MEAT ANALOGUES

FIELD OF THE INVENTION

The present invention relates to processes for producing fat compositions for meat analogues. The present invention also relates to fat compositions for meat analogues. The invention also relates to processes for producing meat analogues comprising the fat compositions.

The present invention also relates to processes for producing a meat analogue. In particular, the present invention relates to processes for adhering a fat analogue to at least one protein source. The present invention also relates to processes for adhering a first protein source to a second protein source, to provide a meat analogue.

BACKGROUND

Veganism and vegetarianism is an increasingly common lifestyle choice around the globe, and particularly in the UK and USA. Veganism is defined as not consuming dairy, meat, fish or egg products. This means that the vegan diet must consist of plant based food products that maintain the highest sources of nutrients. Vegetarianism is defined as the practice of not eating meat or fish. As a result of this change in eating habits among the general population there is an increased demand for meat free protein products and meat alternatives.

Additionally, issues around health, sustainability, traceability and animal welfare are also increasingly important influences in consumer purchasing decisions. As a result, meat free protein products are no longer exclusively sold to the consumer group that identifies as vegetarian or vegan. A flexible diet is becoming increasingly popular and the appeal of plant based foods is broadening to include people who also incorporate meat and dairy in their diets but also wish to seek meat alternatives sometimes.

Meat analogues are prepared such that they resemble meat as much as possible in appearance, taste and texture. Meat analogues are typically prepared from proteinaceous fibres of non-meat origin. Raw material from various sources (wheat, soy, pea, chickpea, fava bean, lupine or other grain legumes and oilseeds such as rapeseed, sunflower, linseed and others) are used to produce meat like characteristics.

Meat analogues can also include plant-based fats, or fats obtained from other non-animal sources. However, animal fat analogues can be challenging to produce, particularly in such a way that the fat analogue imitates the animal fat. Animal fats are typically succulent and chewy in texture once cooked. They also provide flavour to animal protein. During cooking, animal fats brown and crisp. This combination of characteristics can be difficult to obtain with plant-based (or other non-animal derived) fats. Methods of manufacturing such fat analogues can be complex, and the specific method steps chosen can greatly influence the resulting sensory profile.

Processes known in the art for producing non-animal derived food compositions may utilise an alginate gelling system. However, such processes generally provide a pre-mixed blend of the dry ingredients needed for alginate gelling, such as an alginate and a source of calcium ions. Once in solution, the pre-mixed blend of alginate will gel immediately. This approach therefore limits the subsequent manufacturing steps that can be undertaken and limits the addition of further ingredients. The use of a chelating agent, such as TSPP, may slow the reaction of alginate with the calcium by preferentially reacting with and sequestering the calcium ions, but generally the use of TSPP alone is not sufficient to overcome the limitations associated with providing a pre-mixed blend of the alginate and other ingredients, including the calcium source. In particular, the fast gelling of the alginate gel can prevent the fat analogue from being poured and layered (for example with other components) to resemble animal fat as part of a meat analogue.

Existing attempts in the art to prevent the alginate gel from setting too quickly include the use of encapsulated calcium. WO 2022074217 describes the use of encapsulated calcium to set a proteinbased alginate gel, which can subsequently be cooked or minced. However, such a protein-based gel does not mimic the taste and texture of animal fat. Additionally, encapsulation is complex from a manufacturing perspective and is generally undesirable in methods of food preparation.

There is a need in the art for simplified and more efficient methods of manufacturing fat compositions, in particular fat compositions for meat analogues. In particular, there is a need to provide processes for producing fat compositions that can be poured to facilitate the production of realistic meat analogues.

Hydrocolloid gelling systems have been described for use in fat analogues. FR3110170 describes a hydrocolloid-based gelling system comprising a hydrocolloid such as locust bean gum, xanthan gum, guar gum or glucomannan. FR2795918 describes a bard substitute comprising a flour and alginate based gelling system. However, such gels do not crisp and brown on cooking, and are not succulent in texture when eaten. Additionally, flours are known to thicken during heating because of gelatinisation, which makes such formulations more difficult to use in manufacturing as they cannot be poured, for example into a mould.

Accordingly, there is a need in the art to provide improved fat compositions for meat analogues.

In addition, many existing processes produce texturized meat-analogue food products which do not mimic the texture, appearance and/or the taste of real meat products. As a result, consumers typically consider such meat-analogue food products to be unappealing and unpalatable. One such area where this is particularly apparent is meat analogues intended to replicate whole joints or cuts of meat, such as a slice of bacon, or a steak. Whole pieces of animal meat often have a layer or rind of fat in contact with and attached to the protein. The protein and fat layers are held together by connective tissues, such as collagen and elastin.

Such whole pieces of animal meat are hard to recreate as “meat analogues” due to the presence of these two visibly and texturally distinct compositions (i.e. the fat and the protein). Existing meat analogues often use one composition to recreate such meat analogues, but may colour and/or flavour separate parts of the composition differently (for example, using one colour to imitate the fat, and a second colour to imitate the protein). This may help to visually recreate the effect of separate protein and fat layers, but is not convincing.

Providing a meat analogue with two distinct layers (for example a fat analogue and a protein analogue) is particularly challenging because meat analogues lack the connective tissues that would normally hold the layers together, for example at the interface between fat and protein, or between protein and protein.

WO 2022112315 describes the use of plant-based binders for binding together components of meat analogues such as burgers. The binders “trap” the components of the foodstuff within a matrix, in order to form a cohesive mass with a smooth texture. The binders described therein comprise a coldset gelling dietary fibre, such as psyllium fibre, a heat-set gelling plant based ingredient, such as flour, and a lipid. The binding agents are dissolved or dispersed in a solvent such as water or oil. All the ingredients are subsequently homogenised to form a gel binder which can bind together plant-based protein. The methods disclosed therein are based on traditional gelling techniques, which require emulsification of the binder and so are complex to manufacture. Use of lipid in the binder also negatively affects the nutritional profile of the meat analogue, as well as increasing costs. Such binders are also not suitable for forming a single interface between two large meat analogue components (such as a protein and a fat), and are instead intended only to form a matrix within an agglomerated product, with a smooth texture throughout.

US2021392929 describes a combination of dietary fibre, such as potato fibre, with a plant-based protein in order to provide a binder. The binders disclosed therein are intended to trap components of a foodstuff within a matrix for the purpose of forming a cohesive mass, such as would be present in a burger. The binders disclosed therein are not suitable for forming a single interface between two meat analogue components. The binders disclosed therein are not suitable for providing a meat analogue with a layered structure, such as one comprising a layer of fat and a layer of protein.

Accordingly, there is a need in the art to provide processes for preparing meat analogues which enable two meat analogue pieces, such as a fat and a protein, or two protein pieces, to be adhered or otherwise attached to each other to resemble animal meat. SUMMARY OF THE INVENTION

In a first aspect, the invention provides a process for producing a fat composition for meat analogues, comprising the steps of:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture;

(d) combining the hydrated oil-alginate mixture from (c) with a browning agent; and

(e) combining the mixture from (d) with a calcium source to provide a final fat composition.

In a second aspect, the invention provides a fat composition for meat analogues, comprising: a fat; an alginate; a browning agent; a calcium source; a chelating agent; and water.

In a third aspect, the invention provides a process for producing a meat analogue, comprising the steps of:

(a) producing a fat composition according to a process as described herein;

(b) layering the fat composition with at least one protein source; and

(c) setting the fat composition with the at least one protein source.

In a fourth aspect, the invention provides a meat analogue comprising a fat composition as described herein and at least one protein source.

In a fifth aspect, the invention provides a bacon analogue comprising a first layer and a second layer, wherein the first layer comprises a fat composition as described herein, and wherein the second layer comprises at least one protein source.

In a sixth aspect, the invention provides a kit comprising a fat, an alginate, dextrin, and a chelating agent.

In a seventh aspect, the invention provides a process for producing a meat analogue, the process comprising the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source; (c) applying an adhering agent to the at least one protein source from (b); and

(d) applying the fat analogue to the at least one protein source from (c).

In an eighth aspect, the invention provides a process for producing a meat analogue, the process comprising the steps of:

(a) providing a first protein source;

(b) providing a second protein source;

(c) applying an adhering agent to the first protein source; and

(d) applying the second protein source to the first protein source from (c).

In a ninth aspect, the invention provides a meat analogue obtained by a process as described herein.

In a tenth aspect, the invention provides a meat analogue comprising at least one protein source and a fat analogue, wherein an adhering agent is provided at the interface between the protein source and the fat analogue, and wherein the adhering agent is configured to adhere the protein source to the fat analogue.

In an eleventh aspect, the invention provides a meat analogue comprising a first protein source and a second protein source, wherein an adhering agent is provided at the interface between the first protein source and the second protein source, and wherein the adhering agent is configured to adhere the first protein source to the second protein source.

In a twelfth aspect, the invention provides the use of psyllium husk and/or guar gum in a method of attaching a fat analogue to at least one protein source in a meat analogue.

In a thirteenth aspect, the invention provides the use of psyllium husk and/or guar gum in a method of attaching a first protein source to a second protein source in a meat analogue.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is an illustrative representation of the interface formed between a fat analogue and a protein source according to the methods of the invention. “A”, grey bar, represents an optional pre-wash agent. “B” represents the adhering agent. The adhering agent, and optionally the pre-wash, attach the fat analogue to the protein source. It is also noted that the “fat analogue” in Figure 1 could be replaced with a second protein source.

Figure 2 shows two examples of bacon analogues. The bacon analogues comprise a protein component (dark brown) and a fat component (white). Figure 2A shows that when a conventional starch is used to adhere these components together, the bacon falls apart when being handled and when sliced. In contrast, Figure 2B shows a bacon analogue prepared using a process of the invention. As can be seen from Figure 2B, the bacon analogue prepared in accordance with the invention has excellent adhesion between the protein and fat components, such that the bacon analogue can be handled and sliced without the pieces coming apart from each other. Note that this Figure is for illustrative purposes only and that bacon analogues may be sliced in a different orientation so as to resemble animal bacon.

SECTION I - FAT COMPOSITIONS

DETAILED DESCRIPTION

The present invention provides processes for producing fat compositions suitable for use in meat analogues. In particular, the invention relates to processes for producing alginate-based gelling fat compositions. The present invention overcomes the existing limitations in manufacturing alginate- based gels by utilising “post-production” addition of the calcium source, advantageously allowing the setting of the gel to be precisely controlled. This approach, combined with the choice of ingredients disclosed herein, provides a fat composition with a pourable viscosity, allowing the further layering and moulding of the fat composition with a protein source, such as a plant-based high moisture protein extrudate. This in turn provides more realistic meat analogues, which resemble animal meat in appearance and texture.

The present invention also provides fat compositions for use in meat analogues, such as those eaten as part of a vegan or vegetarian diet. The fat compositions provide a superior sensory profile that is surprisingly improved over fat compositions in the art, in particular providing a hyper-realistic taste, texture, smell, appearance and cooking experience that closely resembles that of animal-derived fat.

The fat compositions of the invention are based on an alginate gelling system. The use of oils and dextrin surprisingly provides a fat composition that crisps and browns upon cooking, as well as providing succulence, in contrast to existing fat compositions for meat analogues.

The invention also provides meat analogues, such as bacon analogues, and processes for making the same. The meat analogues described herein combine the hyper-realistic fat composition with a high moisture protein extrudate, in order to provide superior hyper-realistic qualities to the meat analogues that are not seen in the art.

Process for producing a fat composition for meat analogues

The invention provides processes for producing fat compositions for meat analogues.

Generally, the processes described herein utilise an alginate gelling system. Alginates, such as sodium alginate, form a gel when in the presence of divalent cations such as calcium ions. The reaction of the alginate with the calcium may be slowed by the addition of a chelating agent, such as TSPP, which preferentially reacts with and sequesters the calcium ions.

Advantageously, the processes of the invention may involve the addition of calcium as a final step in the process, rather than as part of a pre-mixed blend of dry ingredients as a starting material. Such “post-production” addition of calcium offers a number of advantages. The fat composition mixture can be stored prior to the addition of calcium, optimising manufacturing efficiency and preventing waste. Other ingredients can also be added to the mixture in a liquid state prior to the addition of calcium. This can ensure certain ingredients are incorporated properly, which may be difficult to do for some specific ingredients if included as part of a pre-mixed powder or dry blend. In particular, by delaying the setting of the gel through post-production calcium addition, hydration of the alginate is improved prior to the addition of other ingredients, improving its function. In particular, the methods described herein allow for mixing to be “paused” to enable better alginate hydration.

The controlled addition of calcium to the mixture also allows for precise control of gelling timing, in contrast to existing processes when calcium is already included as a starting material.

Post-production addition of calcium allows the use of a different mixing type than the alginate hydration and emulsion formation. It can be advantageous to add the calcium with a different mixing type for more control over the calcium release. It can be advantageous to add the calcium with a lower shear mixing type for a slower calcium release.

A process for producing a fat composition for meat analogues may comprise the steps of:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture;

(d) combining the hydrated oil-alginate mixture from (c) with a browning agent; and

(e) combining the mixture from (d) with a calcium source to provide a final fat composition

Combining the chelating agent with a water-based solvent

In step (a), a chelating agent may be combined with a water-based solvent. The water-based solvent may be any solvent suitable for dissolving the chelating agent and for inclusion in a food product. Suitable water-based solvents are known to the skilled person. The water-based solvent may be water. The water-based solvent may also be a milk, for example a plant-based milk such as almond milk, oat milk or soy milk. The water-based solvent may also be a juice. The chelating agent can be any agent useful for reacting with or otherwise sequestering calcium ions. Thus, the chelating agent may be any compound that reacts with metal ions to form a stable complex. The chelating agent may comprise at least one of tetrasodium pyrophosphate (TSPP), sodium hexametaphosphate, sodium citrate, ethylenediaminetetraacetic acid (EDTA), sodium triphosphate, sodium tripolyphosphate, diphosphates, triphosphates, polyphosphates, or a combination thereof.

