WO2024115686A1

WO2024115686A1 - Food product

Info

Publication number: WO2024115686A1
Application number: PCT/EP2023/083792
Authority: WO
Inventors: Ton KLOS
Original assignee: Meatless BV
Current assignee: Meatless BV
Priority date: 2022-11-30
Filing date: 2023-11-30
Publication date: 2024-06-06
Anticipated expiration: 2025-05-30
Also published as: EP4626249A1

Abstract

Disclosed is a method for preparing a food product comprising mycoprotein and a hydrocolloid, such as an alginate. The method comprises preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water; shaping the pre-mix to form a pre-mix shape; curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; and further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time. Also disclosed is a food product obtainable by the method.

Description

FOOD PRODUCT

FIELD OF THE INVENTION

The present invention relates to a method for preparing food products comprising mycoprotein in combination with hydrocolloids, and to a food product obtainable by the method.

BACKGROUND TO THE INVENTION

Consumers are increasingly leaning towards ways to reduce, eliminate or substitute products originating from livestock in their diets, thereby moving towards vegan products. Reasons for this may be religious, environmental concerns, animal welfare, personal health or simply as a matter of choice. Meat products specifically are facing a lot of scrutinies, as livestock rearing may have a negative environmental effect, such as greenhouse gas emissions, the use of water and (food) resources, and the effects of land clearing measures. The increasing demand for non-livestock-derived products has led to increased efforts of the food industry to come up with vegetarian or vegan substitutes.

The main challenge in developing such substitute products is to create a product with the desired sensory characteristics, such as appearance, texture, smell, taste and the like, while maintaining a healthy nutritional profile. To develop meat substitute products, based on other protein sources than animal proteins, mimicking the fibrous nature and texture of meat is especially challenging. Moreover, it is preferred that these meat substitute products do not contain preservatives, synthetic flavours, colourants, and the like, leading to so-called ‘clean label’ products.

NL1008364 discloses a method of producing an artificial meat product by preparing an emulsion of a non-animal protein, a plant-based thickening agent and water, and subsequently mixing the emulsion with a solution of a calcium salt or a magnesium salt to obtain a fibrous product, and finally removing water from the fibrous product.

WO 2016/120594 discloses an edible formulation comprising edible fungal particles of a filamentous fungus and calcium ions and a method of preparing said edible formulation. The edible fungal particles are provided as a mycoprotein paste. The mycoproteins in the known edible formulation may produce a fibrous structure, and when provided in an aqueous mixture, this fibrous structure may further develop during cooling or freezing.

WO 2022/171646 relates to a process for preparing a vegan edible product from edible non-animal proteins which comprises the following steps i to iii.:

(i) providing a malleable mass by mixing an edible protein component A, which is selected from the group consisting of edible vegetable protein materials, microbial protein materials and mixtures thereof; a water-soluble organic polymeric gelling agent which is capable of being gelled by calcium ions as a component B, which is a water-soluble polysaccharide bearing carboxyl groups or a water soluble salt thereof; optionally a water-swellable nonionic polysaccharide as a component C; and an edible fat or oil of plant origin as a component D; water;

(ii) comminuting the malleable mass into particles and

(iii) bringing the particles into contact with an aqueous solution of a calcium salt to achieve a hardening of the particle, where step (iii) is carried out simultaneously with step (ii) or after step (ii).

The known methods disclosed above do not provide food products having the optimal sensory characteristics needed for certain meat substitute products, such as pieces of chicken, beef chunks, and the like. A further disadvantage of the known methods is that preparing meat substitute products in a timeefficient and continuous way needs improvement. Also, meat substitute products produced by the known methods tend to have a rather disagreeable taste, and optimisation is required.

It is therefore an object of the present invention to at least partly overcome or improve one or more of the disadvantages of the prior art.

SUMMARY OF THE INVENTION

The present invention thereto provides a method for preparing a food product comprising mycoprotein, the method comprising the steps of: a) preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water; b) shaping the pre-mix to form a pre-mix shape; c) curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; d) forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; and e) further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time.

It was found that when a pre-mix shape, comprising a mycoprotein, a plant protein source, an alginate and water, is first contacted from the outside with an aqueous solution comprising calcium, i.e. prior to the formation of individual shapes a thin layer, or skin part, of cured pre-mix is quickly formed on the outside of the pre-mix shape to form a skin-cured pre-mix shape. This cured skin part can reduce or even prevent any sticking of the skin-cured pre-mix shape to processing equipment that is used in forming the individual shapes, allowing for a fast, clean and efficient shaping process.

