FI120572B - A process for processing textured soy protein into ready-to-eat foods - Google Patents

Description

A process for processing textured soy protein into ready-to-eat foods

Field of the Invention 5

The present invention relates to a process for the preparation of ready-to-eat foods and soy protein supplements from textured soy protein and to products made by the process.

Background of the Invention

The texturized soy protein is prepared from non-fat soy flour or soy concentrate, which is extruded and processed into granules, pieces or powder. It is sold as a dried, granular, powdered or burnt product.

15 The texture of water-moistened textured soy protein is similar to minced meat.

Textured soy protein is used in a variety of foods, such as minced meat, meal products and kebabs.

A traditional problem in utilizing textured soy has been to provide 20 completely plant-based products based on various soy protein formulations and having a structure sufficiently solid, for example, to be cut into.

In the process of U.S. Patent 4,250,198, a fibrous vegetable protein is made into dry, room-temperature snack products that mimic meat products. The method comprises preparing an emulsion of a lipid material, water and a proteinaceous emulsifier, as well as an aqueous dispersion of the fibrous plant protein and the binding protein separately, which are mixed into the pulp. The ingredients affecting taste, color, texture, etc. are mixed with either the fat part of the emulsion and the emulsifier or the dry blend protein before dispersing the protein in water. If granular textured vegetable protein is used, it is mixed with the emulsion. The water content of the products prepared by the process is 15-25%, while the water content of the products prepared by the process of the present invention is more than 60%.

The process according to GB 1,599,195 produces a dried powder-like resin product which has the special property of rapid rehydration. The method comprises preparing a mixture of texturized protein, water and a binder and, if desired, adding lipid material to the mixture. The mixture thus obtained is shaped to the desired shape, autoclaved and freeze-dried.

SUMMARY OF THE INVENTION The present invention provides ready-to-eat foods from a textured soy protein using a multi-step manufacturing process and sufficient heat treatment to stabilize the products and achieve good shelf-life at refrigerated temperature. The method of the invention provides completely ready-to-use foods or novel sources of protein for incorporation into foods.

The invention thus relates to a process for the production of ready-to-eat foods and soy protein supplements from a textured soy protein, characterized by separately preparing under vacuum a) a hydrolysed soy protein wherein the textured b) an emulsion comprising water, a vegetable oil and, as an emulsifier, a vegetable protein, preferably soy isolate, and mixing a) and b) under vacuum to form a mass which is shaped or dispensed to give the desired products, cooled.

In the process of the invention, it is essential to first prepare blends, one comprising 3 soy proteins hydrolyzed with a water flavoring mixture and the other an emulsion acting as a binder, into Erik-30 without heat, and combining these into a mass whose structure is stabilized and solidified by heat treatment.

By utilizing a separate emulsion, the product can be blended with the binders that have the desired structure and mouth feel, and, thanks to heat stabilization, the end products also match the desired appearance, structure and mouth feel.

DETAILED DESCRIPTION OF THE INVENTION Preferably, the starting material for the process of the invention is a textured soy protein in lumps, particularly textured soy made in larger pieces (10-60 mm or larger).

1. Hydrolysis of Textured Soybean Protein 15

The texturized dry soy protein preparation is hydrolyzed with an aqueous solution which is mixed with the desired ingredients that affect structure, taste, color, nutritional value and / or shelf life. Water is used in an amount of 3.5 to 5 l / kg soy, preferably about 3-4 l / kg soy. The hydrolysis is carried out in a cooled state, preferably below + 4 ° C.

The time used for hydrolysis can range from 6 hours to 16 hours, and in practice is usually, for example, overnight. The hydrolysis is accelerated under vacuum and vacuum variation.

Hydrolysis, as used herein, refers to the reaction with water and to the treatment of water with the desired active ingredients.

The hydrolysis technique used in the process of the invention provides the ingredients affecting the properties of the finished product evenly in the interior of the textured soy. Ingredients that affect taste, color, nutritional value, texture and / or shelf life 30 are known to those skilled in the art and are conventional in the food industry, for example thickening and thickening agents and seasonings.

2. Modification of hydrolysed soy protein 5

The hydrolyzed, pretreated soy protein is adapted to the grain size required for the further process, for example 2-20 mm. Editing can be done, for example, by grinding, cutting or shaping. In practice, the shaping can be carried out, for example, with a meat grinder, a cutter, a cube machine or a slicing machine.

10 3. Preparation of the emulsion

Separately, a homogeneous emulsion is prepared which acts as the adhesive and curing agent for the final structure of the finished product. The emulsion is prepared from water, vegetable juice and vegetable protein used as an emulsifier, such as soy isolate. Suitable vegetable oils include, for example, soybean oil and rapeseed oil, or a mixture of various vegetable oils. Conventional plant proteins such as soy protein can be used as an emulsifier. The proportions of the ingredients in the emulsion may vary but are roughly about 2/4/1 (oil / water / soy isolate).

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The emulsification is enhanced using a vacuum. The use of a vacuum produces a solid emulsion because air does not whisk into the mixture. The emulsion may be prepared, for example, by a vacuum homogenizer or by a vacuum knife.