The chelating agent may be tetrasodium pyrophosphate (TSPP). The chelating agent may be sodium triphosphate.

The chelating agent may be tetrasodium pyrophosphate (TSPP), and the water-based solvent may be water. The chelating agent may be sodium triphosphate, and the water-based solvent may be water.

The chelating agent may be provided as a powder or other dry ingredient. The step of combining the chelating agent (such as TSPP or sodium triphosphate) with the water-based solvent (such as water) may comprise mixing the chelating agent and the water-based solvent until the chelating agent is dissolved. Combining the water-based solvent with a chelating agent therefore may provide a waterchelating agent mixture. Suitable methods for combining the chelating agent with the water-based solvent are known to the skilled person. The water-based solvent may provide the bulk or majority of the water content desired in the final product. The chelating agent may be useful to control the setting of the alginate-based gelling system, for example to reduce the speed at which the composition sets once a source of calcium ions has been added. A chelating agent can also be used to de-scale water and ensure uniform water quality across manufacturing sites.

In some embodiments, a portion of the total chelating agent is not mixed with the water-based solvent and is instead added at the same time as the calcium source. For example, the mixture may comprise a total of 0.25 wt.% chelating agent, wherein a first portion (for example, 0.15 wt.%) is combined with a water-based solvent to provide a water-chelating agent mixture, and a second portion (for example, the remaining 0.1 wt.%) is added at the same time as the calcium source. This surprisingly results in a more pourable viscosity of the fat mixture, which is advantageous when processing.

For example, a process for producing a fat composition for meat analogues may comprise the steps of:

(a) combining a first portion of a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture;

(d) combining the hydrated oil-alginate mixture from (c) with a browning agent; and

(e) combining the mixture from (d) with a calcium source and a second portion of the chelating agent to provide a final fat composition. The first portion may comprise between approximately 20% and 80% of the total chelating agent, and the second portion may comprise between approximately 80% and 20% of the total chelating agent. The first portion may comprise approximately 20% of the total chelating agent and the second portion may comprise approximately 80% of the total chelating agent. The first portion may comprise approximately 30% of the total chelating agent and the second portion may comprise approximately 70% of the total chelating agent. The first portion may comprise approximately 40% of the total chelating agent and the second portion may comprise approximately 60% of the total chelating agent. The first portion may comprise approximately 50% of the total chelating agent and the second portion may comprise approximately 50% of the total chelating agent. The first portion may comprise approximately 60% of the total chelating agent and the second portion may comprise approximately 40% of the total chelating agent. The first portion may comprise approximately 70% of the total chelating agent and the second portion may comprise approximately 30% of the total chelating agent. The first portion may comprise approximately 80% of the total chelating agent and the second portion may comprise approximately 20% of the total chelating agent.

Combining the oil with an alginate

The process may further comprise a step of combining an oil with an alginate.

The oil may be provided as a liguid at room temperature, or as a solid at room temperature. The alginate may be provided as a powder or other dry ingredient. The step of combining the oil with the alginate may provide an oil-alginate mixture in which the alginate is substantially uniformly distributed in the oil. Suitable methods for combining the oil with the alginate are known to the skilled person. For example, the oil and alginate may be combined in a standard mixer.

In some embodiments, the alginate may be dry-blended with the browning agent until substantially uniformly distributed. The alginate and the browning agent and the oil may be blended until substantially uniformly distributed. In other embodiments, the browning agent may be added after formation of the alginate-oil emulsion.

As described herein, the oil may comprise at least one selected from the group consisting of shea butter, rapeseed oil, canola oil, corn oil, coconut fat, rice bran oil, safflower oil, sesame oil, peanut oil, sunflower oil, linseed oil, avocado oil, grape seed oil, olive oil and palm fat, or a combination thereof. The oil may comprise sunflower oil. The oil may comprise rapeseed oil. The oil may comprise olive oil.

The alginate in the fat composition is the main element responsible for setting the fat composition such that it is solid or semi-solid at room temperature, though it will be appreciated that other setting or gelling agents could be used. Alginates are naturally occurring polymers, which may be obtained from bacterial and algal sources. Alginates are commonly obtained from brown seaweed. The alginate used in the fat compositions described herein may be an alginate salt. The alginate may comprise sodium alginate, potassium alginate, or a combination thereof. Preferably, the alginate is sodium alginate.

Combining the oil-alginate mixture with the water-chelating agent mixture

The process may further comprise a step of combining an oil-alginate mixture with a water-chelating agent mixture. This step may comprise combining the oil-alginate mixture with the water-chelating agent mixture and mixing to provide an alginate-oil emulsion. In particular, this step may provide a stable alginate-oil emulsion. Such a step may involve mixing under conditions of high shear. Methods for mixing under high shear are known to the skilled person. For example, such a step can be performed using commercially available high shear mixers. As used herein, the term “high shear” means the use of shear of at least 1000 rpm, or at least 2000 rpm.

Combining the oil-alginate mixture with the water-chelating agent mixture may also hydrate the alginate. Optionally, the processes described herein may include a “holding” step, in which mixing is paused or stopped for a period of time in order to allow hydration of the mixture. For example, the process may involve a period of 5, 10, 15, 20, or 30 minutes in which no mixing occurs, or during which mixing is paused.

A process for producing a fat composition for meat analogues may comprise:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide an alginate-oil emulsion;

(d) combining the alginate-oil emulsion from (c) with a browning agent; and

(e) combining the mixture from (d) with a calcium source to provide a final fat composition

A process for producing a fat composition for meat analogues may comprise:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing under high shear to provide an alginate-oil emulsion;

(d) combining the alginate-oil emulsion from (c) with a browning agent; and

(e) combining the mixture from (d) with a calcium source to provide a final fat composition

Addition of browning agent(s) To ensure crispiness of the fat composition when cooked, a browning agent is added. The browning agent is selected from the group consisting of xylose, arabinose, galactose, fructose, mannose, sucrose, dextrose, lactose, maltose and dextrin. Preferably, a dextrin is used. Dextrins can be produced from starch using enzymes like amylases, or by applying dry heat under acidic conditions. Preferably, a maize dextrin is used. The dextrin source may also be tapioca or potato. The use of dextrin in particular provides sensory improvements over fat compositions known in the art, for example those using starches to provide browning.

The browning agent will not cause thickening upon heating, such as a starch that would gelatinize under heating. It is advantageous to keep the fat composition pourable (i.e. at a pourable viscosity) such that it can be layered with other meat analogue components (such as protein) and poured into moulds for setting. The ability to set the meat analogues in moulds in turn provides a more realistic appearance.

The processes describe herein may include a step of combining the hydrated oil-alginate mixture (or the alginate-oil emulsion) with a browning agent, such as dextrin.

In alternative embodiments, addition of the browning agent may be omitted. For example, the process may comprise the steps of:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture; and

(d) combining the hydrated oil-alginate mixture from (c) with a calcium source to provide a final fat composition.

Other flavourings, sugars and salts can be added in any of the steps described herein.

“Post-production” addition of calcium ions

As described above, the alginate in the fat composition will only begin to gel or set when in contact with a source of calcium ions. Advantageously, the process steps described above therefore provide a fat composition mixture in liquid form (generally of low viscosity), which does not yet contain a source of calcium ions. This liquid fat composition will only begin to set or gel once the calcium source has been added. This means the fat composition mixture can be stored for a period of time before the calcium is added. For example, the mixture from step (d) may be stored for a period of 1 hour, 2 hours, 4 hours, 8 hours, 12 hours, 24 hours, 48 hours, 3 days, 4 days, 5 days, 6 days, 7 days, 2 weeks, 4 weeks, 1 month, 2 months, 3 months, 4 months, 5 months or 6 months before the addition of the calcium source. The mixture from step (d) may be stored for up to 1 week before the addition of the calcium source, for example if refrigerated. The mixture from step (d) may be frozen and stored for up to 6 months before addition of the calcium source. The mixture from step (d) may be stored for up to 14 days before the addition of the calcium source, for example if refrigerated or frozen.

A further advantage is that the fat composition mixture can be moved prior to the addition of the calcium source, for example, decanted into smaller mixing vessels. This may be advantageous if only a small amount of the final (set or gelled) fat composition is required. For example, the processes described herein allow a large batch of fat composition mixture to be prepared, then a majority of that fat composition mixture can be stored whilst a smaller portion of the fat composition mixture is moved to a smaller mixing vessel for the addition of the calcium source. The fat composition mixture can also be transported before the addition of the calcium source, for example to a different manufacturing facility. The fat composition mixture may therefore be stored and/or transported, for example for up to 14 days, before the addition of the calcium source. The processes described herein therefore allow much greater flexibility in manufacturing, improve manufacturing efficiency and reduce waste.

One further advantage afforded by the processes described herein is that a calcium source can be added during in-line mixing. Accordingly, the fat composition can be prepared as part of a continuous manufacturing pipeline, rather than prepared as part of a batch manufacturing process. Thus, in one embodiment, the calcium source is added to the alginate-oil emulsion (with or without a browning agent) during in-line mixing.

The calcium source in the fat composition provides a source of calcium ions, which react with alginate to form a gel. The source of calcium ions in the composition may be a low solubility calcium source (otherwise known as “sparingly soluble”) calcium source, such as calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, or a combination thereof. Such low-solubility calcium sources are known in the art. The calcium source may be calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, calcium chloride, calcium citrate, calcium gluconate, calcium acetate, or a combination thereof. The fat composition may comprise calcium sulphate.

A process for producing a fat composition for meat analogues may therefore comprise the steps described above, with the exception of the addition of calcium. For example:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture; and

(d) combining the hydrated oil-alginate mixture from (c) with a browning agent.

Such methods may optionally comprise storing the mixture from (d) for a period of up to 1 week. Once a calcium source has been added, the alginate will begin to set (or gel). This process can be controlled further by the use of a low-solubility (otherwise known as “sparingly soluble”) calcium source, such as calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, or a combination thereof. Such low-solubility calcium sources are known in the art. Low-solubility calcium sources release calcium ions at a slower rate compared to other, more soluble calcium sources, and thus help to control the rate at which the alginate sets. As described above, the presence of the chelating agent (such as TSPP) can further control the availability of calcium ions and the setting rate (gelling time) of the alginate.

In some embodiments, the calcium source is added to the mixture under conditions of low shear. This may further aid in extending the gelling time of the fat composition. In some embodiments, the mixing steps of the processes described herein may all be performed under conditions of high shear. In some embodiments, the mixing steps of the processes described herein may all be performed under conditions of high shear, with the exception of the addition of the calcium source, which is combined with the mixture under conditions of low shear.

The calcium source may be combined with water prior to mixing with the other ingredients. It can be advantageous to add the calcium pre-blended in water. In some embodiments, between 5 and 50 % of the total water content of the fat composition can be blended with the calcium prior to mixing with the other ingredients. It can be advantageous to add calcium dispersed in 30% of the total water content of the fat composition.

A process for producing a fat composition for meat analogues may comprise the steps of:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture;

(d) combining the hydrated oil-alginate mixture from (c) with a browning agent; and

(e) combining the mixture from (d) with a calcium source to provide a final fat composition, wherein the calcium source is mixed with water before combining with the mixture from (d).

In the processes described herein, the chelating agent can be tetrasodium pyrophosphate or sodium triphosphate, the oil can be olive oil, the calcium source can be calcium sulphate, the browning agent can be dextrin, and the alginate can be sodium alginate.

Setting the fat composition The processes described herein may also comprise a step of setting the final fat composition after the addition of the calcium source. As used herein, “setting” refers to the process of changing the fat composition into a solid or semi-solid state. For example, such that it holds its shape without a mould.

Setting the final fat composition may include heating the composition. For example, the final fat composition may be heated at between approximately 80 and 120 °C, or 90 and 110 °C. The final fat composition may be heated at approximately 100 °C. Setting may include heating for a duration of approximately 5, 10, 15, 20, 25, 30 or 45 minutes. The final fat composition may be heated at approximately 100 °C for approximately 20 minutes. Heating can be performed by any method known in the art, for example, using steam or in an oven.

Setting may alternatively (or additionally) comprise refrigerating the final fat composition. For example, setting may include keeping the final fat composition at a temperature between 0 and 10 °C, or between approximately 2 and 8 °C. The final fat composition may be refrigerated for a duration of approximately 15 minutes, 30 minutes, 1 hour, 2 hours, 4 hours, 6 hours, 8 hours, 12 hours, 24 hours, or more.

Setting may alternatively (or additionally) comprise freezing the final fat composition. For example, setting may include keeping the final fat composition at a temperature between -20 and 0 °C.

Setting the fat composition may also include a step or steps of layering the fat composition with a protein source, for example when preparing a meat analogue. For example, a first layer of a fat composition prepared according to the processes herein may be provided in a mould. While the fat composition is still in a low viscosity state (in other words, before the alginate gel has set), a second layer of at least one protein source may be added to the fat composition. This process may be repeated to provide a layered structure. Such a layered structure gives a realistic appearance to a meat analogue, for example when sliced. Setting the fat composition may include layering the fat composition with a protein source (or other composition), as well as heating or refrigerating steps.

A process for producing a fat composition for meat analogues may therefore comprise the following steps:

(a) combining a chelating agent with a water-based solvent to provide a water-chelating agent mixture;

(b) combining an oil with an alginate to provide an oil-alginate mixture;

(c) combining the oil-alginate mixture from (b) with the water-chelating agent mixture from (a) and mixing to provide a hydrated oil-alginate mixture;

(d) combining the hydrated oil-alginate mixture from (c) with a browning agent;

(e) combining the mixture from (d) with a calcium source to provide a final fat composition; and

(f) setting the final fat composition. Accordingly, in one embodiment, a process for producing a fat composition for meat analogues may comprise the following steps:

(a) combining tetrasodium pyrophosphate with water;

(b) combining olive oil with sodium alginate;

(c) combining the mixture from (b) with the mixture from (a), and mixing under high shear to form an emulsion;

(d) combining the emulsion from (c) with dextrin;

(e) optionally storing the emulsion from (d) for up to 1 week;

(f) combining the emulsion from (d) with calcium sulphate to provide a final fat composition; and

(g) setting the final fat composition.

