An animal fat replacement product

BACKGROUND

Field

[0001] The present disclosure relates to solid oil-in-water emulsion that may be used as a fat mimetic, or an animal fat replacement product. The pea plant protein and a plant oil in the form of an emulsion, which may be used for the replacement of adipose tissue based animal fat, rendered animal fat or tropical oil, and is suitable for use in vegan patties and meat analogues; methods for making such a fat mimetic; and methods for incorporating the fat mimetic into vegan patties, meat analogues, and other products as a replacement of animal fat, rendered animal fat, or tropical oil.

[0002] Animal meat-based food products, such as burgers, sausages, frankfurters, and salami, are ubiquitous, and consumers have become accustomed to the texture, bite, cook out properties, colour and flavour to such an extent that manufacturers of vegan alternatives do their utmost to emulate these properties.

[0003] Many vegan meat analogue products, such as patties or vegan burgers, use textured vegetable protein as the main building block. Terms like “Rehydrated Textured Soya and Wheat Protein” are used on the ingredient declaration label to describe such structuring agents. These “textured vegetable proteins” (TVP) are the de-fatted concentrated protein fraction of the original plant source, e.g., soya beans. These TVP’s perform admirably in this role of structuring plantbased patties. Though the extrusion is considered a “dry extrusion” or “low moisture extrusion” and has been used as a meat extender or complete replacer for decades. Textured vegetable protein was invented by the agricultural commodities and food processing company Archer Daniels Midland in the 1960s; the company owns the TVP name as a registered trademark. Improvements over the years has led to improved hydration properties and increased resilience with the result that today, TVP’s can deliver the firm, fibrous texture of meat.

[0004] To confer the unctuous properties of animal meat patties and sausages, such as juiciness and succulence, manufacturers of vegan products such as patties or sausages routinely add back a refined plant-based oil, commonly called vegetable oils. EU legislation stipulated in Food Information Regulation (EU) No 1169/2011 (FIC), that the botanical origin of refined oils should be stated clearly in the ingredient’s declaration. If refined oils or fats of vegetable origin are contained in a product, the specific plant origin must be indicated, for example “palm fat” or “vegetable fat (coconut)”. If such ingredients are summarised as “vegetable oils” or “vegetable fats”, then this must be followed directly by a list of details regarding the specific plant origin (e.g. palm oil, soya oil). This can be followed by the phrase “in variable proportion”. If summarised, they are listed in the ingredients list by the weight percentage of all present plant-based oils and fats. The expression “fully hydrogenated” or “partly hydrogenated”, as appropriate, must accompany the indication of a hydrogenated oil.

[0005] Under EU law, prepacked food that is sold in the EU must bear a label informing consumers about its energy and nutrient content. This is called ‘nutrition declaration' and must appear directly on the package or on a label attached to it. The nutrition declaration must include the following information:

- energy value; and

- amounts of fat, saturates, carbohydrate, sugars, protein and salt.

[0006] The following nutrients can be indicated voluntarily in the nutrition declaration:

- monounsaturates

- polyunsaturates

- polyols

- starch

- fibre

- any of the vitamins or minerals permitted by law.

[0007] Vegan meat alternatives or vegan patties or burgers often comprise refined coconut oil. Coconut oil is the edible oil extracted from the dried meat of the coconut, the fruit of the coconut palm (Cocos nucifera), and a low percentage of unsaturated fatty acids and is up to 90 percent saturated fat. Refined coconut oil involves removal of undesired components to improve coconut oil quality, and can be carried out in four stages: conventional degumming, neutralization, bleaching, and deodorization.

[0008] The fat found in animals is adipose tissue, or fatty tissue, connective tissue consisting mainly of fat cells (adipose cells, or adipocytes), specialised to synthesise and contain large globules of fat, within a structural network of fibres.

[0009] When red meat is prepared for use in burgers, for instance, a portion of fat is incorporated into the muscle meat, and this is minced or ground together to produce a homogenous mix. The mincing is carried out so that the white adipose fatty tissue particles stand out in colour contrast to the red meat background. The connective tissue is made up mainly of collagen which retains large globules of fat, and it is this connective tissue that facilitates the formation of the visible fat particles while also allowing a controlled release of the animal fat during cooking and providing succulence after cooking on eating.

[0010] In the retail trade refined coconut oil (often referred to as CN) has become the fat of choice as a replacement for adipose tissue, for vegan patties or burgers, for a number of reasons among which are the ease of handling, the white appearance, and the melt-in-the mouth properties.

[0011] The debate around the consumption of saturated fats and in particular saturated tropical fats of which coconut oil is one, has raged for decades. For years the alleged negative health effects of coconut oil were publicised because of its high saturated fatty acid content.

[0012] Nevertheless, coconut oil remains relatively expensive compared to other vegetable oils (palm oil and seed oils for instance), and its supply can be negatively influenced by unpredictable and catastrophic weather conditions. Furthermore, the alleged negative environmental impact of coconut oil plantations plays a role in the choice of whether to use coconut oil or not.

[0013] In vegan patties and burgers, the means whereby coconut oil is used is of importance. Many of the vegan burger manufacturers use the same equipment as was and is used to make traditional animal meat burgers, namely bowl choppers. The coconut oil or fat is used in solid form rather than being held in bulk at a storage temperature above its melting point. The terms oil and fat are often used interchangeably. An oil is liquid at room temperature, i.e., about 20°C, and a fat is solid at room temperature.

[0014] Thus, the use of coconut fat in its solid form (at refrigeration temperatures) means that when added to the bowl chopper it breaks up into small pieces but there remains, visible to the naked eye, fragments of the coconut fat in the TVP matrix resulting in an authentic animal meat appearance, a minced meat type of visual that consumers are used to and find appealing and authentic.

[0015] Replacement of the coconut fat or coconut oil with a lower cost, lower carbon footprint, lower saturated fatty acid containing oil would be highly advantageous, and would provide a more sustainable alternative.

[0016] US20090291188A discloses a meat analogue products and methods of making same. The products are made from compositions comprising a mixture of ingredients, including a vegetable protein, a dough conditioner, and less than about 25% by weight flour. These compositions can optionally further comprise: thermally-preformed, texturized, protein components; oils and/or fats; flavors; spices; seasoning; colors; acids; and preservatives. These products can be provided in a log or slab formation and cut into dices, slices, cubes or any other desired geometry, and packaged and/or further processed as necessary (e.g., added to pizza products). Novel methods for the continuous manufacture of these products using a forming heat exchanger are also provided. A continuous process provides casingless food products analogous to meat products such as pepperoni.

[0017] US2018310599A1 is concerned with ground meat-like food products that have structures, textures, and other properties comparable to those of animal meat, and that may therefore serve as substitutes for animal meat. Also provided are processes for production of such ground meat-like food products. US’599 disclose that yeast cell wall material bound with ribose was capable of effecting browning, charring, and caramelization in meat structured protein products during cooking (e.g., by delivering a ‘reducing’ sugar). A greater colour transition from uncooked to cooked state was obtained in the case wherein ribose was bound with yeast cell wall material.

[0018] W02021/009043 describes a ground meat analogue product suitable for vegan consumers. A method of making the ground meat analogue product is described, said method comprising: a. Preparing a plant protein extrudate by wet extrusion; b. Preparing a 10 to 20% (w/w) plant protein dispersion, preferably a soy protein dispersion, suitably, a mixture of 14 to 16% (w/w) soy protein in water; c. Preparing a fat mimetic by emulsifying a protein dispersion and a lipid phase; d. Comminution of the plant protein extrudate; e. Comminution of the fat mimetic; f. Mixing; and g. Optionally moulding into a shape.

[0019] WO’043 discloses that fat mimetic emulsion did not gel without the presence of NaCI, and a plant protein concentration of 10 to 12% (w/w) did not lead to effective binding in vegan burger patties due to an inability to form stable gels. The protein content of the fat mimetic was 3% (w/w).

[0020] US2019/0133162 discloses a meat replica comprising: about 5% to about 88% by weight of a meat dough, wherein the meat dough comprises an isolated plant protein; about 15% to about 40% by weight of an edible fibrous component; about 5% to about 35% by weight of a fat; and about 0.1% to about 18% by weight of a carbohydrate-based gel; wherein, after cooking the meat replica to an internal temperature of 160° F., the meat replica is firmer than the meat replica before cooking.

[0021] The meat replica of US’162 further comprises about 0.01 % to about 4% by weight of a heme-containing protein.

[0022] W02021009075A1 discloses a method of making a bacon analogue product, said method comprising a. Preparing a plant protein extrudate by wet extrusion; b. Preparing a 10 to 20% (w/w) plant protein dispersion, preferably a soy protein dispersion; c. Preparing a fat mimetic by emulsifying a plant protein dispersion and a lipid phase; d. Optionally applying a binding agent to the plant protein extrudate or fat mimetic; e. Arranging the plant protein extrudate, fat mimetic, and plant protein dispersion in layers; f. Pressing the arranged layers; g. Heating to obtain a cohesive mass; h. Cooling; and i. Optionally smoking, slicing or shredding.