25 4. Combination of the emulsion and hydrolyzed soy protein

The hydrolyzed soy protein preparation and the separately prepared emulsion are combined into a homogeneous mixture or pulp. The desired ingredients can be blended into the pulp, such as vegetable fat flakes, vegetable, pie or fruit stomachs, cubes, etc. A vacuum mixer is used to remove air 5 from the mixture. The result of the mixing is a mass which is ready for further processing.

5. Dosing / shaping of pulp 5

The finished mass can be dispensed or shaped into portions of desired size and shape, for example, by filling or shaping into a shell or molds. The design can be done with, for example, sausage syringes (pies, cocktail sausages, loops, sausage sausages, barbecue sausages, etc.), shaping machine (steaks, buns, etc.) or 10 dispensing machines (fritters, cold cuts, patties, etc.).

6. Structural stabilization

The dosed or shaped pulp is heat treated to improve the stability of the structure. The treatment temperature may range from +75 to +121 ° C, preferably from +90 to +95 ° C. The processing time is, for example, 1-2 hours.

Heat treatment solidifies and stabilizes the products and gives them the desired shelf life and shelf life at refrigerator temperature. The heat treatment may be carried out by heating with, for example, air, water vapor, water or autoclave.

Unheated pulp may be made into similar products, fresh or frozen. These products can be redesigned or used as a ingredient and subsequently heated, even for direct use.

25 7. Cooling

Cooked hot products with a water content of more than 60% are cooled immediately after heating to below +6 ° C. Rapid cooling is necessary to achieve adequate shelf life, to extend shelf life and to ensure product safety.

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The method according to the invention can be used to prepare ready-to-use foods for catering or private use, as well as protein sources for foods and meals. Finished products include sausages, cold cuts, steaks, crumbs, cocktail pieces, box dishes, sauces, soups, salads, pizzas, hot sandwiches, etc.

By the method of the invention it is possible, for example, to produce a fully sliced cut sausage from a textured soy protein. The products made by the process of the invention can also be used as a protein supplement in a variety of foods, such as minced meat.

10 Example

Weigh 5.5 kg of textured soy in a dish. Weigh 15 kg of ice water in another container, add 0,5 kg of vegetable oil and 0,1 kg of liquid smoke preparation. A total of about 6 kg of ingredients that are mixed together to influence taste, texture, color and shelf life are mixed into the aqueous mixture. The resulting mixture is poured over textured soy and stirred well, after which the mixture is allowed to stand overnight in a cold store at about + 4 ° C (10-16 h). The next day, the mixture is ground with a meat grinder to a desired grain size, e.g., with a 5 mm perforated plate.

20 Make a base emulsion in the sausage maker. First, cold water is poured into the cutter 101 and 2.5 kg of soy isolate is added thereto using a slow mixing speed for about 4 minutes to obtain a smooth soy gel. Slowly pour 5 kg of vegetable oil into the gel and apply a high (3000 rpm) agitation speed. When the emulsion has started to form, close the cutter cover and start the vacuum. Emulsification is continued for 3 to 4 min in vacuum at the highest blade speed (5050 rpm). When the solid emulsion is formed, stop the cutter and open the lid.

To the cutter is added pre-milled textured soybean moistened with the emulsion, treated. The lid is closed, the vacuum is applied and the mass is smoothed at a slow mixing speed of 30 cutters until the mass is even.

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The finished mass is taken from the cutter and filled with sausage spray into the casings for heat treatment. '' Sausages '' are hung from the strings of the strings to the canes and the cart. The wagon is pushed into the oven and heat-treated for about 120 min at +95 ° C.

5 Cool rapidly with a cold water spray and transfer to a cold store at temperatures below + 4 ° C.

Claims (9)

A process for the production of ready-to-eat foods and soy protein supplements from textured soy protein, characterized in that it is prepared separately in vacuo: a) and b) an emulsion comprising water, vegetable oil and, as an emulsifier, vegetable protein, 10 and blended in a) and b) under vacuum to form a mass which is shaped or dispensed into the desired products which are heat stabilized and cooled. Method according to claim 1, characterized in that the textured soy protein used as the starting material is in pieces of 10-60 mm or larger. 3. A process according to claim 1, characterized in that the hydrolyzed soy protein is processed to the desired grain size before being combined with the emulsion. Process according to Claim 1, characterized in that the vegetable oil used in the emulsion is soybean oil, rapeseed oil or a mixture of vegetable oils. A process according to claim 1, characterized in that the vegetable protein used as the emulsifier is soy protein. 25 Method according to Claim 1, characterized in that, during mixing of the pulp, vegetable fat flakes, vegetable, pie or fruit strips or cubes are mixed. Method according to Claim 1, characterized in that the shaping or dispensing of the pulp is performed by filling or separately shaping the shell or molds. Method according to Claim 1, characterized in that the pulp formulation or dispensing according to the claim is carried out by means of a sausage syringe, molding machine or dispensing machine. Process according to Claim 1, characterized in that the thermal stabilization 10 is carried out at a temperature of from +75 ° C to +121 ° C, preferably from +90 to +95 ° C.