In some cases, the chelating agent may be omitted from the fat composition. In such cases, a process for producing a fat composition may comprise the steps of:

(a) combining an oil with an alginate and a browning agent;

(b) combining the mixture from (a) with water to hydrate the mixture; and

(c) combining the hydrated mixture from (b) with a calcium source to provide the fat composition.

Fat compositions

The present invention provides fat compositions. The fat compositions described herein may be used in meat analogues to replicate the taste, texture and appearance of animal-derived fat whilst being substantially free of animal-derived products.

Much like animal-derived fat, the fat compositions described herein have a consistency such that the fat composition is solid enough to stand up on its own and be easily sliced with a knife. In particular, the fat will be solid at room temperature, white in colour and have a flexible texture. When the fat composition is cooked, it becomes crispy and succulent and so is texturally advantageous compared to other fat compositions of the art. In addition, the fat compositions described herein brown on cooking. Overall, the taste, texture and appearance closely resemble animal fat (adipose tissue and connective tissue).

The fat compositions described herein are suitable for use in any meat analogue. Meat analogues can replace meat in a vegetarian or vegan diet, and are prepared such that they resemble meat as much as possible in appearance, taste and texture. Taste, as used herein, refers to what is perceived by the gustatory system, whilst texture refers to the mechanical characteristics of the meat analogue, which correlate with sensory perceptions of the meat analogue. Generally, meat analogues are substantially free of animal products, such as animal-derived proteins and/or animal-derived fats. However, meat analogues are not limited to those food compositions which are substantially free of animal products, since meat analogues may also comprise cultivated animal products, such as cultivated animal protein or cultivated animal fat. As used herein, the term “meat analogue” encompasses any food compositions that are not produced by traditional animal agriculture methods (such as farming and slaughter). Thus, the term “meat analogue” also includes fish analogues and the like.

The fat compositions described herein are also suitable for use generally in food compositions. For example, the fat compositions may be used in dairy analogues, such as cheese analogues, cream analogues, yoghurt analogues, butter analogues, or ice cream analogues, or may be used in baked goods analogues, such as cakes, biscuits and confectionery.

The fat compositions may comprise a fat, an alginate, a browning agent, a calcium source, and a chelating agent. The browning agent may comprise dextrin. The fat may also comprise water, or a water-based solvent (such as a plant milk).

The fat in the fat composition may comprise at least one selected from the group consisting of shea butter, rapeseed oil, canola oil, corn oil, coconut fat, rice bran oil, safflower oil, sesame oil, peanut oil, sunflower oil, linseed oil, avocado oil, grape seed oil, olive oil and palm fat, or a combination thereof. The fat in the fat composition may be an oil. The fat may comprise sunflower oil. The fat may comprise rapeseed oil. The fat may comprise olive oil.

The alginate in the fat composition is the main element responsible for setting the fat composition such that it is solid or semi-solid at room temperature, though it will be appreciated that other setting or gelling agents could be used. Alginates are naturally occurring polymers, which may be obtained from bacterial and algal sources. Alginates are commonly obtained from brown seaweed. The alginate used in the fat compositions described herein may be an alginate salt. The alginate may comprise sodium alginate, potassium alginate, or a combination thereof. Preferably, the alginate is sodium alginate.

The browning agent provides crispiness to the fat composition on cooking. In addition, the browning agent may also provide a realistic visual sensory experience while cooking, as the fat composition turns brown to resemble cooked animal fat. The browning agent is selected from the group consisting of xylose, arabinose, galactose, fructose, mannose, sucrose, dextrose, lactose, maltose and dextrin. Preferably, a dextrin is used. Dextrins can be produced from starch using enzymes like amylases, or by applying dry heat under acidic conditions. Preferably, a maize dextrin is used. The use of dextrin in particular provides sensory improvements over fat compositions known in the art, for example those using starches to provide browning.

The calcium source in the fat composition provides a source of calcium ions, which react with alginate to form a gel. The source of calcium ions in the composition may be a low solubility calcium source (otherwise known as “sparingly soluble” calcium source), such as calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, or a combination thereof. Such low-solubility calcium sources are known in the art. The calcium source may be calcium sulphate, calcium carbonate, calcium lactate, dicalcium phosphate, calcium chloride, calcium citrate, calcium gluconate, calcium acetate, or a combination thereof. The fat composition may comprise calcium sulphate.

The chelating agent can be any agent useful for reacting with or otherwise sequestering calcium ions. Thus, the chelating agent may be any compound that reacts with metal ions to form a stable complex. The chelating agent may comprise at least one of tetrasodium pyrophosphate (TSPP), sodium hexametaphosphate, sodium citrate, ethylenediaminetetraacetic acid (EDTA), sodium triphosphate, sodium tripolyphosphate, diphosphates, triphosphates, polyphosphates, or a combination thereof. The chelating agent may be tetrasodium pyrophosphate (TSPP). The chelating agent may be sodium triphosphate.

The fat composition may therefore comprise olive oil, sodium alginate, calcium sulphate, dextrin, and tetrasodium pyrophosphate (TSPP). The fat composition may comprise olive oil, sodium alginate, calcium sulphate, dextrin, tetrasodium pyrophosphate (TSPP), and water. The fat composition may therefore comprise olive oil, sodium alginate, calcium sulphate, dextrin, and sodium triphosphate. The fat composition may comprise olive oil, sodium alginate, calcium sulphate, dextrin, sodium triphosphate, and water.

The fat composition may be free of vegetable flour.

References to values in “wt.%” throughout this specification are based on the total weight of the fat composition, unless stated otherwise.

The fat composition may comprise between approximately 5 to 40 wt.% of the fat, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 10 to 25 wt.% fat. The fat composition may comprise approximately 10 to 20 wt.% fat. The fat composition may comprise between approximately 5 to 20 wt.% of the fat. The fat composition may comprise between approximately 6 to 17 wt.% of the fat. The fat composition may comprise between approximately 7 to 15 wt.% of the fat. The fat composition may comprise between approximately 8 to 14 wt.% of the fat. The fat composition may comprise between approximately 9 to 13 wt.% of the fat. The fat composition may comprise between approximately 10 to 12 wt.% of the fat. The fat composition may comprise between approximately 10.5 to 11 .5 wt.% of the fat. The fat composition may comprise approximately 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19 or 20 wt.% of the fat.

The fat composition may comprise between approximately 1 .5% to 40 wt.% of the fat, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 1 .5% to 20 wt.% of the fat. The fat composition may comprise between approximately 1 .5% to 15 wt.% of the fat. The fat composition may comprise between approximately 1 .5% to 10 wt.% of the fat. The fat composition may comprise between approximately 1 .5% to 8 wt.% of the fat. The fat composition may comprise between approximately 2% to 7.5 wt.% of the fat. The fat composition may comprise between approximately 2.5% to 7.5 wt.% of the fat. The fat composition may comprise between approximately 3% to 7 wt.% of the fat. The fat composition may comprise between approximately 3.5% to 6.5 wt.% of the fat. The fat composition may comprise between approximately 3% to 15 wt.% of the fat. The fat composition may comprise between approximately 3% to 14 wt.% of the fat. The fat composition may comprise between approximately 3% to 13 wt.% of the fat. The fat composition may comprise between approximately 3% to 12 wt.% of the fat. The fat composition may comprise between approximately 3% to 11 wt.% of the fat.

The fat composition may comprise between approximately 10 to 25 wt.% fat, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise approximately

The fat composition may comprise between approximately 1 to 4 wt.% of the alginate, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 1 to 3 wt.% of the alginate. The fat composition may comprise between approximately 1 to 2 wt.% of the alginate. The fat composition may comprise between approximately 1.1 to 4 wt.% of the alginate, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 1 .1 to 3 wt.% of the alginate. The fat composition may comprise between approximately 1 .1 to 2 wt.% of the alginate. The fat composition may comprise between approximately 1 .25 to 4 wt.% of the alginate. The fat composition may comprise between approximately 1 .25 to 3 wt.% of the alginate. The fat composition may comprise between approximately 1 .25 to 2.5 wt.% of the alginate. The fat composition may comprise between approximately 1 .25 to 2 wt.% of the alginate.

The fat composition may comprise between approximately 5 to 20 wt.% of a browning agent, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 5 to 18 wt.% of a browning agent. The fat composition may comprise between approximately 5 to 15 wt.% of a browning agent. The fat composition may comprise between approximately 8 to 12 wt.% of a browning agent. The fat composition may comprise between approximately 9 to 11 wt.% of a browning agent. The fat composition may comprise approximately 5,

6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19 or 20 wt.% of a browning agent, wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise between approximately 5 to 20 wt.% of dextrin, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 5 to 18 wt.% of dextrin. The fat composition may comprise between approximately 5 to 15 wt.% of dextrin. The fat composition may comprise between approximately 8 to 12 wt.% of dextrin. The fat composition may comprise between approximately 9 to 11 wt.% of dextrin. The fat composition may comprise approximately 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19 or 20 wt.% of dextrin, wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise between approximately 0.1 to 1 wt.% of the calcium source, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 0.2 to 0.8 wt.% of the calcium source. The fat composition may comprise between approximately 0.3 to 0.7 wt.% of the calcium source. The fat composition may comprise between approximately 0.35 to 0.6 wt.% of the calcium source. The fat composition may comprise between approximately 0.4 to 0.5 wt.% of the calcium source. The fat composition may comprise between approximately 0.25 to 1 wt.% of the calcium source. The fat composition may comprise between approximately 0.3 to 0.9 wt.% of the calcium source. The fat composition may comprise between approximately 0.4 to 0.8 wt.% of the calcium source. The fat composition may comprise between approximately 0.5 to 0.7 wt.% of the calcium source. The fat composition may comprise approximately 0.3, 0.35, 0.4, 0.45, 0.5, 0.55, 0.6, 0.65 or 0.7 wt.% of the calcium source, wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise between approximately 0.05 to 1 wt.% of chelating agent, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise approximately 0 to 1 wt.% of chelating agent. The fat composition may comprise between approximately 0.1 to 0.5 wt.% of chelating agent. The fat composition may comprise approximately 0 to 0.5 wt.% of chelating agent. The fat composition may comprise between approximately 0.1 to 0.4 wt.% of chelating agent. The fat composition may comprise approximately 0 to 0.4 wt.% of chelating agent. The fat composition may comprise between approximately 0.15 to 0.4 wt.% of chelating agent. The fat composition may comprise between approximately 0.15 to 0.35 wt.% of chelating agent. The fat composition may comprise between approximately 0.15 to 0.3 wt.% of chelating agent. The fat composition may comprise between approximately 0.1 to 0.25 wt.% of chelating agent. The fat composition may comprise between approximately 0.15 to 0.25 wt.% of chelating agent. The fat composition may comprise approximately 0.05, 0.1 , 0.15, 0.2, 0.25, 0.3, or 0.35 wt.% chelating agent, wherein the wt.% is based on the total weight of the fat composition. In other cases, the fat composition does not comprise a chelating agent.

For all the quantities indicated herein, it will be appreciated that water, or a water-based solvent, can make up the remaining wt.% of the fat composition.

The fat composition may comprise: approximately 5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of a browning agent; approximately 0.1 to 1 wt.% of the calcium source; and approximately 0.1 to 1 wt.% of the chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 1 .5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of a browning agent; approximately 0.1 to 1 wt.% of the calcium source; and approximately 0.1 to 1 wt.% of the chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; and approximately 0.1 to 1 wt.% of the chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 1 .5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; and approximately 0.1 to 1 wt.% of the chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; approximately 0.1 to 1 wt.% of the chelating agent; and water; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 1 .5 to 40 wt.% of the fat; approximately 1 to 4 wt.% of the alginate; approximately 5 to 20 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; approximately 0.1 to 1 wt.% of the chelating agent; and water; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 5 to 40 wt.% olive oil; approximately 1 to 4 wt.% sodium alginate; approximately 5 to 20 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% tetrasodium pyrophosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 1 .5 to 40 wt.% olive oil; approximately 1 to 4 wt.% sodium alginate; approximately 5 to 20 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% tetrasodium pyrophosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 10 to 12 wt.% of the fat; approximately 1 to 2 wt.% of the alginate; approximately 5 to 15 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; and approximately 0.1 to 1 wt.% of the chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2% to 8 wt.% of the fat; approximately 1 to 2 wt.% of the alginate; approximately 5 to 15 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; and approximately 0.1 to 1 wt.% of the chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 10 to 12 wt.% of the fat; approximately 1 to 2 wt.% of the alginate; approximately 5 to 15 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; approximately 0.1 to 1 wt.% of the chelating agent; and approximately 70 to 80 wt.% water; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2 to 8 wt.% of the fat; approximately 1 to 2 wt.% of the alginate; approximately 5 to 15 wt.% of dextrin; approximately 0.1 to 1 wt.% of the calcium source; approximately 0.1 to 1 wt.% of the chelating agent; and approximately 70 to 80 wt.% water; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 10 to 12 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% tetrasodium pyrophosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2 to 8 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% tetrasodium pyrophosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 10 to 12 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2 to 8 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0.1 to 1 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2 to 8 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.4 to 0.8 wt.% calcium sulphate; and approximately 0.1 to 0.4 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 10 to 25 wt.% fat; approximately 1 to 2 wt.% alginate; approximately 5 to 15 wt.% dextrin; approximately 0.4 to 0.8 wt.% calcium source; and approximately 0.1 to 0.4 wt.% chelating agent; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 10 to 25 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.4 to 0.8 wt.% calcium sulphate; and approximately 0.1 to 0.4 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2 to 8 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.1 to 1 wt.% calcium sulphate; and approximately 0 to 1 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may comprise: approximately 2 to 8 wt.% olive oil; approximately 1 to 2 wt.% sodium alginate; approximately 5 to 15 wt.% dextrin; approximately 0.4 to 0.8 wt.% calcium sulphate; and approximately 0 to 0.4 wt.% sodium triphosphate; wherein the wt.% is based on the total weight of the fat composition.