[0023] Also disclosed is a bacon analogue product comprising: a. Plant protein extrudate; b. Plant protein dispersion, preferably a soy protein dispersion; c. Fat mimetic comprising a protein isolate dispersion emulsified in a lipid phase; and d. Optional a binding agent.

[0024] The fat mimetic of WO’075 comprises about 30% (w/w) of a protein dispersion comprising a protein isolate and about 70% (w/w) of a lipid phase. Typically, the protein dispersion is a protein isolate dispersion or a protein concentrate dispersion, preferably a protein isolate dispersion. Typically, the protein isolate dispersion is a soy, potato, pea, or canola protein isolate dispersion, preferably a soy protein isolate dispersion. Typically, the protein isolate dispersion comprises 10 to 20% (w/w) soy protein isolate. [0025] The fat mimetic of WO’075 can be prepared, by emulsifying about 70 % (w/w) lipid- phase and about 30 % of a SPI dispersion. The SPI dispersion can be about 10%. The resulting total concentration can be about 3 % SPI in the emulsion. The lipid phase may contain canola oil or it may contain about 70 % canola oil and about 30 % solid fat. The solid fat can be melted into the oil. A food processor can be used to make the emulsion. The oil phase may be slowly added to the SPI dispersion while constantly stirring. When all the oil is mixed in, about 1 % sodium chloride and about 0.75 % of, for example, a 10 % transglutaminase solution (about 25 mg TG/ g SPI) can be added. The emulsion can then be filled into flexible aluminum forms and heat treated, for example, in a heating chamber. First, it can be heated to a core temperature of about 40 °C. This can be kept constant for about one hour. This gives the transglutaminase the possibility to react. Next, the product can be heated at a chamber temperature of about 90 °C. It should reach a core temperature of about 85 °C to deactivate the enzyme and ensure protein gelation. It can then be cooled with a cold shower for about 10 min. It can then be stored at about 2 °C.

[0026] There is a market and commercial need for fat mimetics in plant based manufactured foods. See, e.g., IFT FIRST: Mintel highlights need for fat innovation in plant-based foods (foodnavigator-usa.com) (https:/www.foodnavigator-usa.com/Article/2022/07/15/ift-fir st-mintel- highlights-need-for-fat-innovation-in-plant-based-foods). The article explains that, while still a growing $7.4bn industry, plant-based foods have some significant hurdles to overcome around formulation especially in the area of fat content, according to Mintel.

[0027] This article specifically has links to 5 other articles, which are relevant to understanding a background of the present disclosure:

[0028] (1) Plant-based cheese, meat, formulation gamechanger? Motif FoodWorks gains exclusive access to two ‘transformative’ technologies (foodnavigator-usa.com) (https://www.foodnavigator-usa.com/Article/2021/05/13/Plant- based-cheese-meat-formulation- gamechanger-Motif-FoodWorks-gains-exclusive-access-to-two-tr ansformative-technologies).

[0029] (2) EXPO WEST 2022: ‘It’s something we discovered serendipitously... ’ EPG modified plant-based oil has exciting potential in meat alternatives, says Epogee (foodnavigator- usa.com) (https://www.foodnavigator-usa.eom/Article/2022/03/16/EXPO-W EST-2022-lt-s- something-we-discovered-serendipitously-EPG-modified-plant-b ased-oil-has-exciting-potential- in-meat-alternatives-says-Epogee).

[0030] (3) ‘It’s such a clear pain point for formulators... ’ Yali Bio joins race to create more

‘animal-like’ fats in meat, dairy alternatives (foodnavigator-usa.com) (https://www.foodnavigator- usa.com/Article/2022/03/08/lt-s-such-a-clear-pain-point-for- formulators-Yali-Bio-joins-race-to- create-more-animal-like-fats-in-meat-dairy-alternatives) [0031] (4) Fat... the final frontier for meat alternatives? Designer fat co Lypid raises $4m to commercialize microencapsulated vegan oils that behave like animal fat (foodnavigator-usa.com) (https://www.foodnavigator-usa.eom/Article/2022/03/03/Fat-th e-final-frontier-for-meat- alternatives-Designer-fat-co-Lypid-raises-4m-to-commercializ e-microencapsulated-vegan-oils- that-behave-like-animal-fat).

[0032] (5) Mission Barns, and Silva Sausage test-drive hybrid sausages blending cell- cultured animal fat and plant-based protein (foodnavigator-usa.com) (https://www.foodnaviqator- usa.com/Article/2021/10/20/Mission-Barns-and-Silva-Sausage-t est-drive-hybrid-sausages- blending-cell-cultured-animal-fat-and-plant-based-protein).

[0033] It would also be desirable to have a coconut fat or coconut oil replacement product having as clean an ingredient declaration as possible avoiding where possible the use of ingredients which are deemed (in the current market) unacceptable or less than acceptable by the final discerning consumer.

SUMMARY

[0034] In one aspect, the present invention provides a method for manufacturing a solid oil- in-water emulsion composition comprising, consisting essentially of or consisting of the steps of:

(i) providing a composition comprising: protein, fat, and water, wherein: the protein is present in an amount of from 7 wt% to 22 wt%, the fat is present in an amount of from 7 wt% to 45 wt%, wherein wt% is based on the total weight of the composition, and water;

(ii) heating the composition of step (i) to a temperature in the range of from 60°C to 95°C to provide a heated composition;

(iii) homogenizing the heated composition of step (ii) at a homogenizing pressure of at least 50 bar;

(iv) cooling the homogenized composition of step (iii) to provide the solid oil-in-water emulsion composition having a hardness of at least 0.37 N preferably, at least 0.95 N when measured at a temperature of from 4 to 10°C. [0035] Suitably, the protein is non-dairy protein, preferably, the protein is not animal derived protein, even more preferably, the protein is plant protein.

[0036] The protein may be present in an amount of from 8 wt% to 20 wt%, such as from 8 wt% to 18 wt%, preferably from 9 wt% to 15 wt%, such as from 9.5 wt% to 13.5 wt%, optionally, from 10 wt% to 12 wt% based on the total weight of the composition. Preferably, the protein is plant protein.

[0037] The protein may be plant-derived protein, or a protein isolate sourced therefrom. The protein may for example be obtained from pea, rice, fava bean, nuts, beans, whole grains, flax, oat, barley, quinoa, almond, walnut, chia, lentil, chickpeas, pumpkin seed, soybean, hemp seed, kidney bean, black bean, sunflower, including protein isolates sourced therefrom, and mixtures thereof.

[0038] Suitably, the protein is pea protein and/or fava bean protein. Preferably, the protein is pea protein.

[0039] Suitably, the fat is not animal derived fat, preferably the fat is plant fat. More preferably, the fat is oil, even further preferably, the fat is plant-derived oil (i.e. plant oil).

[0040] The fat may be present in an amount of from 10 wt% to 40 wt%, such as from 15 wt% to 35 wt%, preferably from 20 wt% to 30 wt%, such as from 22 wt% to 28 wt% based on the total weight of the composition.

[0041] The fat may for example be obtained from palm, rapeseed, soy, coconut, canola, sunflower, olives, shea nut, almond, peanut, sunflower, hazelnut, brazil nut, pecan, walnut, avocado, pomegranate, sesame, grapeseed, safflower, rice bran, corn, peanut, cottonseed, linseed, sesame, hemp, flaxseed, cocoa butter, agai palm, or combinations thereof.

[0042] Preferably, the fat is rapeseed oil and/or canola oil.

[0043] The weight ratio of the protein to the fat, preferably oil, in the solid oil-in-water emulsion is in the range of from 1 :0.7 to 1 :4.5, or 1 :0.8 to 1 :4, optionally, 1 :0.9 to 1 :3.6, for example 1 :1 to 1 :3.5, preferably from 1 :1 to 1 :3, such as 1 :1 .2 to 1 :2.8, more preferably 1 :1 .4 to 1 :2.6, such as from 1 :1 .5 to 1 :2.5, such as from 1 :1 .8 to 1 :2.4, or 1 :1 .8 to 1 :2.3, even more preferably from 1 :1 .9 to 1 :2.3, for example 1 :1 .9 to 1 .2.2. For example, an advantageous weight ratio of the protein to the fat, preferably oil, in the solid oil-in-water emulsion is 1 :2.23.

[0044] The composition comprises water. Optionally, water accounts for the balance of the weight of the composition, in addition to the protein, fat and any optional additives. Suitably, water is present in an amount of from 45 wt% to 80 wt%, optionally 50 to 78 wt% such as from 55 wt% to 70 wt%, preferably 60 wt% to 68 wt%, such as 60 to 66 wt% based on the total weight of the composition.

[0045] Suitably, the heating step (ii) involves heating the composition of step (i) to a temperature in the range of from 68°C to 95°C, preferably to a temperature in the range of from about 70°C to 80°C, for example, from about 71 °C to 75°C, such as to about 72°C. The heating step may be carried out for a period of at least 5 seconds, such as 10 seconds, preferably at least 15 seconds. Advantageously, the heating step may function as an antimicrobial treatment, and also gels the protein, facilitating emulsification of the fat phase with the water phase.