It has also been found that the skin-cured pre-mix shape allows it to easily form individual shapes while substantially preserving the cured skin part. Substantially preserving the skin part means that the formed individual shapes also comprise a cured skin part, at least over a part of their surface area, such as at least 50%, preferably at least 75 wt.%, more preferably at least 80 wt.%, most preferably at least 90 wt.%, and up to 100 wt.% of their surface area. For instance, if the individual shapes are formed from the skin-cured pre-mix shape by cutting, the cured skin part may be disrupted at the cuts but will still be present over the remaining, uncut, surface area of the individual shapes.

According to the invention, the cured skin part of the skin-cured pre-mix shape and/or the skin-cured individual shapes envelops an uncured core part of the pre-mix shape and/or individual shapes. This is because the curing is effectuated by contacting the pre-mix shape from the outside with the first aqueous solution. In this process, the first aqueous solution may diffuse into the pre-mix shape from the outside towards the inside of the pre-mix shape over some distance. This distance may influence the thickness of the cured skin part.

The first contact time should be sufficiently long to obtain the cured skin part. This first contact time may depend somewhat on the desired thickness of the skin part, as will be further elucidated below.

According to step e) of the method of the invention, the individual shapes are cured further by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time, thereby providing the food product. The second contact should be sufficiently long to enable the further curing of the individual shapes. With the wording ‘further curing' is meant that the core parts of the individual shapes are allowed to also cure at least over part of their cross-sectional area, preferably over essentially all of their cross-sectional area. The second contact time may depend on the desired cure of the core part, as will be further elucidated below. It is not excluded that in the step e) of further curing, the skin part may be cured to a further extent than was obtained in step c). The invented method uses an alginate in the pre-mix. Alginates are the metal salts of alginic acid, a naturally occurring, edible polysaccharide found in for example brown algae. The foremost reason behind the use of hydrocolloids such as alginates in food products is their ability to modify the rheology of the food product. Alginates are typically used as thickening and gelling agents. Suitable alginates may for instance comprise sodium and potassium alginates, without being limited thereto. Alginate may be obtained in filamentous, granular, or powdered form. According to the invention, the pre-mix containing the alginate is contacted with an aqueous solution that comprises calcium, such as a calcium salt solution. The alginate polymer chains are then linked by the calcium ions, leading to gelation. This linking process is referred to as ‘curing’ or ‘further curing’ in the present application.

To obtain the desired sensory characteristics of the food product, the individual shapes are further cured or ‘ripened’ in step e) of the process. In contrast to the quick formation of the cured skin part of the pre-mix shape, curing or ‘ripening’ the individual shapes may take longer. It has been found that further curing or ripening the individual shapes by contacting the individual shapes with a calcium solution in the order of hours at typical refrigeration temperatures is particularly suited to obtain a food product with the desired sensory characteristics needed for certain meat substitutes, such as pieces of chicken, beef chunks, minced meat and the like.

While the calcium solution can contain any suitable calcium salt to have a curing effect, it may be desirable to use salts other than calcium chloride. Nonlimiting examples of preferred calcium salts, which are allowed for food applications, are calcium acetate, calcium orthophosphate, calcium carbonate, calcium lactate, calcium ascorbate, calcium propionate, calcium sulfate, or any combinations thereof.

It was found that different sources of edible mycoprotein are suitable to be used in the method according to the invention. Edible mycoprotein from Fusarium and Rhizopus are particularly suitable.

The method according to the invention may lead to the desired food product with plant protein sources of different origin and different amounts of said plant protein sources. The plant protein sources can for instance be selected from sources rich in proteins, such as, but not limited to, pea protein, faba bean protein, potato protein, or rice protein; also, sources having a lower protein content, such as, but not limited to, rice flour or faba bean flour, can be used. To obtain a food product having a desired nutritional profile, it is preferred to use sources rich in proteins.

During the development of the invention, it turned out that the ratio of the amount of the mycoprotein and the amount of the plant protein source can have an effect on the texture of the food product. When the relative amount of the mycoprotein, compared to the amount of plant protein source, is lower, it can provide for a smoother texture of the food product, while a higher relative amount of the mycoprotein can lead to a food product with a more fibrous texture.