The fat composition may further comprise at least one protein source, though it is not necessary. The at least one protein source may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or combinations thereof. The fat composition may comprise pea protein. The fat composition may comprise soy protein. The fat composition may comprise pea protein and soy protein.

The fat composition may comprise the at least one protein source in an advantageously low amount, so as to resemble animal-derived fat. The at least one protein source, if present, may be present in an amount between approximately 0.01 to 4 wt.%, wherein the wt.% is based on the total weight of the fat composition. The fat composition may comprise between approximately 0.5 to 3.5 wt.% of the at least one protein source. The fat composition may comprise between approximately 1 to 3 wt.% of the at least one protein source. The fat composition may comprise between approximately 1 .5 to 2.5 wt.% of the at least one protein source. The fat composition may comprise approximately 0.5, 1 , 1.5, 2, 2.5, 3, 3.5, or 4 wt.% of the at least one protein source, wherein the wt.% is based on the total weight of the fat composition.

The fat composition may further comprise other ingredients. One further ingredient is salt, i.e. kitchen salt (sodium chloride), although the addition of potassium chloride is also envisaged. The amount of salt may be from 0.1 to 1 .5 wt.% based on the total weight of the fat composition. Other further ingredients include flavours, e.g. smoke flavour, herbs, spices, colourants, yeast extract and acidulants, e.g. citric acid, lactic acid. The amount of further ingredients may be from 0 to 5 wt.% based on the total weight of the fat composition.

Meat analogues

As noted above, meat analogues can replace meat in a vegetarian or vegan diet, and are prepared such that they resemble meat as much as possible in appearance, taste and texture. Generally, meat analogues are substantially free of animal products, such as animal-derived proteins and/or animal- derived fats. However, this need not always be the case, since meat analogues may also comprise cultivated animal products, such as cultivated animal protein or cultivated animal fat. As used herein, the term “meat analogue” encompasses any food compositions that are not produced by traditional animal agriculture methods (such as farming and slaughter). Thus, the term “meat analogue” also includes fish analogues and the like. The invention provides meat analogues comprising a fat composition as described herein and at least one protein source.

The at least one protein source may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or a combination thereof. The protein source provides the protein that would otherwise be provided by animal meat, for example from farmed animals.

Plant protein refers to any protein derived from a plant source. The plant protein may be any commonly used plant protein, in particular pea protein, soy protein, wheat protein, fava bean protein, chickpea protein, oat protein, lentil protein, maize protein, mung bean protein, hemp protein, pumpkin protein, and combinations thereof.

The at least one protein source may comprise pea protein. The at least one protein source may comprise soy protein. The at least one protein source may comprise a combination of pea protein and soy protein.

As an alternative or in addition to plant protein, meat analogues produced according to the processes described herein may also be prepared using cultured meat protein. “Cultured meat protein” (also described as “cultivated meat protein” or “lab-grown meat”) refers to animal-based protein obtained through a process of culturing animal cells. It is noted that the use of cultured meat protein is described herein for a “meat analogue”, although it will be appreciated that the protein is in fact animal protein. The use of cultured meat protein in a meat analogue has the potential to provide animal based protein whilst alleviating some of the ethical and environmental concerns around animal farming and associated land and water use.

Meat analogues produced according to the processes described herein may also be prepared using fermented proteins. Fermented proteins can be used either instead of or in addition to other protein sources described herein (such as plant protein). The term “fermented proteins” encompasses plant or other proteins that have been fermented through microbial anaerobic digestion, typically to improve the flavour, texture, or nutritional value of the protein. An example of a fermented protein is tempeh. Fermented proteins also encompass the use of microorganisms to produce proteins directly, for example by genetically engineering yeast cells to produce a protein of interest. In the present invention, fermented proteins may be obtained by any method known in the art.

Meat analogues produced according to the processes described herein may also be prepared using fungal proteins. Fungal proteins can be used either instead of or in addition to other protein sources described herein (such as plant protein). As used herein, the term “fungal protein” encompasses any protein produced by or derived from fungi, such as mycoprotein. The advantages of the processes described herein are not limited to those meat analogues comprising the protein sources described above. Any other protein source may be used.

The at least one protein source may be prepared in a variety of ways. In some embodiments, the at least one protein source comprises a high moisture protein extrudate. As used herein, the term “high moisture protein extrudate” refers to a protein source that has a solid, fibrous structure, with a plurality of aligned fibres in a same or similar orientation. The solid and fibrous structure of high moisture protein extrudate provides a realistic look and texture to the meat analogue.

As would be understood by a person of skill in the art, high moisture protein extrudate can be obtained by a process of high moisture extrusion, for example by inputting the protein source through a single ortwin barrel extruder and cooling die. High moisture extrusion (or high moisture extrusion cooking) describes a process that allows the formation of strands or larger pieces from protein rich powders, slurries or small pieces such as plant proteins, meat and fish. High-moisture extrusion of plant proteins has recently gained increasing attention for producing meat alternatives. The combination of heating and subsequent cooling of the protein-water mixture (with optional starches, colour, oil, and fibres) facilitates the texturization of the product and produces a layered or fibrous structure with a ‘meat like’ appearance. High moisture extrusion is characterised by processing materials with a high water content, compared to traditional extrusion methods. Typically, the materials used in high moisture extrusion have a water weight higher than 40% and often higher than 50%. Often, high moisture extrusion is combined with a twin screw extruder for making unconventional food products.

In other embodiments, the at least one protein source comprises a textured vegetable protein (TVP). In contrast to high moisture protein extrudate, TVP is typically rehydrated and held together with other ingredients as a paste-like material. TVP may have a non-layered fibrous structure. Rehydrated TVP may have few, short fibres, said fibres running in different orientations to each other.

Meat analogues as described herein may comprise a fat composition in an amount between approximately 1 to 50 wt.%. Meat analogues as described herein may comprise a fat composition in an amount between approximately 1 to 50 wt.%, and the at least one protein source in an amount between approximately 50 to 99 wt.%, wherein the wt.% is based on the total weight of the meat analogue. Meat analogues as described herein may comprise a fat composition in an amount between approximately 1 to 25 wt.%. Meat analogues as described herein may comprise a fat composition in an amount between approximately 1 to 25 wt.%, and the at least one protein source in an amount between approximately 75 to 99 wt.%, wherein the wt.% is based on the total weight of the meat analogue.

The ratio of fat composition to protein source can depend on the meat analogue product. The meat analogue may be a bacon analogue, a mincemeat analogue, a burger analogue, a sausage analogue, a meatball analogue, a beef analogue, a pork analogue, a lamb analogue, a sliced meat analogue, a chicken joint analogue, a pork joint analogue, a lamb joint analogue, a beef joint analogue, a fish analogue, or a steak analogue.

The meat analogue may be a bacon analogue. The bacon analogue may comprise a first layer and a second layer, wherein the first layer comprises a fat composition as described herein, and wherein the second layer comprises at least one protein source. The at least one protein source in the bacon analogue may be a high moisture protein extrudate. The at least one protein source in the bacon analogue may have a fibrous structure. The bacon analogue may comprise several layers of the fat composition and the protein source. Such a layered structure resembles the appearance of animal bacon. Bacon analogues may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or a combination thereof.

The meat analogues described herein may be structured such that the fat composition holds together (in other words, surrounds) the at least one protein source, or the one or more protein pieces (such as chunks or pieces of high moisture protein extrudate). For example, the protein source may be at least 5 mm x 5 mm in any two directions. The protein source may be at least 10 mm x 10 mm in any two directions.

Meat analogues (such as bacon analogues) may comprise at least two layers, for example three, four, five, six or seven layers. Meat analogues (such as bacon analogues) may comprise a first layer and a second layer, wherein the first layer comprises a fat composition as described herein, and wherein the second layer comprises at least one protein source, and wherein the first and second layers are repeated to imitate the appearance of an animal meat product (such as bacon).

It will also be appreciated that the fat compositions described herein can be used in other food analogues which are not specifically meat analogues. Such food analogues include cheese analogues, dairy analogues, pate analogues, butter analogues and lard analogues, as described in more detail above.

Process for producing a meat analogue

The invention also provides processes for producing a meat analogue, using the fat compositions and methods of manufacturing the same as described herein.

In particular, the use of two different compositions in the meat analogues described herein - a first fat composition and a second protein source - provides the meat analogues of the invention with a hyper- realistic sensory profile. The meat analogues closely resemble animal meat prior to cooking. During cooking, the fat compositions provide browning and crispness. When eaten, the fat composition provides succulence and the protein source provides texture. Thus, the meat analogues described herein are surprisingly superior to the meat analogues available in the art.

A process for producing a meat analogue may comprise the following steps:

(a) producing a fat composition as described herein;

(b) layering the fat composition with at least one protein source; and

(c) setting the fat composition with the at least one protein source.

The at least one protein source may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or combinations thereof. The protein source may comprise pea protein. The protein source may comprise soy protein. The protein source may comprise a combination of pea and soy protein.

The at least one protein source may be a high moisture protein extrudate. As used herein, the term “high moisture protein extrudate” refers to a protein source that has a solid, fibrous structure, with a plurality of aligned fibres in a same or similar orientation. The solid and fibrous structure of high moisture protein extrudate provides a realistic look and texture to the bacon analogue, as described in more detail above. The at least one protein source may have a fibrous structure.

As described above, in order to produce a meat analogue, a process of layering the fat composition with at least one protein source may be used, in order to give the appearance of animal meat. The layers may be set in a mould and subsequently sliced. Preferably, the slices resemble slices of animal meat. The amount of fat composition used in the processes described herein can be adapted depending on the meat analogue to be prepared.

The invention also includes a process for making a meat analogue, comprising combining a fat composition as described herein with a protein source, wherein the fat composition is set and chopped into chunks or pieces, and mixed with the protein source.

Fat compositions as described herein may also be useful for recreating the skin of animal meat, such as a chicken skin. The invention therefore also includes a process for making a meat analogue, comprising combining a fat composition as described herein with a protein source, wherein the fat composition surrounds the protein source. In such meat analogues, the fat composition can surround, coat, envelop, package or otherwise encase the protein source, either fully or partially. Preferably, the fat analogue resembles the skin of animal meat in appearance.

Process for producing a bacon analogue

The invention also provides processes for producing a bacon analogue, using the fat compositions and methods of manufacturing the same as described herein. In particular, the use of two different compositions in the bacon analogues described herein - a first fat composition and a second protein source - provides the bacon analogues of the invention with a hyper-realistic sensory profile. The bacon analogues closely resemble animal bacon prior to cooking. During cooking, the fat compositions provide browning and crispness. When eaten, the fat composition provides succulence and the protein source provides texture. Thus, the bacon analogues described herein are surprisingly superior to the bacon analogues available in the art.

A process for producing a bacon analogue may comprise the following steps:

(a) producing a fat composition as described herein;

(b) layering the fat composition with at least one protein source; and

(c) setting the fat composition with the at least one protein source.

The at least one protein source may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or combinations thereof. The protein source may comprise pea protein. The protein source may comprise soy protein. The protein source may comprise a combination of pea and soy protein.

The at least one protein source may be a high moisture protein extrudate. As used herein, the term “high moisture protein extrudate” refers to a protein source that has a solid, fibrous structure, with a plurality of aligned fibres in a same or similar orientation. The solid and fibrous structure of high moisture protein extrudate provides a realistic look and texture to the bacon analogue, as described in more detail above. The at least one protein source may have a fibrous structure.

As described above, in order to produce a bacon analogue, a process of layering the fat composition with at least one protein source may be used, in order to give the appearance of animal bacon. The layers may be set in a mould and subsequently sliced. Preferably, the slices resemble slices of animal bacon, such as either streaky bacon or back bacon. The amount of fat composition used in the processes described herein can be adapted depending on the bacon analogue to be prepared. For example, if back bacon is desired, the process may use a lower amount of fat composition so as to give the appearance of a single rind of fat, in comparison to streaky bacon which typically has a higher fat content.

Kits

The invention further provides kits comprising a fat, an alginate, a browning agent, and a chelating agent.

The kits of the invention may provide all the components necessary to produce a fat composition according to the methods described herein, with the exception of the calcium source. The components of the kit may be provided in a powder or other solid, dry form. The components may be provided separately (for example, in separate containers), or may be provided as a pre-mixed blend. The components of the kit may also be provided in liquid or semi-liquid state. Again, the components may be provided separately or may be provided already mixed. As noted above, one advantage of the processes described herein is that the components for producing the fat composition can be mixed and stored prior to the addition of a calcium source.

In some embodiments, the kit may further comprise a calcium source. Preferably, the calcium source is provided separately to the other components (for example, in a separate container). The kit may comprise a fat, an alginate, a browning agent and a chelating agent, wherein the fat, alginate, browning agent and the chelating agent are provided as a pre-mixed blend, and may further comprise a calcium source.

The kit may also comprise at least one protein source, flavourings, sugar, salt, or combinations thereof.

Aspects and embodiments described herein with the term “comprising” may include other features or steps within the scope. It is also understood that aspects and embodiments described as “comprising” also describes aspect and embodiments wherein the term “comprising” is replaced by the term “consisting essentially of’ or “consisting of’.

The phrase "selected from the group comprising" may be substituted with the phrase "selected from the group consisting of and vice versa, wherever they occur herein.

It is also understood that the application discloses all combinations of any of the above aspects and embodiments described above with each other, unless the context demands otherwise. Similarly, the application discloses all combinations of the preferred and/or optional features either singly or together with any of the other aspects, unless the context demands otherwise.

The invention will now be described with reference to the following non-limiting Examples.