[0046] Suitably, the homogenization step (iii) is carried out at a homogenization pressure of at least 100 bar to provide the homogenized composition. Suitably, the homogenizing step (iii) is carried out at a homogenizing pressure in the range of from about 100 bar to about 300 bar, preferably, from 200 bar to 300 bar. Notably, at higher oil content to protein ratio, if the homogenization pressure is not sufficiently high, the resulting product will not be sufficiently homogenous, and the oil and water phases split, leading to a sub-optimal product.

[0047] The temperature of the heated composition during homogenization may be in the range of from 50°C to 90°C, such as from 50 to 80°C.

[0048] The homogenized product may optionally be moulded, for example, the homogenized product may be allowed to cool in a mould, leading to the formation of a moulded solid oil-in-water emulsion product.

[0049] The cooling step (iv) may reduce the temperature of the homogenized composition of step (iii) to a temperature less than 25°C, for example to a temperature below 10°C, such as to below 5°C. For example, the homogenized composition may be allowed to cool or cooled to a temperature in the range of from -20°C to 10°C, such as from -5 to 8°C, preferably from 0°C to 5 °C, or from 2°C to 4°C.

[0050] The method provides a solid oil-in-water emulsion composition may have a hardness in the range of from 0.5 N to 5.0 N, such as from 0.95 N to 4.0 N, preferably from 0.95 N to 3.3 N, such as from about 1 .3 to 1 .8 N.

[0051] The method provides an oil-in-water emulsion that may have a median particle size in the range of from 0.2 pm to 1.2 pm, preferably from 0.2 pm to 0.5 pm.

[0052] The oil-in-water emulsion and/or the composition of step (i) of the method may optionally include additives such as colourants, flavours, texturizers, starches, pH regulators or buffers, preservatives, food protection ingredients or solid particles. Further optionally the flavours are fat soluble and/or oil soluble. Further optionally the flavours are vegan. Further optionally the flavours are made up of taste modulation technology, optionally to enhance the succulence properties. Optionally, the flavours work in synergy with the oil-in-water emulsion. Optionally, the flavours increase the succulence of the end product. Optionally, the solid oil-in-water emulsion may include a flavour to aid the delivery of fat properties in the final application. Optionally, the flavour may be an oil soluble flavour which is made up of taste modulation technology to enhance the succulence properties; optionally this may be a fat based vegan flavour to help mimic animal fat taste delivery; optionally it works in synergy with the emulsion. Advantageously, the method of the present invention can optionally provide a solid oil-in-water emulsion composition having improved succulence.

[0053] In another aspect, the present invention provides a solid oil-in-water emulsion composition comprising, consisting essentially of, or consisting of: protein, fat, and water, wherein: the protein is present in an amount of from 7 to 22 wt% protein, the fat is present in an amount of from 7 wt% to 45 wt% and water, optionally the water is present in an amount of from 45 wt% to 80 wt%, optionally 50 to 78 wt% such as from 55 wt% to 70 wt%, preferably 60 wt% to 68 wt%, such as 60 to 66 wt% based on the total weight of the solid oil-in-water emulsion composition, wherein the solid-oil-in-water emulsion composition has a hardness of at least 0.37 N, preferably at least 0.95 N when measured at a temperature of from 4 to 10°C.

[0054] The solid oil-in-water emulsion may be free of animal derived ingredients, for example, the solid oil-in-water emulsion may be suitable for consumption by vegans. For example, the protein may be plant derived protein. The fat may be plant derived fat, for example, a plant derived oil.

[0055] The protein, preferably plant derived protein, may be present in an amount of from 8 wt% to 20 wt%, such as from 8 wt% to 18 wt%, preferably from 9 wt% to 15 wt%, such as from 9.5 wt% to 13.5 wt%, optionally from 10 wt% to 12 wt% based on the total weight of the composition.

[0056] The fat, preferably plant derived fat, such as plant derived oil, may be present in an amount of from 10 wt% to 40 wt%, such as from 15 wt% to 35 wt%, preferably from 20 wt% to 30 wt%, such as from 22 wt% to 28 wt% based on the total weight of the composition.

[0057] The protein may be obtained from pea, rice, fava bean, nuts, beans, whole grains, flax, oat, barley, quinoa, almond, walnut, chia, lentil, chickpeas, pumpkin seed, soybean, hemp seed, kidney bean, black bean, sunflower, including protein isolates sourced therefrom, and mixtures thereof. Suitably, the protein is pea protein and/or fava bean protein. Preferably, the protein is pea protein. Notably, when soy protein, fava bean protein or potato protein are used, homogenization is an optional step in the method of the invention.

[0058] Preferably, the fat is an oil. Suitably, the fat is obtained from palm, rapeseed, soy, coconut, canola, sunflower, olives, shea nut, almond, peanut, sunflower, hazelnut, brazil nut, pecan, walnut, avocado, pomegranate, sesame, grapeseed, safflower, rice bran, corn, peanut, cottonseed, linseed, sesame, hemp, flaxseed, cocoa butter, agai palm, or combinations thereof. Suitably, the fat is rapeseed oil and/or canola oil.

[0059] The weight ratio of the protein to the fat, preferably oil, in the solid oil-in-water emulsion, may be in the range of from 1 :0.7 to 1 :4.5, or 1 :0.8 to 1 :4, optionally, 1 :0.9 to 1 :3.6, for example 1 :1 to 1 :3.5, preferably from 1 :1 to 1 :3, such as 1 :1 .2 to 1 :2.8, more preferably 1 :1 .4 to 1 :2.6, such as from 1 :1 .5 to 1 :2.5, such as from 1 :1.8 to 1 :2.4, or 1 :1 .8 to 1 :2.3, even more preferably from 1 :1 .9 to 1 :2.3, for example 1 :1 .9 to 1 .2.2. For example, and advantageous weight ratio of the protein to the fat, preferably oil, in the solid oil-in-water emulsion is 1 :2.23.

[0060] The solid oil-in-water emulsion suitably has a hardness is in the range of from 0.37 N to 7.0 N, for example from 0.5 N to 5.0 N, such as from 0.95 N to 4.0 N, preferably from 0.95 N to 3.3 N, such as from about 1 .3 to 1 .8 N when measured at a temperature in the range of from 4 to 10°C.

[0061] The median particle size of the solid oil-in-water emulsion may be in the range of from 0.2 pm to 1 .2 pm, preferably from 0.2 pm to 0.5 pm.

[0062] The solid oil-in-water emulsion may be used as an animal fat replacement product.

[0063] In another aspect, the present invention provides a food product comprising the solid oil-in-water emulsion of the invention.

[0064] The food product may be a burger, sausage, chicken or fish product, suitably, the food product is a plant based: burger, sausage, chicken or fish alternative product, and hybrid plant and meat products e.g. a 50:50 plant based-meat based product, preferably, the food product is suitable for vegan consumption. For example, the food product may be a vegan burger or a vegan sausage. The food product may be a clean label product.

[0065] In another aspect, the present invention provides for use of the solid oil-in-water composition in the manufacture of a food product, such as a vegan food product. For example, use of the solid oil-in-water emulsion composition in the manufacture of a vegan burger or vegan sausage.

[0066] Advantageously, the solid oil-in-water emulsion composition and products disclosed herein, such as the solid oil-in-water emulsion composition and products of the method hereinbefore described may be cut, diced, chopped, cooked and/or packaged. The oil-in-water emulsion product is an excellent animal fat replacement product, and finds utility in the manufacture of vegan friendly food products, for example, vegan sausages and/or burgers. Further advantageously, the solid oil-in-water emulsion composition and products disclosed herein, such as the solid oil-in-water emulsion composition and products of the method hereinbefore described, can optionally have improved succulence.

[0067] Advantageously, the oil-in-water emulsion composition has an extended shelf life and remains stable and free of microbial contamination when stored under suitable conditions for at least 6 months. The product may be produced cost effectively and will have less environmental impact than comparative products.

Brief description of the drawings

Figure 1 is a flow diagram of a process as disclosed herein

Figure 2 show pea protein isolate in a powder hopper

Figure 3 shows a pea protein and water paste

Figure 4 shows the mixture of pea protein, water and oil.

Figure 5 shows the heated composition.

Figure 6 shows a non-homogenized composition

Figure 7a shows the mixture of protein, oil and water prior to heating.

Figure 7b shows the composition following heating/cooking.

Figure 7c shows the composition after homogenization, prior to cooling.

Figure 8 shows images of particles from samples before and after homogenization that were produced using different mixers.

Figure 9 shows a thermal analysis graph.

Figure 10 shows how oil-in-water emulsion compositions prepared using various homogenization pressures performed when fried.

Figure 11 shows moulds following removal of compositions made at different homogenization pressures therefrom. Figures 12 and 13 show the de-moulded solid oil-in-water emulsions prepared without homogenization and prepared at various homogenization pressures.

