetable protein powders, which enables the creation of a versatile food ingredient for vegetarian products. The method involves processing BSG and vegetable protein powders through texturization using a specialized extrusion process, followed by drying and micronutrient enrichment. The resulting protein product has a water content of 5-12% and exhibits a fibrous texture comparable to meat products, making it suitable for vegetarian food applications such as burger patties.

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Process for preparing a vegetarian meat analogue product with improved taste and texture. The process involves hydrating textured plant protein along with dry flavorings, adding binders and oil to the hydrated protein, and shaping the resulting mass into the meat analogue. This allows better flavor delivery compared to adding flavors after hydrating the protein. Using emulsion binders and specific ratios of flaky and granular textured protein also improves texture.

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A method for producing textured food products through thermoplastic extrusion that enhances protein structure and functionality through controlled moisture and temperature conditions. The process involves precise control of moisture levels and temperature during extrusion to achieve optimal protein denaturation and hydration, resulting in a fibrous matrix that can be cut into uniform pieces. The product is then dried to a controlled moisture level, cooled, and packaged for consumption. This approach enables the production of textured food products with improved texture and functional characteristics compared to traditional methods.

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Method to manufacture fibrous meat alternatives using extrusion cooking and solid state fermentation. The process involves first extruding the raw ingredients like oilcakes, spent grains, etc to create a porous structure. Then, solid state fermentation is done in the presence of fungi to convert carbohydrates into protein. A second extrusion step at high temperature and pressure is used as a kill step to cook the fermented ingredients and create a fibrous texture similar to meat.

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A high-throughput extrusion process for making textured vegetable protein (TVP) with meat-like texture and flavor. The process involves feeding a blend of dry proteins like soy and gluten with water into a co-rotating twin-screw extruder at specific ratios. The extruded molten product is cooled in a die to form aligned protein fibers. This cooled fibrous protein is then mechanically shredded to consistent size. The process allows making TVP with meat-like texture and flavor at high throughput by precisely controlling the feed ratios and extrusion conditions.

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A device for producing plant tissue protein products like textured vegetable protein (TVP) with improved texture and flavor compared to existing methods. The device uses an extruder with a back pressure valve that opens at a certain pressure. The extruder pushes vegetable protein paste through a die into a sealed chamber filled with steam. The back pressure prevents the material from being extruded back into the extruder. The high temperature and pressure steam further shapes and cooks the protein into a better texture with reduced beany flavor.

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Processing vegetable protein vegetarian meat jerky through a low-humidity extrusion process that maintains a moisture content below 40% while achieving a desired texture and structure. The method involves processing vegetable protein, starch, seasoning, and water in a controlled extrusion process to create a jerky product with a fiber structure similar to meat. The seasoning composition includes plant-derived flavor enhancers, while the manufacturing process maintains a lower moisture content compared to traditional high-humidity extrusion methods.

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A method for producing a tissue protein material with meat-like texture and improved discharge stability from an extruder using a cutting edge roll. The method involves kneading a mixture of plant-derived protein powder, calcium acetate, starch, and water. The kneaded material is extruded through a die at high temperature and pressure using an extruder. Instead of cutting the extruded material, it is passed through a pair of rolls with square-edged annular blades facing each other. This forms a cut groove on both sides of the material to give it a fibrous texture. The cutting edge roll allows continuous production of the textured protein material without disrupting extrusion stability. Calcium acetate provides the meaty texture without affecting extruder discharge.

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Texturizing pea protein compositions for food applications, particularly for meat and fish analogues, through a novel wet spinning process. The process involves suspending a finely ground pea protein solution in water, then fractionating it using hydrocyclones or centrifugal decanters to separate protein and soluble components. The protein fraction is then isolated through precipitation or membrane separation, followed by drying and processing through a vibrated fluid bed. The resulting textured protein products exhibit a fibrous structure with enhanced mechanical properties and water retention capacity compared to conventional pea protein isolates.

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