EXAMPLES

The following experiments assessed the texture, appearance and cooking experience of different fat compositions. In particular, the effects of different alginate gelling systems, browning agents and preparation methods were assessed.

Materials & Methods All the following fat compositions were prepared using water as the water-based solvent. High shear mixing was used to hydrate the gelling agent (i.e. the alginate), and to form a stable emulsion of the oil, alginate and water. The fat compositions were prepared using commercially available mixing apparatus. Once prepared, the fat compositions were poured into moulds and set in the fridge. Samples were then unmoulded, sliced, and fried in a pan.

Experiment 1

The following experiment was performed in order to assess the effects of different combinations of gelling systems and browning agents on the cooking experience. The components of each composition and the effects on cooking experience are shown in Table 1 below.

The results of this experiment show that a combination of 10% oil and 10% dextrin was optimal for crisping, browning, and succulence. Sample #15 was particularly advantageous in this regard. Other experiments (not shown) indicate a range of dextrins can be used as a browning agent to achieve browning and crisping.

The experiments also showed that both calcium carbonate and calcium sulphate were sufficient to set the alginate gel and would be useful as a calcium source. Experiment 2

The following experiments were performed in order to assess the effects of the gelling system formulation and methods of mixing the formulation. The results are shown in Table 2 below.

The results of this experiment show that mixing all the ingredients at the start resulted in no gel formed. The finding that the specific order of ingredient addition was critical to gel formation and quality was surprising. Mixing TSPP first, then alginate, with calcium added last was found to provide the best gel.

The experiments also suggest that the optimum level of alginate was around 1 .5%. The gel begins to thicken more quickly at levels higher than 2%. Pre-mixing the calcium with water prior to its addition to the other ingredients reduced the appearance of calcium precipitate (ppt).

The results of these experiments also show that without a browning agent, such as dextrin, the cooking experience is poor, with no melting or crisping of the fat composition when cooked. SECTION II - ADHESION

DETAILED DESCRIPTION

The present invention is based on the surprising discovery that cold set gelling agents such as psyllium husk and/or guar gum can be used in a process for producing meat analogues, in order to adhere a fat component of the meat analogue to a protein component of the meat analogue. Cold set gelling agents such as psyllium husk and/or guar gum can also be used to adhere a first protein component to a second protein component in a meat analogue. Cold set gelling agents such as psyllium husk and/or guar gum can therefore be used to provide meat analogues with a layered structure, and which resemble animal meat in a more realistic way.

Animal-derived meat joints often comprise a joint or solid piece of meat, with a layer or rind of fat on one surface. For example, a sirloin steak. Animal-derived meat joints can also comprise layers of meat alternating with layers of fat. For example, a bacon joint (or slice), or pork belly. In animal- derived meat products, the protein and fat layers are held together by connective tissues, such as collagen and elastin.

In meat analogues, which are substantially free of animal products, the distinct protein and fat components can be provided by two different compositions, in order to provide a more realistic appearance, texture and taste. However, it is challenging to adhere or attach these different compositions together, due to the absence of connective tissues.

The inventors have surprisingly found that psyllium husk and guar gum are exceptional adhering agents for this purpose. As described in the Examples that follow, psyllium husk and guar gum each provide adhesion between the fat analogue and protein source that exceeds that which can be obtained with other adhering agents commonly used in the art.

Meat analogue

Meat analogues can replace meat in a vegetarian or vegan diet, and are prepared such that they resemble meat as much as possible in appearance, taste and texture. Taste, as used herein, refers to what is perceived by the gustatory system, whilst texture refers to the mechanical characteristics of the meat analogue, which correlate with sensory perceptions of the meat analogue. Generally, meat analogues are substantially free of animal products, such as animal-derived proteins and/or animal- derived fats. However, meat analogues are not limited to those food compositions which are substantially free of animal products, since meat analogues may also comprise cultivated animal products, such as cultivated animal protein or cultivated animal fat. As used herein, the term “meat analogue” encompasses any food compositions that are not produced by traditional animal agriculture methods (such as farming and slaughter). Thus, the term “meat analogue” also includes fish analogues and the like. The processes described herein may be used generally to produce food compositions, and are not limited to the production of meat analogues per se. For example, the processes may be used to produce dairy analogues, such as cheese analogues, cream analogues, yoghurt analogues, butter analogues, or ice cream analogues, or to produce baked goods analogues, such as cakes, biscuits and confectionery.

In particular, the invention provides processes for producing meat analogues that resemble a joint or piece of meat, with a rind or layer of fat attached. The meat analogue may be a bacon analogue. In this case, the aim of the meat analogue is to replicate the taste, texture and appearance of bacon. The meat analogue may also be a beef joint analogue, a steak analogue, a pork joint analogue, a pork belly analogue, a lamb joint analogue, a duck breast analogue, or a sliced meat analogue.

In addition to the one or more protein sources and fat analogues described herein, meat analogues may further comprise flavourings, such as meat flavourings and/or salt, emulsifiers, binding agents, starch, such as potato starch, water, fibre, vitamins, and/or oil, such as rapeseed oil. Once the meat analogue has been prepared, for example by the methods disclosed herein, it may also be marinated to further enhance the taste. It may also be sliced or cut to further resemble the appearance of meat.

Meat analogues described herein may comprise a fat and a protein, with an adhering agent provided at the interface between the fat and protein to enable adhesion of these components to each other. The meat analogues may comprise multiple layers of fat and protein, which may be arranged in a repeating layered pattern or at random. The adhering agent can be a cold set gelling agent, in particular psyllium husk or guar gum. Although it is convenient for the protein and fat to be provided in layers (e.g. to recreate a bacon product), it is not necessary for a layered structure to be used.

Rather, any shape will function in the invention provided the adhering agent can be applied at the interface between the different components.

In the meat analogues described herein, the adhering agent is a distinct component that is separate to the fat and protein. Rather than being mixed throughout the meat analogue or into a fat composition, as in prior art food products, the adhering agent in this case is provided at the interface between components of the meat analogue. In other words, the adhering agent is provided on the surface where the protein meets the fat analogue. As will be described herein, the adhering agent provides exceptional adhesion between the fat analogue and the protein, which far exceeds the adhesion obtained when adhering agents are simply mixed into a fat composition.

Meat analogues may also comprise a first protein adhered or attached to a second protein, instead of a fat analogue. The composition of the adhering agents described herein, and their location at the interface between the components (in this case, between pieces or layers of protein) again means that exceptional adhesion is obtained compared to meat analogues of the prior art. The provision of the adhering agent at the interface between components of the meat analogue has particular advantages when recreating food products which tend to be thinly sliced, such as bacon or cold cuts products. With meat analogues that aim to recreate large joints of meat, such as those with a large protein component and a layer of fat covering the protein component, there is a large surface area for contact between the protein and the fat. This means that adhesion is easier to achieve, and binding or adhering agents can typically be mixed into a fat composition. However, in this case, the product is still very fragile and must be handled carefully to prevent the components separating, for example during cooking. Thus, realistic whole-meat products (such as steak) are still difficult to recreate when the binding or adhering agent is mixed with a fat or other composition, and provide sufficient adhesion to hold the components together. The problem is even greater with food products which are thinly sliced. In this case, the surface area for contact between e.g. a fat layer and a protein layer is very small, so thin slices tend to fall apart easily. The present invention overcomes these issues by providing the adhering agent directly at the interface between fat and protein components (or between protein components). This means whole-meat analogues can be produced with excellent adhesion between fat and protein layers, and meat analogue products such as bacon can be thinly sliced from a larger joint without falling apart. Both can also be handled and cooked without separation of the components. These advantages are not seen in the prior art.

Accordingly, meat analogues described herein may comprise at least one protein source and a fat analogue, wherein an adhering agent is provided at the interface between the protein source and the fat analogue, and wherein the adhering agent is configured to adhere the protein source to the fat analogue.

Meat analogues described herein may alternatively comprise a first protein source and a second protein source, wherein an adhering agent is provided at the interface between the first protein source and the second protein source, and wherein the adhering agent is configured to adhere the first protein source to the second protein source.

A pre-wash can also be used to further enhance adhesion between the components of the meat analogues described herein. Such a pre-wash may comprise water and a thickening agent, as described in more detail elsewhere herein. Generally, the pre-wash is also provided at the interface between components of the meat analogue.

The present invention also includes meat analogues obtained or obtainable by the processes described herein.

Protein sources Meat analogues typically comprise one or more proteins or protein sources. The one or more protein sources may comprise one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, bacterial proteins, yeast proteins, algal proteins, or a combination thereof. The protein source provides the protein that would otherwise be provided by animal meat, for example from farmed animals.

Plant protein refers to any protein derived from a plant source. The plant protein may be any commonly used plant protein, in particular pea protein, soy protein, wheat protein, fava bean protein, chickpea protein, oat protein, lentil protein, maize protein, mung protein, hemp protein, pumpkin protein, and combinations thereof.

The protein can be granulated or extruded and can also be hydrolysed. A plant protein isolate may also be used, such as a soy protein isolate. Protein isolate is a highly refined or purified form of protein with a minimum protein content of 90% on a moisture-free basis. In the case of soy, it may be made from defatted soy flour which has had most of the non-protein components, fats and carbohydrates removed.

The at least one protein source may comprise pea protein. The at least one protein source may comprise soy protein. The at least one protein source may comprise a combination of pea protein and soy protein.

As an alternative or in addition to plant protein, meat analogues produced according to the processes described herein may also be prepared using cultured meat protein. “Cultured meat protein” (also described as “cultivated meat protein” or “lab-grown meat”) refers to animal-based protein obtained through a process of culturing animal cells. It is noted that the use of cultured meat protein is described herein for a “meat analogue”, although it will be appreciated that the protein is in fact animal protein. The use of cultured meat protein in a meat analogue has the potential to provide animal based protein whilst alleviating some of the ethical and environmental concerns around animal farming and associated land and water use.

Meat analogues produced according to the processes described herein may also be prepared using fermented proteins. Fermented proteins can be used either instead of or in addition to other protein sources described herein (such as plant protein). The term “fermented proteins” encompasses plant or other proteins that have been fermented through microbial anaerobic digestion, typically to improve the flavour, texture, or nutritional value of the protein. An example of a fermented protein is tempeh. Fermented proteins also encompass the use of microorganisms to produce proteins directly, for example by genetically engineering yeast cells to produce a protein of interest. In the present invention, fermented proteins may be obtained by any method known in the art. Meat analogues produced according to the processes described herein may also be prepared using fungal proteins. Fungal proteins can be used either instead of or in addition to other protein sources described herein (such as plant protein). As used herein, the term “fungal protein” encompasses any protein produced by or derived from fungi, such as mycoprotein.

The at least one protein source may comprise ingredients such as protein isolates, protein concentrates, flours or any other foods which contain greater than 9% protein content. Protein isolates and protein concentrates typically contain at least 40% protein, such as between 40 and 80% protein. Protein isolates and concentrates may be made from any type of protein source (e.g. plant, fungal, etc). Examples of protein isolates useful in the invention are pea protein, soy protein, wheat protein, fava bean protein, chickpea protein, oat protein. Examples of protein concentrates useful in the invention are pea protein, soy protein, wheat protein, fava bean protein, chickpea protein, oat protein, and combinations thereof. Flours useful in the invention as a protein source typically contain at least 10% protein, generally between 10-40% protein. Examples of flours useful in the invention are soy flour, pea flour, wheat flour, fava bean flour, chickpea flour, or oat flour.

The at least one protein source may also comprise (instead of or in addition to any of the protein sources described above) ingredients or foodstuffs which are minimally refined or which are less refined compared to the other protein sources described herein. The at least one protein source may comprise any product which is known to contain protein, such as legumes, pulses, beans, oilseeds, cereals, mushrooms/fungi, algae, potato, vegetable, or fruit. Such products may be provided in any format, for example a powder, a slurry, a blend, chunks, or the natural structure of the product. Examples of such food products include winged beans, soybeans, lupins, mungo beans, fava beans, peanuts, lentils, beans (cranberry, yard-long, hyacinth, mung, kidney, white, moth, yellow, black, pinto, navy), cowpeas, peas, pigeon peas, chickpeas, quinoa, spelt, oats, buckwheat, amaranth, triticale, wheat, barley, teff, sorghum, millet, rye, corn, and rice.

Although generally meat analogues will be understood to mean food products that that are substantially free of animal products, in some cases egg or egg-derived proteins may be used as a protein source, such as egg-white protein. Such products are generally understood to be suitable for consumption by vegetarians but not those following a vegan diet. In many cases, however, the meat analogues described herein do not comprise egg or egg-derived proteins.

The advantages of the processes described herein are not limited to those meat analogues comprising the protein sources described above. Any other protein source may be used. Consequently, the meat analogues described herein may comprise, as a protein source, any composition comprising 7% or greater protein, 10% or greater protein, 15% or greater protein, or 20% or greater protein. The processes described herein may similarly comprise providing a composition comprising 7% or greater protein, 10% or greater protein, 15% or greater protein, or 20% or greater protein as the at least one protein source. When two proteins are used in the processes of the invention, for example when a first protein source is adhered or otherwise attached to a second protein source, the two protein sources can be the same, or they can be different.

The protein sources described herein may be prepared in a variety of ways. In some embodiments, the at least one protein source comprises a high moisture protein extrudate. As used herein, the term “high moisture protein extrudate” refers to a protein source that has a solid, fibrous structure, with a plurality of aligned fibres in a same or similar orientation. The solid and fibrous structure of high moisture protein extrudate provides a realistic look and texture to the meat analogue. However, this same structure also makes it difficult to adhere other components of a meat analogue, such as a fat, to the surface of the high moisture protein extrudate. These issues are overcome with the process of the present invention, in particular the use of an adhering agent, such as psyllium husk or guar gum.