Figure 14 shows a block of the solid oil-in-water emulsion composition of the invention.

Figure 15 shows the composition formed following treatment with citric acid a - immediately after citric acid is added, b - before heating, c - 24 hours after cooling.

Figure 16 shows a grainy composition formed using low shear

Figure 17 shows burgers made using the solid oil-in-water emulsion of the invention and using comparative burgers.

Figure 18 and 19 show results of a sensory assessment regarding purchase intent and results of sensory assessment

Figure 20 shows sausages made with the solid oil-in-water emulsion of the invention and using comparative sausages.

Figure 21 shows the results of sensory assessment

DETAILED DESCRIPTION

[0068] Before the present compositions, methods, and methodologies are described in more detail, it is to be understood that the disclosure is not limited to particular compositions, methods, and experimental conditions described, as such compositions, methods, and conditions may vary. It is also to be understood that the terminology used herein is for purposes of describing particular embodiments only, and is not intended to be limiting, since scope will be limited only in any appended claims.

[0069] As used in this specification and any appended claims, the singular forms "a", "an", and "the" include plural references unless the context clearly dictates otherwise. Thus, for example, references to "a plant protein" includes one or more plant proteins of the type described herein which will become apparent to those persons skilled in the art upon reading this disclosure and so forth.

[0070] Unless defined otherwise, 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 disclosure belongs. Any methods and materials similar or equivalent to those described herein may be used in the practice ortesting of the disclosure, as it will be understood that modifications and variations are encompassed within the spirit and scope of the instant disclosure.

[0071] Unless otherwise stated, each range disclosed herein will be understood to encompass and be a disclosure of each discrete point and all possible subranges within the range.

[0072] As used herein, "about," "approximately," "substantially," and "significantly" will be understood by a person of ordinary skill in the art and will vary in some extent depending on the context in which they are used. If there are uses of the term which are not clear to persons of ordinary skill in the art given the context in which it is used, "about" and "approximately" will mean plus or minus <10% of particular term, and "substantially" and "significantly" will mean plus or minus >10% of the particular term. "Comprising", "consisting essentially of and “consisting of have their customary meaning in the art.

[0073] The solid oil-in-water emulsion composition (i.e. fat mimetic, fat replacement, alternative fat product) of the present disclosure can be made with plant protein (e.g., pea protein), water, liquid oil (e.g., rapeseed oil) and may or may not contain additives, such as starches, flavourings, colourants, texturizers, solid particles, buffers, food preservation additives or hydrocolloids.

[0074] In some aspects, the plant protein may be referred to as an emulsifier or may have the function of an emulsifier in the fat mimetic.

[0075] In some aspects, the fat mimetic may contain no e-numbers, or stated differently, a label for the fat mimetic product will not list any e-numbers (meaning no such ingredient is included).

[0076] In some aspects, the fat mimetic may be obtained using a high sheer mixer and/or a high-speed mixer, and the resulting mixed product may then be further homogenized in a homogenizer.

[0077] In some aspects, the fat mimetic may be in the form of a gel or may be referred to herein as a gel.

[0078] In some aspects, a firmer gel (or simply a firmerfat mimetic product) may be obtained by, for example, increasing the homogenization pressure, which may be performed, for example, through a two stage or single stage homogenization.

[0079] In some aspects, the homogenization pressure may be, for example, more than 150 bar, such as, for example, a pressure in the range of 150-400bar. [0080] A representative process for manufacturing the solid oil-in-water emulsion or fat mimetic of the present invention is shown in Figure 1.

[0081] The solid oil-in-water emulsion may be used as source of lipids/fats for vegan or plant-based patties, and/or in hybrid plant-meat products. The solid oil-in-water emulsion of the invention may advantageously be employed as an animal fat replacement product, or a fat mimetic, or fat alternative product.

[0082] In one aspect the present invention provides a method for manufacturing a solid oil- in-water emulsion composition comprising the steps of:

(i) providing a composition comprising: protein, fat, and water, wherein: the protein is present in an amount of from 7 wt% to 22 wt%, optionally the protein is plant protein, the fat is present in an amount of from 7 wt% to 45 wt%, optionally, the fat is plant fat, and water, optionally, the water is present in an amount of from 45 wt% to 80 wt%, such as from 50 wt% to 78 wt%, preferably from 55 wt% to 65 wt% based on the total weight of the composition;

(ii) heating the composition of step (i) to a temperature in the range of from 60°C to 95°C to provide a heated composition,

(iii) homogenizing the heated composition of step (ii) at a homogenizing pressure of at least 50 bar, preferably at least 100 bar to provide a homogenized composition,

(iv) cooling the homogenized composition of step (iii) to provide the solid oil-in- water emulsion composition having a hardness of at least 0.37 N preferably, at least 0.95 N when measured at a temperature of from 4 to 10°C; suitably the solid-oil-in-water emulsion composition comprises protein in an amount of from 7 wt% to 22 wt%, fat in an amount of from 7 wt% to 45 wt%, and water.

[0083] Suitably, the protein may be present in an amount of from about 9 wt% to 15 wt%, preferably from 9.5 wt% to 13.5 wt%, more preferably from 10 wt% to 12 wt% based on the total weight of the composition. If too little protein is used the oil-in-water emulsion will not gel, and the product will not achieve sufficient hardness. If too much protein is used, the oil-in-water emulsion becomes very viscous, and homogenization can become challenging. In addition, particle size increases with increasing protein concentration. Furthermore, the greater the amount of protein the greater is the cost of production.

[0084] Suitably, the fat is present in an amount of from 20 wt% to 30 wt%, preferably from 22 wt% to 28 wt% based on the total weight of the composition. If too little fat is used, the resulting oil-in-water emulsion will not impart the desired unctuousness to food products, and the succulence of such products will be sub-optimal. If too much fat is used, the resulting composition will split i.e. it becomes more difficult to form a stable emulsion. An optimal fat content in the solid oil-in-water emulsion of the present invention is in the range of from 20 wt% to 30 wt%, preferably from 22 wt% to 28 wt%.

[0085] Preferably, the composition in step (i) has a protein content in the range of from about 9 wt% to 15 wt%, and a fat content in the range of from 20 wt% to 30 wt% based on the total weight of the composition.

[0086] Suitably, the composition in step (i) has a protein content in the range of from about 9 wt% to 15 wt%, and a fat content in the range of from 22 wt% to 28 wt% based on the total weight of the composition.

[0087] Suitably, the composition in step (i) has a protein content in the range of from about 9.5 wt % to 13.5 wt% and a fat content in the range of from 20 wt% to 30 wt% based on the total weigh of the composition.

[0088] Suitably, the composition in step (i) has a protein content in the range of from about 9.5 wt% to 13.5 wt% and a fat content in the range of from about 22 wt% to 28 wt% based on the total weigh of the composition.

[0089] Suitably, the weight ratio of the protein to the fat in the composition in step (i) is in the range of from 1 :0.7 to 1 :4.5, or 1 :0.8 to 1 :4, optionally, 1 :0.9 to 1 :3.6, for example 1 :1 to 1 :3.5, preferably from 1 :1 to 1 :3, such as 1 :1.2 to 1 :2.8, more preferably 1 :1.4 to 1 :2.6, such as from 1 :1 .5 to 1 :2.5, such as from 1 :1 .8 to 1 :2.4, or 1 :1 .8 to 1 :2.3, even more preferably from 1 :1 .9 to 1 :2.3, for example 1 :1 .9 to 1 .2.2. For example, an advantageous weight ratio of the protein to the fat, preferably oil, is 1 :2.23.

[0090] For example, the composition in step (i) may have a protein content in the range of from 9 wt% to 15 wt%, a fat content in the range of from 20 wt% to 30 wt% and a weight ratio of the protein to the fat in the composition may be in the range of from 1 :1 .8 to 1 :2.4.

[0091] Suitably, the heating step (ii) is an antimicrobial treatment step, which also aids gelification of the protein and emulsification of the composition. [0092] Suitably, the homogenizing step is carried out at a homogenizing pressure in the range of from 100 bar to 400 bar, such as from 200 bar to 300 bar. This advantageously aids firmness i.e. increases hardness in the solid oil-in-water emulsion, and reduces particle size, making dispersion of the product in the manufacture of food products faster. This is a significant advantage over coconut fat.

[0093] As outlined above, the protein may be obtained from pea, rice, fava bean, nuts, beans, whole grains, flax, oat, barley, quinoa, almond, walnut, chia, lentil, chickpeas, pumpkin seed, soybean, hemp seed, kidney bean, black bean, sunflower, including protein isolates sourced therefrom, and mixtures thereof. Suitably, the protein is pea protein and/or fava bean protein. Preferably, the protein is pea protein. Notably, when soy protein, fava bean protein or potato protein are used, homogenization is an optional step in the method of the invention.