The invented method yields a food product. By this is meant that a product is obtained that is in principle edible. However, additional steps may be required to meet regulations, such as those related to microbial requirements. The food product obtained in the method of the invention after step e) may for instance be subjected to further processing steps including performing the method under clean room conditions to avoid microbial contamination, rinsing the individual shapes; adjusting the pH of the individual shapes; treating the individual shapes at elevated temperatures, such as pasteurization to remove microbial contamination; cooling the individual shapes; freezing the individual shapes; removing water from the individual shapes; combining several pieces of (further processed) food product into another (semi-)finished food product, such as patties, balls, fillet, meat-like cuts, and the like; and any combinations thereof. To reduce or remove any microbial contamination, the food product is preferably heat-treated at an elevated temperature after having been further cured in step e) of the invention. Such a treatment may for instance comprise heating the food product to a temperature above 60°C, preferably to a temperature between 65°C and 100°C, more preferably between 70°C and 95°C, even more preferably between 75°C and 90°C, for a period of time that ranges from 5 to 100 min, more preferably from 10 to 80 min, even more preferably from 15 to 60 min and most preferably from 20 to 50 min, such as at about 25 min to obtain the food product. Heat-treatment of the food products may occur in a water bath. Preferably, the heating of the food product in the water bath is done such that a rinsing action on the food product takes place. Following the heating of the food product, the heat-treated food product preferably is cooled to freezing temperatures; this will allow storage and transport of the food product under hygienic conditions. The freezing temperatures are below 0°C, preferably are between -10°C and -40°C, most preferably between -30°C and -40°C .

The present invention also provides a food product obtainable by the invented method and its embodiments described herein having novel specific properties.

The invention in particular provides a food product obtainable by the invented method and having a calcium content lower than known in the art, preferably between 5 and 2000 ppm, more preferably between 50 and 1500 ppm, even more preferably between 100 and 1000 ppm, even more preferably between 150 and 600 ppm, and most preferably between 200 and 450 ppm. The calcium content is relative to the total weight of the food product, preferably after having treated the individual shapes at elevated temperatures to individual shapes to remove any microbial contamination, as disclosed hereinabove. The skin and the core of the food product obtainable according to the invention preferably are essentially fully cured. The food product obtainable by the invented method may surprisingly contain a relatively low calcium content while at the same time having a relatively high degree of cure, preferably a complete cure. A complete cure is meant to be a chemically complete cure, as well as a geometrically complete cure, wherein the individual shapes are chemically completely cured over their complete cross-section.

The present invention further provides a device for preparing a food product comprising mycoprotein, the device comprising the following components, in the order of i) to v): i. a feeding unit for providing a pre-mix comprising at least a mycoprotein, a plant protein source, an alginate, and water; ii. shaping means for shaping the pre-mix to form a pre-mix shape; iii. a curing unit for curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; iv. a forming unit for forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; v. a further curing unit for further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time, thereby providing the food product.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described further in more detail. Each embodiment defined may be combined with any other embodiment or embodiments unless clearly indicated to the contrary. In particular, any feature indicated as being preferred or advantageous may be combined with any other feature or features indicated as being preferred or advantageous. The present invention provides a method for preparing a food product comprising mycoprotein, the method comprising the steps of: a) preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water; b) shaping the pre-mix to form a pre-mix shape; c) curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time; d) forming individual shapes from the pre-mix shape while substantially preserving the cured skin part; and e) further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time, thereby providing the food product.

It was found that when a pre-mix shape, comprising a mycoprotein, a plant protein source, an alginate and water, is first contacted from the outside with a solution of calcium, before forming individual shapes, a thin layer of cured premix is quickly formed on the outside of the pre-mix shape as a cured skin part. This cured skin part can reduce or prevent, or at least hinder, any sticking of parts of the pre-mix shape to processing equipment that may be used during formation of the individual shapes. The individual shapes are then further cured by contacting them with a second aqueous solution comprising calcium for a second contact time. This two-step curing process allows obtaining the desired sensory characteristics of the resulting food product, such as, but not limited to, appearance, texture, taste and bite. It also provides flexibility in obtaining the desired sensory characteristics.

The pre-mix may be prepared according to any known method. It should be appreciated that the pre-mix is a mixture of at least a mycoprotein, a plant protein source, an alginate, and water, and thus represents a mixture of solids and a liquid or liquids. The ingredients of the pre-mix may be mixed together in one step. In a preferred embodiment however, the plant protein source, the alginate and water are mixed separately to provide a slurry. The mycoprotein is subsequently mixed with the plant protein source/alginate/water slurry, and optionally additional water and/or additional alginate, to provide the pre-mix. Mixing equipment known to one skilled in the art may be used in this mixing step. This embodiment has proven to be beneficial for the properties of the resulting food product.

The pre-mix can have a consistency that allows it to be shaped, preferably into a substantially stable pre-mix shape, for instance by hand or by machine. The pre-mix therefore is preferably provided as a paste with a certain, albeit variable, consistency. The desired consistency and ability to shape may be obtained by for instance providing a sufficiently high solid content of the premix. This sufficiently high solids content can be determined by routine experimentation of one skilled in the art.

The pre-mix shape is suitably formed by shaping the pre-mix. The shaping may be carried out by hand or by any suitable shaping equipment known in the art.