As would be understood by a person of skill in the art, high moisture protein extrudate can be obtained by a process of high moisture extrusion, for example by inputting the protein source through a single ortwin barrel extruder. High moisture extrusion (or high moisture extrusion cooking) describes a process that allows the formation of strands or larger pieces from protein rich powders, slurries or small pieces such as plant proteins, meat and fish. High-moisture extrusion of plant proteins has recently gained increasing attention for producing meat alternatives. The combination of heating and subsequent cooling of the protein-water mixture facilitates the texturization of the product and produces a layered or fibrous structure with a ‘meat like’ appearance. High moisture extrusion is characterised by processing materials with a high water content, compared to traditional extrusion methods. Typically, the materials used in high moisture extrusion have a water weight higher than 40% and often higher than 50%. Often, high moisture extrusion is combined with a twin screw extruder for making unconventional food products.

Protein sources useful in the process described herein can also be prepared using PowerHeater™ technology (Source Technology, Denmark). This type of extrusion technology transfers thermal energy to the at least one protein source to coagulate the protein (and any carbohydrate) and produce a texturized product.

In other embodiments, the at least one protein source comprises a textured vegetable protein (TVP). In contrast to high moisture protein extrudate, TVP is typically rehydrated and held together with other ingredients as a paste-like material. TVP may have a non-layered, fibrous structure. Rehydrated TVP may have few, short fibres, said fibres running in different orientations to each other, or may have no fibres. TVP may be made into a batter-like paste in combination with stabilisers and flavourings. When TVP is provided as a protein source, the TVP may also comprise other ingredients. For example, TVP may be mixed with a methylcellulose emulsion to provide at least one protein source, which is then used in the methods described herein. The at least one protein source may alternatively or additionally comprise binders and protein powders. For example, the at least one protein source may comprise a mixture of TVP, protein powders, and binders. Suitable additives to the at least one protein source include alginate, fibres, citrus fibre, wheat gluten, starches, salt and flavourings.

The skilled person is familiar with methods to provide both high moisture protein extrudate and textured vegetable protein.

The processes described herein may therefore comprise the application of a fat to a protein source which is TVP or which is a high moisture extrudate, in order to produce a meat analogue. In some cases, the meat analogue may contain protein prepared in different ways. For example, the meat analogue may comprise a layer of protein which is a high moisture extrudate, adhered to a layer of fat, which in turn is adhered to a layer of protein which is TVP. Or, the meat analogue may comprise solely high moisture extrudate, or solely TVP, adhered to a fat. As described herein, the processes of the invention also provide advantages when adhering two protein sources to each other, without a layer of fat. In such cases, the meat analogue may comprise two or more high moisture extrudate proteins adhered to each other, two or more TVP proteins adhered to each other, or a mixture of high moisture extrudate and TVP proteins adhered to each other. The protein can be prepared according to the food product which the meat analogue aims to recreate.

Fat analogues

Described herein are processes for producing a meat analogue, in which a fat analogue is adhered or otherwise attached to a protein source. The term “fat analogue” refers to a composition comprising a fat, which is substantially free of animal products. For example, a fat analogue is used to replace animal fat in the meat analogues described herein, and is suitable for consumption as part of a vegan or vegetarian diet.

The fat analogue can be any fat analogue known in the art. Preferably, the fat analogue is a waterbased fat analogue. The fat analogue may comprise a glucomannam gum, a fat, a browning agent, a coagulating agent, and water. In other embodiments, the fat analogue may comprise water, an alginate, and a fat, and may optionally further comprise a calcium source and a chelating agent. A fat analogue may be a hydrocolloid-based gel. A fat analogue may also further comprise dextrin. In some embodiments, the fat analogue may comprise water, an alginate, a fat, a calcium source, a chelating agent, and dextrin. The fat in the fat analogue may be a plant based fat. For example, the fat may be selected from the group consisting of shea butter, rapeseed oil, canola oil, corn oil, coconut fat, rice bran oil, safflower oil, sesame oil, peanut oil, sunflower oil, linseed oil, avocado oil, grape seed oil, olive oil and palm fat, and mixtures thereof. The fat in the fat analogue may be a cultured fat, such as lab-grown adipose cells or tissue. Whilst the cultured fat may be cultured animal fat (such as animal fat cells), such fats are still considered “fat analogues” as they are not produced through the traditional route of animal agriculture and slaughter. The fat may be fully or partly hydrogenated, although unsaturated fats are preferred fortheir health benefits. It is advantageous if the fat used has a melting point of less than 60 °C.

The fat analogue may be provided in a solid state. The fat analogue may be provided in a liquid state. The fat analogue may be provided in a semi-liquid state (alternatively referred to as semi-solid or quasi-solid), in other words, a state between a solid and a liquid. The fat analogue should be provided in a state in which it can be applied to the at least one protein source. In preferred embodiments, the fat analogue is provided in a liquid or semi-liquid state, for example at a pourable viscosity.

Adhering agent

The processes described herein utilise an adhering agent to adhere or otherwise attach a fat analogue to at least one protein source, in order to provide a realistic meat analogue. The processes described herein also utilise an adhering agent to adhere or otherwise attach a first protein source to a second protein source.

The adhering agent may be any suitable cold set gelling agent, in particular psyllium husk or guar gum.

The inventors have surprisingly found that both psyllium husk and guar gum are exceptional adhering agents for this purpose. Psyllium husk (alternatively referred to as psyllium, psyllium fibre, psyllium husk fibre powder, and ispaghula), of the plant genus Plantago, is known as a health food supplement and laxative. Guar gum (alternatively referred to as guaran) is a galactomannan polysaccharide obtained from guar beans, and is known as a stabiliser. Yet, surprisingly, both psyllium husk and guar gum outperform conventional adhering agents such as starches and flours.

The adhering agent used in the process of the invention may comprise psyllium husk. Any part of the psyllium plant may be used. Psyllium husk may be provided in the form of a powder (e.g. a dry powder). The adhering agent may also be provided in the form of a powder (e.g. a dry powder). Advantageously, the adhering agent (such as psyllium husk or guar gum) can be applied to a protein source in powdered form. Thus, it is not necessary to include a step of emulsifying the adhering agent with a lipid or other ingredients. The adhering agent may also be provided in the form of a paste or other semi-solid, or a liquid.

The adhering agent may comprise between approximately 10 to 100 wt.% psyllium husk, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise between approximately 25 to 100 wt.% psyllium husk. The adhering agent may comprise between approximately 40 to 100 wt.%, approximately 50 to 100 wt.%, approximately 60 to 100 wt.%, approximately 70 to 100 wt.%, approximately 80 to 100 wt.%, approximately 90 to 100 wt.%, or approximately 95 to 100 wt.% psyllium husk. The adhering agent may comprise approximately 25 wt.%, 40 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 95 wt.%, or 100 wt.% psyllium husk. In some embodiments, the adhering agent comprises approximately 75 wt.% psyllium husk. In some embodiments, the adhering agent consists of psyllium husk.

The adhering agent may comprise between approximately 10 to 100 wt.% guar gum, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise between approximately 25 to 100 wt.% guar gum. The adhering agent may comprise between approximately 40 to 100 wt.%, approximately 50 to 100 wt.%, approximately 60 to 100 wt.%, approximately 70 to 100 wt.%, approximately 80 to 100 wt.%, approximately 90 to 100 wt.%, or approximately 95 to 100 wt.% guar gum. The adhering agent may comprise approximately 25 wt.%, 40 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 95 wt.%, or 100 wt.% guar gum. In some embodiments, the adhering agent comprises approximately 75 wt.% guar gum. In some embodiments, the adhering agent consists of guar gum.

The adhering agent may comprise both psyllium husk and guar gum. For example, the adhering agent may comprise between 20 to 80 wt.% psyllium husk, and between 20 to 80 wt.% guar gum, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise between 30 to 70 wt.% psyllium husk, and between 30 to 70 wt.% guar gum. The adhering agent may comprise between 40 to 60 wt.% psyllium husk, and between 40 to 60 wt.% guar gum. The adhering agent may comprise 37.5 wt.% psyllium husk, and 37.5 wt.% guar gum. The adhering agent may comprise 60 wt.% psyllium husk, and 10 wt.% guar gum. The adhering agent may comprise 50 wt.% psyllium husk, and 25 wt.% guar gum. The adhering agent may comprise 40 wt.% psyllium husk, and 35 wt.% guar gum. The adhering agent may comprise approximately 45 wt.% psyllium husk and 30 wt.% guar gum, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise 60 wt.% guar gum, and 10 wt.% psyllium husk. The adhering agent may comprise 50 wt.% guar gum, and 25 wt.% psyllium husk. The adhering agent may comprise 40 wt.% guar gum, and 35 wt.% psyllium husk. The adhering agent may comprise approximately 45 wt.% guar gum and 30 wt.% psyllium husk, wherein the wt.% is based on the total weight of the adhering agent.

In alternative embodiments, the adhering agent used in the process of the invention may comprise corn starch. When corn starch is used as the adhering agent, the adhering agent may be provided in the form of a dry powder or in the form of a paste or other semi-solid. The adhering agent may also be provided as a liquid. The adhering agent may comprise between approximately 25 to 100 wt.% corn starch, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise between approximately 40 to 100 wt.%, approximately 50 to 100 wt.%, approximately 60 to 100 wt.%, approximately 70 to 100 wt.%, approximately 80 to 100 wt.%, approximately 90 to 100 wt.%, or approximately 95 to 100 wt.% corn starch. The adhering agent may comprise approximately 25 wt.%, 40 wt.%, 50 wt.%, 60 wt.%, 70 wt.%, 75 wt.%, 80 wt.%, 85 wt.%, 90 wt.%, 95 wt.%, or 100 wt.% corn starch. In some embodiments, the adhering agent comprises approximately 75 wt.% corn starch. In some embodiments, the adhering agent consists of corn starch.

In other embodiments, the adhering agent comprises both corn starch and psyllium husk. For example, the adhering agent may comprise between 20 to 80 wt.% psyllium husk, and between 20 to 80 wt.% corn starch, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise between 40 to 60 wt.% psyllium husk, and between 40 to 60 wt.% corn starch. The adhering agent may comprise 60 wt.% psyllium husk, and 40 wt.% corn starch. The adhering agent may comprise approximately 45 wt.% psyllium husk and 30 wt.% corn starch, wherein the wt.% is based on the total weight of the adhering agent.

In other embodiments, the adhering agent comprises both corn starch and guar gum. For example, the adhering agent may comprise between 20 to 80 wt.% guar gum, and between 20 to 80 wt.% corn starch, wherein the wt.% is based on the total weight of the adhering agent. The adhering agent may comprise between 40 to 60 wt.% guar gum, and between 40 to 60 wt.% corn starch. The adhering agent may comprise 60 wt.% guar gum, and 40 wt.% corn starch. The adhering agent may comprise approximately 45 wt.% guar gum and 30 wt.% corn starch, wherein the wt.% is based on the total weight of the adhering agent.

Although some exemplary cold set gelling agents are described above, the adhering agent may comprise other cold set gelling agents. These may be instead of or in addition to the exemplary cold set gelling agents describe above, such as psyllium husk and/or guar gum. The adhering agent may comprise beta-glucan, arrowroot powder, chia seed powder, flax seed powder, xanthan gum, agar agar, or combinations thereof. Thus, in some embodiments, the adhering agent may comprise betaglucan. In some embodiments, the adhering agent may comprise arrowroot powder. In some embodiments, the adhering agent may comprise chia seed powder. In some embodiments, the adhering agent may comprise flax seed powder. In some embodiments, the adhering agent may comprise xanthan gum. In some embodiments, the adhering agent may comprise agar agar.

The adhering agent may comprise seeds used for the production of mucilage, plant husk, plant extracts used as food thickeners, plant mucilage, exopolysaccharides, or any refined or processed forms of said agents.

The adhering agent may comprise gum talha, gum ghatti, gum karaya, gum tragacanth, arabinogalactan (AG), dextran, pectin, tapioca dextrin, locust bean gum, guar gum, alginate, carrageenan, tara gum, fenugreek gum, konjac mannan, xanthan gum, gellan, and curdlan, carboxymethyl cellulose (CMC), methyl cellulose (MC), hydroxyl-propyl cellulose (HPC), hydroxyl propyl methyl cellulose (HPMC), carbopol, polyethylene oxide, polyvinylpyrrolidone, poly(vinyl alcohol) (PVA), pullulan, and chitosan, gum angaco, brea gum, gum cashew, gum damson, jeol, myrrh, scleroglucan, or any combination thereof. The adhering agent may comprise a gelling agent. The adhering agent may comprise a thickener. The adhering agent may comprise carrageenan, modified starches, furcellaran, gellan gum, galactomannans, pectin, curdlan, xyloglucan, modified cellulose, konjac, microcrystalline cellulose, glucans, or combinations thereof.

In other embodiments, the adhering agent may comprise tapioca flour, potato starch, or combinations thereof. These may be instead of or in addition to psyllium husk and/or guar gum.

The adhering agent may also comprise other flours, starches or thickeners, though this is not necessary. The adhering agent may also comprise flavourings, sugars, salt, or combinations thereof. When provided as a paste or other semi-solid, or a liquid, the adhering agent may further comprise any suitable liquid component, such as water.

Advantageously, the adhering agent may not comprise a lipid. The adhering agent may not comprise a protein.

Pre-wash

The processes described herein may comprise a step of applying a pre-wash to the at least one protein source, prior to applying the adhering agent. As used herein, the term “pre-wash” refers to a liquid composition used to further enhance the adhesion between the fat analogue and the at least one protein source, or between a first protein source and a second protein source.

The function of the pre-wash is to provide a liquid interface between the protein source and the adhering agent. The pre-wash can improve the ability of an adhering agent, such as psyllium husk or guar gum, to coat or otherwise stick to a protein source. The pre-wash may comprise any waterbased composition that provides a liquid interface between the protein source and the adhering agent. The pre-wash may be water-based. The pre-wash may comprise water and at least one thickening agent. The at least one thickening agent may be selected from the group consisting of a flour, a starch, a gum, or a combination thereof. The at least one thickening agent may comprise a flour and a starch. The at least one thickening agent may comprise a flour and a gum. The at least one thickening agent may comprise a starch and a gum. The at least one thickening agent may comprise a flour, a starch, and a gum. The thickening agent may aid in the removal of liquid from the final product, for example by absorbing water.