[0094] Preferably, the fat is an oil. Suitably, the fat is obtained from palm, rapeseed, soy, coconut, canola, sunflower, olives, shea nut, almond, peanut, sunflower, hazelnut, brazil nut, pecan, walnut, avocado, pomegranate, sesame, grapeseed, safflower, rice bran, corn, peanut, cottonseed, linseed, sesame, hemp, flaxseed, cocoa butter, agai palm, or combinations thereof. Suitably, the fat is rapeseed oil and/or canola oil.

[0095] The solid oil-in-water emulsion composition has a hardness of at least 0.37 N, suitably a hardness in the range of from 0.95 N to 3.3N, such as from 1 .3 N to 1 .8 N.

[0096] The solid oil-in-water emulsion preferably has a median particle size in the range of from 0.2 pm to 0.5 pm.

[0097] The solid oil-in-water emulsion may comprise additives known to the person skilled in the art. Optionally the solid oil-in-water emulsion comprises additives such as colourants, flavours, texturizers, starches, pH regulators or buffers, preservatives, food protection ingredients or solid particles. Further optionally the flavours are fat soluble and/or oil soluble. Further optionally the flavours are vegan. Further optionally the flavours are made up of taste modulation technology, optionally to enhance the succulence properties. Optionally, the flavours work in synergy with the oil-in-water emulsion. Optionally, the flavours increase the succulence of the end product. Optionally, the solid oil-in-water emulsion may include a flavour to aid the delivery of fat properties in the final application. Optionally, the flavour may be an oil soluble flavour which is made up of taste modulation technology to enhance the succulence properties; optionally this may be a fat based vegan flavour to help mimic animal fat taste delivery; optionally it works in synergy with the emulsion.

[0098] Suitably, the solid oil-in-water emulsion composition comprises protein in an amount of from 7 wt% to 22 wt%, and fat in an amount of from 7 wt% to 45 wt% based on the total weight of the solid oil-in-water emulsion composition. [0099] An optimal protein content in the solid oil-in-water emulsion composition is in the range of from 9 wt% to 15 wt%, and a particularly preferred protein content is in the range of from 9.5 wt% to 13.5 wt%, such as from 10 wt% to 12 wt% based on the total weight of the solid oil-in- water emulsion composition.

[00100] An optimal fat content in the solid oil-in-water emulsion composition of the present invention is in the range of from 20 wt% to 30 wt%, preferably from 22 wt% to 28 wt% based on the total weight of the solid oil-in-water emulsion composition.

[00101] An optimal water content in the solid oil-in-water emulsion composition is 55 wt% to 70 wt%, preferably 60 wt% to 68 wt%, such as 60 to 66 wt% based on the total weight of the solid oil-in-water emulsion composition.

[00102] Suitably, the solid oil-in-water emulsion composition has a density in the range of from 0.8 g/cm ³ to 1 .1 g/cm ³ , preferably from 0.9 g/cm ³ to 1 .05 g/cm ³ , for example from 0.95 g/cm ³ to 1 .03 g/cm ³ , when measured at room temperature.

[00103] A particularly preferred aspect of the present invention provides a method for manufacturing a solid oil-in-water emulsion composition comprising the steps of:

(i) providing a composition comprising: protein, fat, and water, wherein: the protein is present in an amount of from 9.5 wt% to 13.5 wt%, wherein the protein comprises pea protein, the fat is present in an amount of from 22 wt% to 28 wt%, wherein the fat comprises rapeseed oil, and water, optionally, the water is present in an amount of from 55 wt% to 65 wt% based on the total weight of the composition;

(ii) heating the composition of step (i) to a temperature in the range of from 60°C to 95°C to provide a heated composition,

(iii) homogenizing the heated composition of step (ii) at a homogenizing pressure of at least 200 bar, to provide a homogenized composition,

(iv) cooling the homogenized composition of step (iii) to provide the solid oil-in- water emulsion composition having a hardness of 0.95 N to 3.3 N when measured at a temperature of from 4 to 10°C; wherein the solid-oil-in-water emulsion composition comprises protein in an amount of from 9.5 wt% to 13.5 wt%, fat in an amount of from 22 wt% to 28 wt%, and water.

[00104] In another aspect, the present invention provides a method for manufacturing a solid oil-in-water emulsion composition comprising the steps of:

(i) providing a composition comprising: protein, fat, and water, wherein the weight ratio of the protein to the fat, preferably oil, is in the range of from 1 :0.7 to 1 :4.5, or 1 :0.8 to 1 :4, optionally, 1 :0.9 to 1 :3.6, for example 1 :1 to 1 :3.5, preferably from 1 :1 to 1 :3, such as 1 :1.2 to 1 :2.8, more preferably 1 :1.4 to 1 :2.6, such as from 1 :1 .5 to 1 :2.5, such as from 1 :1 .8 to 1 :2.4, or 1 :1 .8 to 1 :2.3, even more preferably from 1 :1 .9 to 1 :2.3, for example 1 :1 .9 to 1 :2.2; advantageously about 1 :2.23;

(ii) heating the composition of step (i) to a temperature in the range of from 60°C to 95°C to provide a heated composition,

(iii) homogenizing the heated composition of step (ii) at a homogenizing pressure of at least 50 bar, preferably at least 100 bar to provide a homogenized composition,

(iv) cooling the homogenized composition of step (iii) to provide the solid oil-in- water emulsion composition having a hardness of at least 0.37 N preferably, at least 0.95 N when measured at a temperature of from 4 to 10°C, wherein the solid oil-in-water emulsion composition comprises protein in an amount of from 7 wt% to 22 wt%, optionally the protein is plant protein, the fat is present in an amount of from 7 wt% to 45 wt%, optionally, the fat is plant fat, and water, optionally, the water is present in an amount of from 45 wt% to 80 wt%, optionally 50 to 78 wt% such as from 55 wt% to 70 wt%, preferably 60 wt% to 68 wt%, such as 60 to 66 wt% based on the total weight of the solid oil-in-water emulsion composition.

[00105] In a preferred aspect, the present invention provides a method for manufacturing a solid oil-in-water emulsion composition comprising the steps of:

(i) providing a composition comprising: protein, fat, and water, wherein the weight ratio of the protein to the fat, preferably oil, is in the range of from 1 :1 .9 to 1 :2.3, for example about 1 :2.23;

(ii) heating the composition of step (i) to a temperature in the range of from 60°C to 95°C to provide a heated composition, (iii) homogenizing the heated composition of step (ii) at a homogenizing pressure of at least 200 bar to provide a homogenized composition,

(iv) cooling the homogenized composition of step (iii) to provide the solid oil-in- water emulsion composition having a hardness in the range of from 0.95 N to 3.3 N, such as from 1 .2 to 2.5 N when measured at a temperature of from 4 to 10°C, wherein the solid oil-in-water emulsion composition comprises protein in an amount of from 9.5 wt% to 13.5 wt%, fat in an amount of from 22 wt% to 28 wt%, and water, preferably in an amount of from 60 to 66 wt% based on the total weight of the solid oil-in-water emulsion composition, wherein the protein preferably comprises pea protein, and the fat preferably comprises rapeseed oil; wherein further optionally, the solid oil-in-water emulsion composition comprises additives such as flavours, colourants, texturizers, starches, pH regulators or buffers, preservatives, food protection ingredients or solid particles.

[00106] Advantageously, the solid oil-in-water emulsion composition (i.e. fat mimetic) of the present disclosure does not require a dough conditioner. Thus, a dough conditioner may not be included in the emulsion composition of the present invention.

[00107] In some aspects, the solid oil-in-water emulsion composition (i.e. fat mimetic) of the present disclosure does not require the presence a heme-containing protein. Thus, a hemecontaining protein may not be included in the emulsion composition of the present invention.

[00108] In some aspects, the solid oil-in-water emulsion composition (i.e. fat mimetic) of the present disclosure does not require the presence or use of ribose. Thus, ribose may not be included in the emulsion composition of the present invention.

[00109] In the following, although embodiments of the present disclosure are described in further detail by means of Examples, the present disclosure is not limited thereto.

[00110] The following section outlines recipe variations. The first recipe is ideal, there is a bench, pilot, and plant example included with this recipe. Along with further details analysis including but not limited to product visuals through processing, varying homogenization pressures with texture profile analysis (TPA), particle size, melting profile (Differential Scanning Calorimetry), pH, moisture, shelf life, and de-mouldability. Recipes 1-3 all produced what is considered to be an acceptable product. Recipes 4-6 produced products not considered to be optimal.

[00111] Texture profile analysis (TPA) can be used to objectively measure properties of food products, and indeed of the solid oil-in-water emulsion composition of the invention. Hardness is a measure of resistance to localized plastic deformation induced by mechanical indentation. Hardness may be measured using a texture profile analyser.

[00112] Herein, hardness was measured with a Stable Micro System TAXT-plus Texture Analyser, using a Stable Micro System Load cell, and a Stable Micro System Probe P/0.5R. A weight was used to calibrate the load cell.

To measure hardness using the texture analyser:

• the probe (P/0.5R) was attached to the analyser;

• the height (position) of the probe and load cell were calibrated

• a software method is selected which captures hardness

• the parameters forthe analyser are set- e.g. how fast the arm of the analyser is to move, how far into the product the probe needs to go.

• The following parameters were chosen:

• The sample is placed under the probe and the texture unit is set to run

• Each sample is read 3 times, rotating the sample each time to a fresh area for indentation

• The hardness is determined from the maximum peak force during the compression run (average of three runs).

[00113] Hardness - is defined as the maximum peak force during the compression run and has often been substituted by the term firmness. Units are kilograms (Kg), grams (g) or Newtons (N). Grams may be converted to Newtons by multiplying the gram amount by the acceleration due to gravity i.e. 0.009806652 ms ^-2 . [00114] Examples

Recipe 1 - optimal recipe - bench, pilot, and plant example

Recipe 2 - Recipe with starch

Recipe 3 - Scanima processing [00115] Comparative examples

Recipe 4 - High moisture content

Recipe 5 - Low pH (1 % citric acid)

Recipe 6 - Low sheer processing (blendtech)

[00116] Example recipe 1 :

[00117] Plant/Factory scale method

[00118] Room temperature water was added to a high-speed Stephan cooker (Stephan TG400, 400L, https://www.machineryworld.com/product/stephan-combicut-tc-4 00-compact- processing-vessel/). [00119] Pea protein isolate (>80% protein content) was added through a powder hopper (see

Figure 2) and the protein-water mixture was mixed at speed 2 (high speed cutting action) for about 2 mins at about 1500RPM. A lump-free brown paste was formed. [00120] Rapeseed oil (e.g., Refined rapeseed oil Kosher, Kerfoot Avril Group, Country of Origin Belgium, water activity (Aw) of about 0-0.3) was added and mixing at speed 2 (high speed cutting action) was continued for about 2 minutes until a whitish stiff paste/gel was formed. Other seed oils can be used, such as, e.g., sunflower, soya, etc., and other examples are named herein.

[00121] The temperature of the blend was taken using a temperature probe. The temperature was about 28°C.

[00122] The mixture was heated to about 82°C using direct steam and mixing at speed 2 (for about 5 mins).

[00123] The mixture was transferred to a holding hopper, and then to a warmed homogenizer (e.g., APV Gaulin homogenizer, http://gaulinhomogenizer.com/)

[00124] The heated mixture was subsequently homogenized at about 250 bar, ideally, in some aspects, in a range of about 200 to about 300 bar. The firmness of the product increases with higher pressure. There is a significant difference in hardness/gel strength between homogenized and non-homogenized product (see below for results showing difference in hardness vs homogenization pressure).

[00125] The homogenized composition can be transferred to a mould, or package, for example by hot filling using filling pump, scales, sealer, printer & metal detection. A filling temperature over about 75°C is preferable.

[00126] The product may be packed into 9-11 kg bag in box, such as, for example, Blue liner in a carboard box - L210xW97xH508 supplied by SAICA Pack Ireland.

[00127] Boxes can be racked and stored in the cold stores. It may take, for example, a period of about 18 hours for the temperature of the boxed product to drop from about 75°C to about 8°C, furthermore it may take, for example, an additional about 8 hours for the temperature to fall to about 3°C. Temperatures were monitored on 3 different samples using temperature data logger TG-4080 % TV-4020 (https://www.geminidataloggers.com/data-loggers/tinytag-view -2/tv-4020).

[00128] The solid oil-in-water emulsion product may then be stored and refrigerated.

[00129] Lab scale production using Thermomixer

[00130] Room temperature water was added to a high-speed cooker e.g. Vorwerk Thermomixer https://www.vorwerk.co.uk/shop/.

[00131] Pea protein (about >80% protein content) was added and the protein-water mixture was mixed at speed 6 (high speed cutting action) for about 3 mins until a lump-free brown paste formed - see Figure 3).

[00132] Rapeseed oil (Refined rapeseed oil Kosher, Kerfoot Avril Group, Country of Origin Belgium, Aw about 0-0.3) was added and mixing was continued at speed 6 (high speed cutting action) for about 3 minutes until a whitish stiff paste/gel formed - see Figure 4). Other seed oils can be used.

[00133] The edges of the machine were scraped down.

[00134] Natural flavours were added with mixing at speed 6, for 3 mins.

[00135] The temperature of the blend was taken using a temperature probe (approx. 28°C).

[00136] The mixture was heated to about 82°C and mixing was continued at speed 6 (about 7 mins) using indirect heat - as the heating element is at the bottom of the thermomixer care should be taken to ensure a vortex is maintained to keep product moving and heating equally. Figure 5 shows the heated composition.

[00137] The product was allowed to cool overnight.

[00138] During the cooling process, the product formed a paste rather than a gel (See Figure 6).

[00139] Method at pilot stage [00140] Room temperature water was added to a high-speed cooker (e.g., Stephan 25L, UMSK 24E, 25L capacity).

[00141] Pea protein isolate (>80% protein content - 86% protein content) was added and the resulting combination was mixed at speed 2 (about 1500rpm -high-speed cutting action with scraping) for about 2 mins, until a brown paste with no lumps formed. Note, the machine range for mixing is low to high i.e. about 750 rpm = speed 1 , and about 3000 rpm = speed 3.

[00142] Rapeseed oil (Refined rapeseed oil Kosher, Kerfoot Avril Group, Country of Origin Belgium, Aw about 0-0.3) was added to the mixture of protein and water, and mixing was continued at speed 2 (high speed cutting action) for about 2 minutes until a whitish stiff paste/gel was formed. Other seed oils can be used.

[00143] The edges of the machine were simultaneously scraped down.

[00144] The temperature of the blend (i.e. a composition comprising protein, oil and water) was taken using a temperature probe and determined to be approx. 28°C. Figure 7a shows the mixture of protein, oil and water prior to heating.

[00145] The mixture of protein, oil and water was heated to 82°C using direct steam and mixing at speed 2 (about 5 mins) at about 2 bar steam pressure. This provides a heated composition. Figure 7b shows the composition following heating/cooking.

[00146] The heated composition was transferred to a homogenizer, and homogenized at about 250 bar, ideally for example in a range of about 200 to about 300 bar. The firmness of the product increases with increasing homogenization pressure. There is a significant difference in firmness/hardness/gel strength between homogenized and non-homogenized product. Figure 7c shows the composition after homogenization, prior to cooling.

[00147] The homogenized product was hot filled into a mould/container/packaging, which was then bagged and refrigerated.

[00148] Properties of the composition prior to and after homogenization are illustrated in Table 4. [00149] Homogenization

[00150] To create a firmer gel, an increase in homogenization pressure can be used, and this can be performed through two stages or in a single stage homogenization.

[00151] Ideally more than 150bar pressure is used for homogenization. There is a direct correlation between increase in homogenization pressure and increase in hardness (TPA). Hardness can for example be measured in grams or Newtons.

[00152] Homogenization creates a firmer gel which aids mouldability and use in factories.

[00153] Homogenization also reduces the particle size.

[00154] Below is an example of the direct correlation between increase homogenization pressure and increase in hardness (g). Hardness was assessed using the Stable Micro Systems TA.XT plusC (https://www.masontechnoloqy.ie/products/laboratory/texture- analyser/ta-xtplusc/).

[00155] Particle Size

[00156] Particle size may be assessed using a Beckmann coulter LS 13 320. The sample is prepared using 0.5g of product with 100ml of water and 1g of washing up liquid solution. This is mixed using an overhead silverson high speed for 10 seconds, and the resulting mixture is analysed using the Beckmann Coulter machine at using the following settings: Optical model: 1.46-0.1. rf780d PIDS included, Fluid R.I.: 1.332, Sample R.I.: 1.46 i0.1 , LS 13 320 Aqueous Liquid Module, Pump speed: 50, Fluid: water. Particle size is reported as the median particle size. [00157] Particle size measured under microscope at 400 x magnification (using the oil-in- water emulsion composition that was produced at pilot scale in a 10kg batch using the method listed above (recipe 1 pilot) and analysed 2 days after. An Olympus microscope was employed to assess particle size.

[00158] Figure 8 shows images of particles from samples before and after homogenization that were produced using different mixers. It is clear from the images of the homogenized samples, that the particle size is much smaller and more uniform after homogenization.

[00159] Differential Scanning Calorimetry (DSC)

[00160] To assess the thermal stability of the solid oil-in-water emulsion of the invention, differential scanning calorimetry (DSC) was carried out on the product. Differential scanning calorimetry (DSC) is a thermal analysis technique which measures the temperature and heat flow associated with transitions in materials as a function of temperature and time. This figure illustrates the change in state measured through the heat cycle. Figure 9 shows the coconut oil melts optimally at 22.9C. The red line indicates the full profile in which coconut oil is changing state. There is no significant change of state in the oil in water emulsion of the present invention.