Examples of suitable flours include rice flour, wheat flour, maize flour, polenta flour, gram flour, breadcrumbs, or combinations thereof. Examples of suitable starches include maize starch, potato starch, wheat starch, rice starch, tapioca starch, or combinations thereof. Examples of suitable gums include xanthan gum (also known as E415), Arabic gum, guar gum, hydroxypropyl methylcellulose (HPMC), or combinations thereof. The pre-wash may comprise at least one thickening agent selected from the group consisting of rice flour, maize starch, potato starch, xanthan gum, or a combination thereof. In one embodiment, the pre-wash comprises water and rice flour. In one embodiment, the pre-wash comprises water and maize starch. In one embodiment, the pre-wash comprises water and potato starch. In one embodiment, the pre-wash comprises water and xanthan gum. In one embodiment, the pre-wash comprises water, rice flour, and maize starch. In one embodiment, the pre-wash comprises water, rice flour, and potato starch. In one embodiment, the pre-wash comprises water, rice flour, and xanthan gum. In one embodiment, the pre-wash comprises water, maize starch and potato starch. In one embodiment, the pre-wash comprises water, maize starch and xanthan gum. In one embodiment, the pre-wash comprises water, potato starch and xanthan gum. In one embodiment, the pre-wash comprises water, rice flour, maize starch, and potato starch. In one embodiment, the pre-wash comprises water, rice flour, maize starch, and xanthan gum. In one embodiment, the pre-wash comprises water, rice flour, potato starch and xanthan gum. In one embodiment, the pre-wash comprises water, maize starch, potato starch and xanthan gum. In one embodiment, the pre-wash comprises water, rice flour, maize starch, potato starch and xanthan gum. The pre-wash may also comprise flavourings, sugars, salts, or combinations thereof.

Process for producing a meat analogue

The invention provides process for producing meat analogues, in particular meat analogues in which a fat analogue is adhered or otherwise attached to a protein in order to provide a realistic appearance, texture and taste to the meat analogue.

The process for producing a meat analogue may comprise the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source;

(c) applying an adhering agent to the at least one protein source from (b); and

(d) applying the fat analogue to the at least one protein source from (d).

Advantageously, as described above, the adhering agent may comprise psyllium husk. The adhering agent may alternatively, or additionally, comprise guar gum. The adhering agent may comprise a cold-set gelling agent.

The processes described herein also advantageously do not require the addition of a lipid at the same time as or as part of the adhering agent. The processes described herein also do not require a step of emulsification. In particular, it is not necessary to emulsify the adhering agent, such as psyllium husk or guar gum.

The process may further comprise a step of applying a pre-wash to the at least one protein source prior to step (c). As described above, the pre-wash is preferably a liquid which can be used to enhance the adhesion between the fat and the protein. In some embodiments, the pre-wash is applied by coating or covering the protein source in the pre-wash, for example by submerging the protein source in a container of the pre-wash. The protein source may then be removed from the pre-wash. In some embodiments, the protein source retains a layer of pre-wash on its exterior surface. For example, the protein source may retain an amount of pre-wash that corresponds to between approximately 5 and 10% of the weight of the protein source, prior to the pre-wash step. The protein source may retain an amount of pre-wash that corresponds to between 5.5 and 7.5% of the weight of the protein source prior to the pre-wash step. The protein source may retain an amount of pre-wash that corresponds to 6.5% of the weight of the protein source prior to the pre-wash step. As an example, the protein source may have a weight of 100 g prior to the pre-wash step. After applying the pre-wash to the protein source, any excess may be removed or allowed to drain off, such that the total combined weight of the protein source and the pre-wash may be 106.5 g (in other words, 6.5 g of pre-wash has been retained on the protein source).

The process for producing a meat analogue may therefore comprise the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source;

(c) applying a pre-wash to the at least one protein source;

(d) applying an adhering agent to the at least one protein source from (c); and

(e) applying the fat analogue to the at least one protein source from (d).

The adhering agent can be applied by any means known in the art (irrespective of whether the method includes the step of applying a pre-wash). For example, the adhering agent may be provided as a dry powder, in which case the protein source can be dusted or coated with the adhering agent. The adhering agent may also be provided as a paste or other semi-solid, or as a liquid. In which case, the adhering agent may be “painted” onto the protein source, or the protein source may be submerged in the adhering agent. As described above, the adhering agent preferably comprises psyllium husk and/or guar gum. Surprisingly, the psyllium husk and/or guar gum may be provided as a powder, and may be applied to the protein source as a powder, dust or “pre-dust”. Advantageously, it is not necessary to emulsify the adhering agent (e.g. psyllium husk or guar gum) prior to application to the protein.

In some embodiments, the adhering agent is applied by coating or covering the protein source in the adhering agent, for example by dusting the protein source with a powdered form of the adhering agent. The protein source may retain a layer of the adhering agent on its exterior surface. For example, the protein source may retain an amount of adhering agent that corresponds to between approximately 0.5 and 6 % of the weight of the first protein source, prior to the pre-wash step. The protein source may retain an amount of adhering agent that corresponds to between 1 and 5 % of the weight of the protein source prior to the pre-wash step. The protein source may retain an amount of adhering agent that corresponds to between 1 and 5 % of the weight of the protein source prior to the pre-wash step. The protein source may retain an amount of adhering agent that corresponds to 2% of the weight of the protein source prior to the pre-wash step. As an example, the protein source may have a weight of 100 g prior to the pre-wash step. After applying the adhering agent to the protein source, any excess may be removed, such that the total combined weight of the protein source and the adhering agent may be 102 g (in other words, 2 g of adhering agent has been retained on the protein source).

Once the adhering agent has been applied to the at least one protein source, the fat analogue is then applied to the protein source. This step can be achieved by any suitable means known in the art. The step of applying the fat analogue to the at least one protein source may comprise layering the fat analogue with the at least one protein source. For example, if the fat analogue is provided as a liquid or semi-liquid, this step may comprise placing the protein source in a mould, then adding the fat analogue to the mould such that it covers, surrounds or otherwise contacts the protein source to allow adhesion to occur. The way in which the fat analogue is applied can depend on the animal-derived meat that the meat analogue is intended to resemble. For example, where a bacon analogue is desired, the fat analogue may be layered with the protein source in a way that resembles a slice of bacon when the bacon analogue is sliced. The meat analogue produced by the processes described herein may have a layered structure. For example, the meat analogue may comprise a first layer comprising a fat analogue, and a second layer comprising a protein source.

The steps of the methods described herein may also be performed using extrusion methods, such as co-extrusion of the fat analogue and protein source (or co-extrusion of two or more proteins). As an example, in a co-extrusion method, the fat analogue and protein source (such as TVP) may be extruded simultaneously from separate nozzles or feeders and subsequently pressed together or otherwise combined. The adhering agent may also be co-extruded at the same time such that it is provided at the interface between the fat and protein.

The steps of the methods described herein may also be performed using technologies such as 3D printing.

In some cases, the processes described herein may comprise multiple steps of applying a pre-wash and adhering agent, in order to create multiple layers with adhesive properties. For example, the first pre-wash will create a liquid interface which then adheres with the dry adhering agent. A second prewash can then be applied to create a second liquid layer, which consequently adheres to a second dry layer of adhering agent. The steps of applying the adhering agent and applying the pre-wash may therefore be repeated as often as desired, for example twice, three times, or more. The process may further comprise a step of setting the meat analogue. “Setting” as used herein may refer to setting of the adhering agent, the fat analogue, or both, and means to change into a solid or semi-solid state. For example, when the fat analogue is provided in a liquid state, “setting” can refer to the process of changing the fat analogue into a solid or semi-solid state, such that it holds its shape without a mould. Once the meat analogue or components thereof have been set, the fat analogue and protein source will be adhered together in a manner that resembles animal-derived meat. The meat analogue can then be handled, sliced or prepared in the same way as animal-derived meat.

Setting can be achieved or accelerated by cooling or heating, though it should be appreciated that setting can occur at room temperature or without cooling or heating. Setting can preferably be performed in a mould to maintain the shape of the meat analogue. In the case of cooling, the meat analogue may be kept at a temperature of between approximately -18 to 15 °C, preferably between approximately 0 and 15 °C, or between approximately 2 and 8 °C. In the case of heating, the meat analogue may be heated at a temperature between approximately 40 to 110 °C. The meat analogue may be heated at a temperature between approximately 70 to 110 °C. In some embodiments, the meat analogue may be heated at approximately 100 °C. The duration of the setting step will depend on the specific composition of the fat analogue, the adhering agent and the meat analogue, as well as the temperature applied. In some embodiments, the process involves setting the meat analogue for 1 hour, 2 hours, 4 hours, 6 hours, 10 hours, 12 hours, 24 hours or 48 hours. Generally, when setting is achieved by cooling, the process involves setting the meat analogue for 30 minutes, 1 hour, 2 hours, 4 hours, 6 hours, 10 hours, 12 hours, 24 hours or 48 hours. In some embodiments, the meat analogue may be heated at approximately 100 °C for a duration of between 5 and 30 minutes. In some embodiments, the meat analogue may be heated at between approximately 90 to 110 °C for a duration of between approximately 10 to 30 minutes. In some embodiments, the meat analogue may be heated at approximately 100 °C for a duration of approximately 20 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of between 60 and 100 °C for approximately 5 to 20 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of between 70 and 90 °C for approximately 5 to 15 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of between 70 and 90 °C for approximately 10 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of 80 °C for approximately 5 to 15 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of 80 °C for approximately 10 minutes. In some embodiments, an indirect source of heat is used, for example steam. In some embodiments, the meat analogue is heated in an oven.

Advantageously, the steps of the method need not all be performed immediately following each other. For example, the adhering agent can applied to the protein source, which could subsequently be stored and/or transported before further steps of the method are performed. Subsequently, the fat analogue could be applied and the meat analogue could be set and portioned. Once the adhering agent has been applied, the protein source could be stored for 1 day or more, 2 days or more, 3 days or more, 4 days or more, 5 days or more, 6 days or more, 7 days or more or 14 days or more, before the remaining method steps are performed. Similarly, if a pre-wash is applied, the protein source could be stored and/or transported before the adhering agent is applied. Or, the pre-wash and adhering agent could be applied before storage of the protein source and later application of the fat analogue.

Thus, in some embodiments, the process for producing a meat analogue may comprise the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source;

(c) applying an adhering agent to the at least one protein source from (b);

(d) applying the fat analogue to the at least one protein source from (c); and

(e) setting the meat analogue.

In other embodiments, the process for producing a meat analogue may comprise the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source;

(c) applying a pre-wash to the at least one protein source;

(d) applying an adhering agent to the at least one protein source from (c);

(e) applying the fat analogue to the at least one protein source from (d); and

(f) setting the meat analogue.

In a particular embodiment, the process for producing a meat analogue may comprise the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source;

(c) applying a pre-wash to the at least one protein source;

(d) applying an adhering agent to the at least one protein source from (c), wherein the adhering agent comprises psyllium husk;

(e) applying the fat analogue to the at least one protein source from (d); and

(f) setting the meat analogue.

In a particular embodiment, the process for producing a meat analogue may comprise the steps of:

(a) providing a fat analogue;

(b) providing at least one protein source;

(c) applying a pre-wash to the at least one protein source;

(d) applying an adhering agent to the at least one protein source from (c), wherein the adhering agent comprises guar gum;

(e) applying the fat analogue to the at least one protein source from (d); and

(f) setting the meat analogue. As set out above, the processes of the invention can advantageously be used to adhere a fat analogue to at least one protein source in order to produce a meat analogue.

The invention also provides a process for producing a meat analogue in which a first and a second protein source are adhered together.

Such processes are particularly useful in the production of large meat analogues, such as meat analogues intended to resemble whole joints of meat. In particular, said processes can be used to adhere a first high moisture protein extrudate to a second high moisture protein extrudate. Manufacturing instruments for producing meat analogues may be limited to producing proteins (such as high moisture protein extrudate) at a maximum size (for example, a maximum height or diameter). The processes described herein can overcome these limitations by enabling several pieces of protein (such as high moisture protein extrudate) to be adhered together.

Accordingly, the invention provides a process for producing a meat analogue, the process comprising the steps of:

(a) providing a first protein source;

(b) providing a second protein source;

(c) applying an adhering agent to the first protein source; and

(d) applying the second protein source to the first protein source from (c).

The adhering agent may comprise psyllium husk. The adhering agent may comprise guar gum. The adhering agent may comprise a cold-set gelling agent.

The process may further comprise a step of applying a pre-wash to the first protein source prior to step (c).

As described above, the pre-wash is preferably a liquid which can be used to enhance the adhesion between the first protein and the second protein. In some embodiments, the pre-wash is applied by coating or covering the first protein source in the pre-wash, for example by submerging the first protein source in a container of the pre-wash. The first protein source may then be removed from the prewash. In some embodiments, the first protein source retains a layer of pre-wash on its exterior surface. For example, the first protein source may retain an amount of pre-wash that corresponds to between approximately 5 and 10% of the weight of the first protein source, prior to the pre-wash step. The first protein source may retain an amount of pre-wash that corresponds to between 5.5 and 7.5% of the weight of the first protein source prior to the pre-wash step. The first protein source may retain an amount of pre-wash that corresponds to 6.5% of the weight of the first protein source prior to the pre-wash step. As an example, the first protein source may have a weight of 100 g prior to the prewash step. After applying the pre-wash to the first protein source, any excess may be removed or allowed to drain off, such that the total combined weight of the first protein source and the pre-wash may be 106.5 g (in other words, 6.5 g of pre-wash has been retained on the first protein source).

The process for producing a meat analogue may therefore comprise the steps of:

(a) providing a first protein source;

(b) providing a second protein source;

(c) applying a pre-wash to the first protein source;

(d) applying an adhering agent to the first protein source from (c); and

(e) applying the second protein source to the first protein source from (d).

Advantageously, as described above, the adhering agent may comprise psyllium husk. The adhering agent may comprise guar gum. The adhering agent may comprise a cold-set gelling agent. The adhering agent can be applied by any means known in the art (irrespective of whether the method includes the step of applying a pre-wash). For example, the adhering agent may be provided as a dry powder, in which case the protein source can be dusted or coated with the adhering agent.

In some embodiments, the adhering agent is applied by coating or covering the first protein source in the adhering agent, for example by dusting the first protein source with a powdered form of the adhering agent. The first protein source may retain a layer of the adhering agent on its exterior surface. For example, the first protein source may retain an amount of adhering agent that corresponds to between approximately 0.5 and 6 % of the weight of the first protein source, prior to the pre-wash step. The first protein source may retain an amount of adhering agent that corresponds to between 1 and 5 % of the weight of the first protein source prior to the pre-wash step. The first protein source may retain an amount of adhering agent that corresponds to between 1 and 5 % of the weight of the first protein source prior to the pre-wash step. The first protein source may retain an amount of adhering agent that corresponds to 2% of the weight of the first protein source prior to the pre-wash step. As an example, the first protein source may have a weight of 100 g prior to the prewash step. After applying the adhering agent to the first protein source, any excess may be removed, such that the total combined weight of the first protein source and the adhering agent may be 102 g (in other words, 2 g of adhering agent has been retained on the first protein source).

The second protein source may be applied to the first protein source to provide a layered structure. The meat analogue produced by the processes described herein may have a layered structure. For example, the meat analogue may comprise a first layer comprising a first protein source, and a second layer comprising a second protein source.

The process may further comprise a step of setting the meat analogue. “Setting” as used herein may refer to setting of the adhering agent, the protein sources, or both, and means to change into a solid or semi-solid state. For example, such that the meat analogue holds its shape without a mould. Once the meat analogue or components thereof have been set, the first and second protein sources will be adhered together in a manner that resembles animal-derived meat. The meat analogue can then be handled, sliced or prepared in the same way as animal-derived meat.

Setting can be achieved or accelerated by cooling or heating, though it should be appreciated that setting can occur at room temperature or without cooling or heating. Setting can preferably be performed in a mould to maintain the shape of the meat analogue. In the case of cooling, the meat analogue may be kept at a temperature of between approximately -18 to 15 °C, preferably between approximately 0 and 15 °C, or between approximately 2 and 8 °C. In the case of heating, the meat analogue may be heated at a temperature between approximately 40 to 110 °C. The meat analogue may be heated at a temperature between approximately 70 to 105 °C. In some embodiments, the meat analogue may be heated at approximately 100 °C. The duration of the setting step will depend on the specific composition of the fat analogue, the adhering agent and the meat analogue, as well as the temperature applied. In some embodiments, the process involves setting the meat analogue for 1 hour, 2 hours, 4 hours, 6 hours, 10 hours, 12 hours, 24 hours or 48 hours. Generally, when setting is achieved by cooling, the process involves setting the meat analogue for 30 minutes, 1 hour, 2 hours, 4 hours, 6 hours, 10 hours, 12 hours, 24 hours or 48 hours. In some embodiments, the meat analogue may be heated at approximately 100 °C for a duration of between 5 and 30 minutes. In some embodiments, the meat analogue may be heated at between approximately 90 to 110 °C for a duration of between approximately 10 to 30 minutes. In some embodiments, the meat analogue may be heated at approximately 100 °C for a duration of approximately 20 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of between 60 and 100 °C for approximately 5 to 20 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of between 70 and 90 °C for approximately 5 to 15 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of between 70 and 90 °C for approximately 10 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of 80 °C for approximately 5 to 15 minutes. In some embodiments, the meat analogue may be heated such that the meat analogue achieves an internal temperature of 80 °C for approximately 10 minutes. In some embodiments, an indirect source of heat is used, for example steam. In some embodiments, the meat analogue is heated in an oven.

Thus, in some embodiments, the process for producing a meat analogue may comprise the steps of:

(a) providing a first protein source;

(b) providing a second protein source;

(c) applying an adhering agent to the first protein source;

(d) applying the second protein source to the first protein source from (c); and

(e) setting the meat analogue.

In other embodiments, the process for producing a meat analogue may comprise the steps of:

(a) providing a first protein source; (b) providing a second protein source;

(c) applying a pre-wash to the first protein source;

(d) applying an adhering agent to the first protein source from (c);

(e) applying the second protein source to the first protein source from (d); and

(f) setting the meat analogue.

In a particular embodiment, the process for producing a meat analogue may comprise the steps of:

(a) providing a first protein source;

(b) providing a second protein source;

(c) applying a pre-wash to the first protein source;

(d) applying an adhering agent to the first protein source from (c), wherein the adhering agent comprises psyllium husk;

(e) applying the second protein source to the first protein source from (d); and

(f) setting the meat analogue.

In a particular embodiment, the process for producing a meat analogue may comprise the steps of:

(a) providing a first protein source;

(b) providing a second protein source;

(c) applying a pre-wash to the first protein source;

(d) applying an adhering agent to the first protein source from (c), wherein the adhering agent comprises guar gum;

(e) applying the second protein source to the first protein source from (d); and

(f) setting the meat analogue.

It will also be appreciated that the invention encompasses processes in which a first protein source may be adhered or otherwise attached to a second protein source, and subsequently a fat analogue is adhered or otherwise attached to one of the first or second protein sources, in accordance with the methods disclosed herein. Likewise, the invention also encompasses adhering or otherwise attaching a fat analogue to a first protein source, and subsequently adhering or otherwise attaching a second protein source to either the fat analogue, or the first protein source.

Accordingly, the invention provides a process for producing a meat analogue, the method comprising the steps of:

(a) providing a first protein source;

(b) providing a meat analogue component, wherein the meat analogue component is a fat analogue or a second protein source;

(c) applying an adhering agent to the first protein source, wherein the adhering agent comprises psyllium husk and/or guar gum;

(e) applying the meat analogue component to the first protein source from (c). The invention also provides a process for producing a meat analogue, the method comprising the steps of:

(a) providing a first protein source;

(b) providing a meat analogue component, wherein the meat analogue component is a fat analogue or a second protein source;

(c) applying a pre-wash to the first protein source;

(d) applying an adhering agent to the first protein source from (c), wherein the adhering agent comprises psyllium husk and/or guar gum;

(e) applying the meat analogue component to the first protein source from (d).

In the processes described above, the fat analogue is applied to the at least one protein source such that the adhering agent is located at the interface between the fat analogue and the at least one protein source. Similarly, a first protein source is applied to the second protein source such that the adhering agent is located at the interface between the first protein source and the second protein source.

Uses of psyllium husk

The present invention also encompasses the use of psyllium husk in a method of attaching or adhering components of a meat analogue to each other.

In particular, the present invention encompasses the use of psyllium husk in a method of attaching a fat analogue to at least one protein source. The at least one protein source can be any protein source described herein, such as one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, or a combination thereof. Preferably, the protein source is a high moisture protein extrudate. The protein source may have a fibrous structure, as described herein. The fat analogue may also be any fat analogue described herein. For example, the fat analogue may comprise a fat, an alginate and water, and may optionally further comprise a calcium source and a chelating agent. The fat analogue may also comprise dextrin or another browning agent. The at least one protein source, the fat analogue, or both, may be substantially free of animal products. The meat analogue may have a layered structure. In other words, the meat analogue may comprise a first layer comprising a fat analogue, and a second layer comprising a protein source.

The present invention also encompasses the use of psyllium husk in a method of attaching a first protein source to a second protein source. The first and second protein sources may be the same, or they may be different. For example, the first and second protein sources may both comprise pea protein. In other embodiments, a first protein source may comprise a plant protein, and a second protein source may comprise a fungal protein. The protein source or sources may be any protein source as described herein, for example a high moisture protein extrudate. Said method may be useful when producing analogues of large joints of meat, which may require two or more pieces of protein to be adhered or otherwise joined together. The at least one protein source, the fat analogue, or both, may be substantially free of animal products. The meat analogue may have a layered structure. In other words, the meat analogue may comprise a first layer comprising a first protein source, and a second layer comprising a second protein source, which may be the same or different to the first protein source.

Uses of guar gum

The present invention also encompasses the use of guar gum in a method of attaching or adhering components of a meat analogue to each other.

In particular, the present invention encompasses the use of guar gum in a method of attaching a fat analogue to at least one protein source. The at least one protein source can be any protein source described herein, such as one or more plant proteins, cultured meat proteins, fermented proteins, fungal proteins, or a combination thereof. Preferably, the protein source is a high moisture protein extrudate. The protein source may have a fibrous structure, as described herein. The fat analogue may also be any fat analogue described herein. For example, the fat analogue may comprise a fat, an alginate and water, and may optionally further comprise a calcium source and a chelating agent. The fat analogue may also comprise dextrin or another browning agent. The at least one protein source, the fat analogue, or both, may be substantially free of animal products. The meat analogue may have a layered structure. In other words, the meat analogue may comprise a first layer comprising a fat analogue, and a second layer comprising a protein source.

The present invention also encompasses the use of guar gum in a method of attaching a first protein source to a second protein source. The first and second protein sources may be the same, or they may be different. For example, the first and second protein sources may both comprise pea protein. In other embodiments, a first protein source may comprise a plant protein, and a second protein source may comprise a fungal protein. The protein source or sources may be any protein source as described herein, for example a high moisture protein extrudate. Said method may be useful when producing analogues of large joints of meat, which may require two or more pieces of protein to be adhered or otherwise joined together. The at least one protein source, the fat analogue, or both, may be substantially free of animal products. The meat analogue may have a layered structure. In other words, the meat analogue may comprise a first layer comprising a first protein source, and a second layer comprising a second protein source, which may be the same or different to the first protein source.

The invention will subsequently be described by reference to the following Examples, which should be understood to be illustrative in nature and not limiting on the scope of the invention. EXAMPLES

Materials & Methods

Laboratory trials were conducted with the aim of identifying a method to attach a fat analogue to a piece of high moisture protein extrudate, in order to provide a meat analogue that resembles and can be handled like animal-derived meat products. The high moisture protein extrudate comprised a combination of pea and soy protein as the protein sources, and also included flavourings, oil, salt, maltodextrin and starch. The fat analogues tested were hydrocolloid-based gels, including a waterbased alginate gel, and a konjac gel. In some experiments, the ability of specific adhering agents to attach a piece of high moisture protein extrudate to another piece of high moisture protein extrudate (instead of to a fat) was also assessed.

Example 1

In the following tests, a range of ingredients were added to the fat analogue formulation in an attempt to create a sticky material that would adhere to a protein source.

The meat analogues were assessed based on their adhesion during storage, handling, and slicing. In particular, meat analogues were handled in a manner consistent with forces typical of consumer handling and cutting. Meat analogues were scored based on the following criteria:

The results are shown in Table 1 below.

As can be seen from the above results, achieving adherence between a fat analogue and a protein source was difficult to achieve, and the use of traditional ingredients to provide a “sticky” material did not provide the required adherence necessary for a satisfactory consumer product.

Example 2

In the following tests, a different approach was pursued, in which different agents were tested for their ability to provide an adherent interface between the protein source and the fat analogue. In these experiments, the high moisture protein extrudate was coated in the agent to be tested, and then layered into a solution of the fat analogue (a hydrocolloid-based gel). In some experiments, the high moisture protein extrudate was first dipped into a pre-wash solution prior to application of the adhering agent. The pre-wash solution was made using 1 part powder to 2 parts water, and comprised a wheat flour or rice flour powder base with added starches. In order to identify the optimum conditions for setting the meat analogue, meat analogues were also either heated to 100 °C for 20 minutes, or were kept in the fridge overnight (approximately 18 hours) to set.

After setting, the meat analogues were assessed based on their adhesion during storage, handling, and slicing. In particular, meat analogues were handled in a manner consistent with forces typical of consumer handling and cutting. Meat analogues were scored based on the following criteria: Results

The results of the experiments are shown in Table 2 below.

The results show that psyllium husk and guar gum provide exceptional adhesion between fat analogues and protein sources. Surprisingly, psyllium husk and guar gum outperformed all the conventional starches and flours that are typically used in the art for adherence. For example, commercially available batter washes failed to provide the required adhesion between layers and frequently fell apart when handled.

Further, this unexpectedly high performance was observed even when the quantity of psyllium husk powder was reduced to less than 50% (in some cases, as low as 30%) of the total weight of the adhering agent.

Surprisingly, guar gum also provides excellent adhesion between fat analogues and protein sources. The presence of a pre-wash step generally enhanced the adhesion between the layers and provided more resistance when the layers were pulled apart, although the pre-wash was not an absolute requirement to obtain the desired adhesion levels. Different pre-washes tested (rice flour and wheat flour base) provided the same results. Advantageously, it is believed the psyllium husk adhering agent, and the guar gum adhering agent, could be used with other commercially available pre-wash formulations, in addition to those tested.

When psyllium husk or guar gum was used as an adhering agent, the meat analogue could be set either in the fridge or with heating. Both methods provide good adhesion.

Finally, the use of psyllium husk or guar gum as an adhering agent had no adverse effect on taste or any other organoleptic properties of the meat analogue.

EQUIVALENTS AND SCOPE

Those skilled in the art will appreciate that the present invention is defined by the appended claims and not by the Examples or other description of certain embodiments included herein.

Similarly, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

Unless defined otherwise above, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention. Generally, nomenclatures used in connection with, and techniques of, cell and tissue culture, molecular biology, immunology, genetics and protein and nucleic acid chemistry described herein are those well-known and commonly used in the art, or according to manufacturer’s specifications.

All publications mentioned herein are incorporated herein by reference to disclose and describe the methods and/or materials in connection with which the publications are cited.