[00161] The thermal analysis graph in Figure 9 shows the thermal stability of the solid oil-in- water emulsion composition in the temperature range of cooking and consumption of a typical plant based cooked product (about 40-80°C). The graph shows that the solid oil-in-water emulsion of the present invention has consistent heat flow and therefore did not change physical state in this temperature range.

[00162] Figure 10 shows how oil-in-water emulsion compositions prepared using various homogenization pressures performed when fried. Higher homogenisation pressure produces stronger gel emulsion, which has greater shape retention under thermal stress. The oil-in-water emulsion produced without homogenization performed poorly - as evidenced by the disintegration during and loss in height of the sample. Samples produced with higher homogenization pressures were more stable, and a lesser decrease in height was observed when the samples were fried.

[00163] De-mouldability

[00164] The solid oil-in-water emulsion of the present invention is process friendly because, for example, the product can be manufactured by hot filling the homogenized product into a mould which is then refrigerated (optionally including further packaging steps). The solid oil-in-water emulsion may be readily removed from moulds by the consumer. The solid oil-in-water emulsion can be used directly unlike coconut fat which requires further processing when used at low temperature. [00165] The de-mouldability of the product is enhanced, for example, through an increased homogenization pressure. This is illustrated in Figures 11 to 13.

[00166] The solid oil-in-water emulsion of the present invention was easiest to remove from a mould when produced using higher homogenization pressure. This is evident when the moulds from which the product has been removed are examined as shown in Figure 11 . In the mould where an oil-in-water emulsion composition which was produced without the homogenization step is examined, a significant amount of the emulsion clings to the walls of the mould. In comparison, solid oil-in-water emulsions produced according to the invention (samples produced using a homogenization step at 100 bar, 200 bar or 300 bar), could be more readily and efficiently demoulded. Figures 12 and 13 show the de-moulded solid oil-in-water emulsions prepared without homogenization and prepared at various homogenization pressures.

[00167] Shelf Life

[00168] The following results in Table 6a, 6b show shelf life of the Recipe 1 plant trial completed in a factory following the protocol listed above. The solid oil-in-water emulsion was acceptable up to at least 70 days after manufacture, and up to 6 months after manufacture.

SUBSTITUTE SHEET (RULE 26)

SUBSTITUTE SHEET (RULE 26) [00169] Example recipe 2 (Add starch)

[00170] Room temperature water was added to a high-speed cooker, e.g., Stephan.

[00171] Pea protein was added and the resulting combination was mix at speed 2 (high speed cutting action) for about 2 mins until a lump-free brown paste formed.

[00172] Rapeseed oil was added and mixing was continued at speed 2 (high speed cutting action) for about 2 minutes until a whitish stiff paste/gel formed.

[00173] The edges of the machine mixing bowl were scraped down.

[00174] The temperature of the mixture/blend was taken using a temperature probe (approx. 28°C).

[00175] The mixture was heated to about 82°C using direct steam and mixing at speed 2 (this should take approx. 5 mins) at approx. 1 bar steam pressure.

[00176] The heated composition/mixture was transferred to a warmed homogenizer.

[00177] The composition was homogenized at over 150 bar, such as in a range of about 200 to about 300 bar. The product will get firmer the higher bar. There is a significant difference in hardness/gel strength between homogenised and non homogenized product. [00178] The homogenized product was hot filled into a mould and refrigerated.

[00179] Example recipe 3 - High sheer Scanima

[00180] Examples of natural flavouring include commercially available top note flavour and fermentates.

[00181] Add room temperature water to a high-speed cooker, e.g., a Scanima Model No. SRB-100, Serial No. 90395, 100L.

[00182] Add pea protein and mix at speed 80% sheer with 40% scraper, slator up for about 4 mins (this should form a brown paste with no lumps). [00183] Add oil and mix at speed 80% sheer with 40% scraper, slator up for 4 mins (this should form a whitish stiff paste/gel).

[00184] Heat the mixture to about 82°C using direct steam at speed 80% sheer with 40% scraper, slator up (this should take approx. 5 mins) at approx. 1 bar steam pressure.

[00185] Transfer the mixture to a warmed homogenizer. [00186] Homogenize over 250 bar, such as between about 200 to about 300 bar. The product will get firmer the higher bar pressure. There is a significant difference in hardness/gel strength between homogenised and non homogenized product.

[00187] Hot fill and refrigerate. [00188] Next day evaluation - the product had gelled but was soft, and had come away from sides of the mould. [00189] Comparative Examples

[00190] Example recipe 4

[00191] If the composition used to form the oil-in-water emulsion has a high moisture content, for example about 70% moisture, it was found that homogenization will not be affective in increasing the hardness of the product, without increasing the protein to oil ratio - i.e. by increasing the amount of protein and decreasing the amount of oil.

[00192] Having a firmer product/gel structure is important for de-moulding the product effectively. This also can reduce left over residue in the base, therefore reducing food waste.

[00193] If the protein to oil ratio is increased, the firmness of the product can be improved, such that homogenization increases the hardness of the product.

[00194] Example Recipe 5 (low pH - pH 4.84) [00195] The composition of Table 12 was processed in the same manner as recipe 1 in a thermomixer.

[00196] Water is added including the condensate as indirect jacket using to cook the product in a thermomixer.

[00197] Speed 6 used, created smooth, viscous paste. [00198] - Add room temperature water to a high-speed cooker e.g. Vorwerk Thermomixer https://www. vorwerk. co. uk/shop/ (https ://www . vo rwe rk. co . u k/s h o p/) .

[00199] - Add pea protein isolate (>80% protein content - 86%) and mix at speed 6 (high speed cutting action ) for about 3 mins (this should form a brown paste with no lumps) [00200] - Add rapeseed oil (Refined rapeseed oil Kosher, Kerfoot Avril Group, Country of

Origin Belgium, Aw about 0-0.3) and mix at speed 6 (high speed cutting action) for about 3 minutes (this should form a whitish stiff paste/gel) Other seed oils can be used.

[00206] The product was assessed the next day (after refrigeration overnight). The product was liquid, watery and grainy. The product did not form a gel.

[00207] Suitably, the pH of the composition used to form the solid oil-in-water emulsion has a pH in the range of from about 6 to 8.5, preferably from 7 to 8.

[00208] Example Recipe 6 - low shear processing

[00209] Low sheer processing, e.g., blendtech (Blendtech - Model No. CC-0025, Serial No. 2100104), creates an unhomogenised mix that is liquid with lumps of pea protein. High speed/sheer was required to create a stable emulsion without lumps. [00210] - Add 2/3 of room temperature water to the blendtech cooker at 25RPM (twin screw solid aughers, 25L capacity)

[00211] - Slowly add pea - took 12min 36 secs (6 secs on, 3 off) = viscous paste minimal lumps, stuck to augers.

[00212] - Mix about 1 min 10 secs. [00213] - Add remainder of the water at room temp (took 1 min 16 secs)

[00214] - Mix about 5 mins to hydrate pea protein and remove lumps.

[00215] - Add rapeseed oil (about 1 min 12 secs) - oiled out separated

[00216] - Mix at 60RPM - after 40 secs mixed into suspension [00217] - Cook at about 82°C using direct steam - Thin, some lumps of pea still throughout product.

[00218] Next day product did not gel/set up, the product was liquid with some pea lumps, see

Figure 16.

[00219] Based on the results of the experimentation, in some aspects of the present disclosure a pH in a range of approx. 6.5-7.5 is beneficial for creating a stable solid oil-in-water emulsion that gels. [00220] Based on the results of the experimentation, in some aspects of the present disclosure, homogenization, ideally between about 200 to 300 bar, is beneficial to create a gel that can be suitably handled and processed.

[00221] Based on the results of the experimentation, in some aspects of the present disclosure, it is beneficial for the product to be cooled, and maintained at a temperature in the range of from -5°C to 5°C for 24 hours before using.

[00222] Example 7

[00223] The following recipes were used to prepare oil-in-water emulsions. The amount of oil is varied in the compositions.

[00224] Example 8

[00225] A particularly preferred solid oil-in-water composition is described in the below table: [00226] Homogenization of the above composition at 250 bar resulted in a product having particularly desirable properties as shown below:

[00227] Advantageously, the solid oil-in-water emulsion product is cream/off-white in colour making it particularly suitable as an animal fat replacement product.

[00228] As is evident from the data presented in Table 16, when the amount of fat (e.g. oil) is in the range of from about 7 wt% to about 45 wt%, optionally from about 10 wt% to about 40 wt%, solid oil-in-water emulsions according to the invention may be formed. A smaller particle size and more homogenous solid oil-in-water emulsion was achieved when the amount of oil is in the range of from 15 wt% to 35 wt%. As is evident from sample 1x, the optimal amount of fat, preferably oil, is in the range of from 20 wt% to 30 wt%, preferably in the range of from 22 wt% to 28 wt% based on the total weight of the composition.

[00229] In Table 17, the level of protein was varied.

[00230] As is evident from the data presented in Table 17, when the amount of protein is in the range of from about 7 wt% to about 22 wt%, optionally from about 10 wt% to about 20 wt%, solid oil-in-water emulsions according to the invention may be formed. A smaller particle size and more homogenous solid oil-in-water emulsion was achieved, when the amount of protein is in the range of from 9 wt% to 15 wt%. As is evident from sample 1x, the optimal amount of protein is in the range of from 9 wt% to 15 wt%, preferably in the range of from 9.5 wt% to 13.5 wt%, such as from 10 wt% to 12 wt% based on the total weight of the composition.

[00231] In preferred embodiments, the amount of fat, preferably oil, is in the range of from 20 wt% to 30 wt%, and the amount of protein is in the range of from 10 wt% to 15 wt% based on the total weight of the composition. For example, the amount of fat, preferably oil, may be in the range of from 22 wt % to 28 wt%, and the amount of protein may be present in an amount of from 9.5 wt% to 13.5 wt%.

[00232] As outlined above, the solid oil-in-water emulsion composition has a hardness of at least 0.37 N (37.7 g), preferably, at least about 0.95 N (96.9 g) when measured at a temperature of from 4 to 10°C. For example, the solid oil-in-water emulsion composition may have a hardness in the range of from from 0.37 N to 7.0 N, for example from 0.5 N to 5.0 N, such as from 0.95 N to 4.0 N, preferably from 0.95 N to 3.3 N, such as from about 1.1 to 2.5 N, for example from 1 .3 to 1 .8 N.

[00233] As outlined above, the solid oil-in-water emulsion composition may be used as an animal fat replacement product, and may for example be used in the manufacture of a food product, preferably a food product suitable for vegan consumption and hybrid plant-based-meat- based products.

[00234] The solid oil-in-water emulsion composition may be used to form a food product such as a burger, sausage or fish product, suitably, wherein the food product is a plant based burger, sausage or fish alternative product, preferably, wherein the food product is suitable for vegan consumption.

[00235] In some aspects, the present disclosure provides an animal fat replacement product or a fat mimetic product (i.e. the solid oil-in-water emulsion composition or product) that may be vegan and clean label. The ingredients may be free from dairy, e-numbers, palm oil, and/or hydrogenated oils. Suitably, the emulsion compositions disclosed herein are free from animal derived ingredients/components, and are suitable for use in the manufacture of vegan products, such as vegan food products. [00236] The solid oil-in-water emulsion product disclosed herein can be used as a direct replacement for coconut fat. This can be used without grinding, unlike coconut fat, therefore removing a current processing step for some manufacturing process, e.g. plant based burgers/ sausages.

[00237] The unique characteristics deliver similar attributes in term of succulence, as coconut fat, with significant nutritional benefits. For example, in some embodiments the solid oil-in-water emulsion composition (i.e. the fat mimetic) of the present disclosure can provide approx. 75% reduction in fat and 90% reduction in saturated fat. In some aspects, the fat mimetic may additionally enhance the savoury profile of the products.

[00238] The present disclosure can fill a gap in the market to replace coconut fat with a clean label alternative that is nutritionally optimised. The fat mimetic can be easy to pack and use and incorporated well into vegan meat alternative. Cooking losses can also be controlled, and eating sensory properties are such that succulence is added.

[00239] Example 9 - Vegan Burger

(A) Add the iced water to the textured vegetable proteins (TVP) in a Kenwood bowl. Place the mix in a chiller for at least 20 minutes to allow the TVP to hydrate. After 20 minutes, record the temperature of the mix, if not below 2 degrees place the mix in blast chiller until it is below 2 degrees *lced water is used as the Methyl Cellulose solubilizes best at cold temperature. (B) Add the binder, flavour and colourants and liquid flavours to the bowl. Mix at speed one in the Kenwood mixer for 90 seconds, stop and scrape down the sides of the bowl after every 30 seconds.

(C) Add the grated Coconut Fat (The coconut fat should be grated down to 3 mm) or fat replacer system (i.e. solid oil-in-water emulsion disclosed herein) and the Vegetable oil to the bowl. Mix for 60 seconds at speed 1 . Scrape down the sides Every 30 seconds.

(D) Add the rusk, mix for 60 seconds or until all ingredients have been dispersed. Form into 100 g burgers.

(E) Refrigerate for 1 day before cooking to allow flavour profile to develop fully.

[00240] Figure 17 shows samples of the vegan burgers made using either coconut oil or with the solid oil-in-water emulsion of the present invention.

[00241] Sensory Results

[00242] Nine (9) blind sensory panels were carried out. Each time the vegan burger prepared with the solid oil-in-water emulsion composition of the invention was preferred over the vegan burger prepared with coconut.

[00243] Sensory panel carried out blind using 3-digit codes e.g. 489 & 264.

[00244] Instruction given - “Please rate each attribute from 1 (dislike) to 5 (like)”

Succulence 1 (least succulent)

Bite/Texture 1 (softest)

Flavour 1 (least preferred taste)’

[00245] An example of the sensory panel results is shown in Tables 20a and 21 :

RECTIFIED SHEET (RULE 91 ) ISA/EP

[00246] Internal guidance testing with 50 participants

[00247] An internal guidance assessment was carried out with 50 Kerry employees. The assessment took place at the Sensory Booths at Kerry’s Innovation Centre in Naas on 22 June 2022. The assessment was carried out in confidence. The participants in the assessment completed a self-directed questionnaire which asked questions relating to the samples:

• Liking in terms of the overall product via a 10-point hedonic scale (dislike extremely to like extremely • Intensity scores in terms of specific attributes via a line scale (none to very)

• Preference

[00248] Samples

[00249] Samples were supplied by the innovation team and stored in ambient conditions till the testing session. Just before testing the products were pan fried for 15 minutes on medium heat. Samples were served hot in Styrofoam cups. Samples were labelled with 3-digit blinding codes and were presented to panellists in a randomised balanced order.

[00250] Data Analysis

[00251] Paired sample t-test was utilised to analyse the data (EyeQuestion).

[00252] Limitations [00253] As this study was carried out in-house and with a small sample size (n=50), findings should be used for research guidance only. Figure 18 provides an indication of purchase intent by panellists following the assessment. Figure 19 provides an indication of how trial samples i.e. vegan burgers manufactured with the solid oil-in-water emulsion of the invention, in comparison to vegan burgers manufactured with the same quantity of coconut oil instead of the solid oil-in- water emulsion of the invention. Advantageously, no significant difference was observed in the liking of appearance, aroma or flavour of the trial burgers versus the control burgers.

[00254] Table 22 - Nutritional information comparison between trial burgers versus control burgers

[00255] As is evident from the above data, the trial burger contained considerably less fat, when a 1 :1 weight equivalent of the solid oil-in-water emulsion was employed to replace coconut oil in the manufacture of the vegan burger.

[00256] The solid oil-in-water emulsion composition may be for example be employed to manufacture a food product having a fat content that is up to 75% less than a comparable food product manufactured using coconut oil.

[00257] Example 10 - Vegan burger

Nutritional Information [00258] In example 11 , the trial burger that was manufactured using the solid oil-in-water emulsion composition of the present invention had 52.5% less fat, 91% less saturated fat and 24% less calories than the control burger that was manufactured using coconut oil.

[00259] Exam pie 12 - Vegan Sausages

[00260] Method for manufacture of vegan sausages

[00261] A. Add the water to the TVP in a Kenwood bowl. Place the mix in a chiller for at least 20 minutes to allow the TVP to hydrate [00262] B. Add the Taste System, the Functional Binder and the liquid Roast Flavour to the bowl containing the hydrated TVP.

[00263] Mix at speed one in the Kenwood for 90 seconds, stop and scrape down the sides of the bowl after every 30 seconds.

[00264] C. Add the fried off onions and the IQF (individually quick frozen) parsley to the bowl. Add the solid oil-in-water emulsion composition of the invention or the grated coconut fat and the vegetable oil to the bowl.

[00265] Mix for 60 seconds at speed 1 . Scrape down the sides every 30 seconds.

[00266] D. Add the Rusk and Inulin to the mix.

[00267] Mix for 60 seconds or until all ingredients have been dispersed. Place mix in chiller for at least 2 hours before filling into sausage casing.

[00268] Fill into sausage casing and chill or freeze.

Nutrition

[00269] In example 12, the trial sausage that was manufactured using the solid oil-in-water emulsion composition of the present invention had 46% less fat, 92% less saturated fat and 21 % less calories than the control sausage that was manufactured using coconut oil.

[00270] The trial and control sausages were assessed in the same manner as the vegan burger described above with a panel of 52 people (Kerry employees, in confidence). A blind sensory assessment was carried out using anonymous codes in controlled conditions. The trial sausages manufactured using the solid oil-in-water emulsion composition of the invention achieved comparable scores with the control sample in terms of overall liking, appearance, aroma, flavour and texture/mouthfeel.

[00271] The words “comprises/comprising” and the words “having/including” when used herein with reference to the present invention are used to specify the presence of stated features, integers, steps or components but do not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[00272] It is appreciated that certain features of the invention, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the invention which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable subcombination.