Both the pre-mix shape and the individual shapes have a skin part and a core part, wherein the skin part and the core part are mutually exclusive, and together form the complete cross-section of the pre-mix shape and/or the individual shapes.

The method of the invention is suitable for preparing a range of different food products, with different textures, appearances, nutritional profiles, etc. The method of the invention is particularly suitable for providing meat substitute products having a larger size than minced beef for instance, such as pieces of chicken, beef chunks, and the like. It is however also suitable to obtain minced beef substitute products.

Throughout the application, a “food product” and “food products” are synonymously used to also describe multiple pieces of a food product.

Throughout the application, an “aqueous solution comprising calcium”, “a solution of calcium”, and a “calcium solution” are synonymously used to describe a solution of calcium in water. Such a solution can be suitably prepared by dissolving a calcium salt in water and produces calcium ions.

The first and the second calcium solution used in respectively the first and the second curing step, can be selected to be different, such as, but not limited to, having a different composition of calcium salts and/or a different calcium concentration. In another embodiment, they can be the same solution. Preferably, the first and the second calcium solution are the same, at least with respect to the type of calcium salt used, as this allows for a simpler process.

As mentioned hereinbefore, the formation of the cured skin part develops during the first contact time and this may happen quickly or even almost instantaneously. In contrast to the formation of the cured skin part of the premix shape on the outside thereof, the further curing of step e) of the core part of the individual shapes may take significantly longer. In an embodiment, the present invention provides a method as defined herein, wherein the second contact time is longer than the first contact time.

Providing the cured skin part of the pre-mix shape allows for a cleaner process, possibly without clogging or sticking of parts of the skin-cured pre-mix shape to processing equipment for forming the individual shapes. It further allows obtaining the desired sensory characteristics of the food product, such as, but not limited to, appearance, taste, texture and bite. Surprisingly, providing the cured skin part of the skin-cured pre-mix shape, while a core part of the skin-cured pre-mix shape remains softer allows the individual shapes to be easily formed by pulling or tearing the individual shapes from the skin-cured pre-mix shape, leading to skin-cured individual shapes with relatively rough edges. This provides a more natural and appealing look to the produced food product. By contrast, and not according to the invention, when curing the skin- cured pre-mix shape substantially fully before forming the individual shapes - i.e. where both the skin part and the core part of the skin-cured pre-mix shape are cured in one step - , pulling or tearing the individual shapes from the skin- cured pre-mix shape is more difficult or even impossible, and the skin-cured pre-mix shape needs to be broken or cut into the individual shapes. This leads to a more artificial appearance with strongly delineated edges of the individual shapes. Such shapes are not appealing. Also, by contrast, and not according to the invention, when individual shapes are formed from the pre-mix prior to any curing, i.e. skin-curing and further curing, the pieces have a less natural appearance, being more lumpy and having an unsmooth surface and only limited fibrous textural appearance. Additionally, shaping of individual pieces from pre-mix prior to curing leads to more loss of pre-mix that remains sticking to the equipment after completion of the process. It also leads to more efforts, in terms of water usage and cleaning time, to clean the equipment after completion of the process. Furthermore, by contrast, and also not according to the invention, when individual shapes are formed by from a pre-mix to which calcium ions were already added, the resulting individual shapes are not desirable since they are very sticky, they have limited firmness and they lack a meat- like appearance.

According to the invention, the first contact time necessary for curing the skin part of the pre-mix shape can be selected within a suitable range, that still leaves an uncured core part in the skin-cured pre-mix shape. In a useful embodiment, a method is provided wherein the first contact time is at most 120 minutes (min.), preferably at most 60 min. (sec.), even more preferably at most 10 min., yet even more preferably at most 10 sec.. The first contact time is non-zero and is preferably at least 5 sec., more preferably at least 4 sec., more preferably at least 3 sec., even more preferably at least 2 or 1 sec., yet even more preferably at least 0.5 or 0.3 sec., and most preferably at least 0.2 or 0.1 sec.. It turned out that very short first contact times of around 0.1 to 5 sec. already may provide the effect of providing the skin part having a suitable thickness.

To allow for a faster process of forming the individual shapes, it is advantageous to have the first contact of the pre-mix with the first calcium solution as short as possible. On the other hand, depending on the desired size of the individual shaped products, and the viscosity or malleability of the skin-cured pre-mix shape, longer contact times could be beneficial to avoid clogging or fouling of the process equipment.

Contacting the pre-mix shape with the first calcium solution can be performed in several different ways, such as, but not limited to, by spraying, pouring, submersing, and other methods easily envisioned by one skilled in the art. Preferably, contacting the pre-mix shape with the first calcium solution is performed by spraying. In another preferred embodiment, contacting the premix shape with the first aqueous calcium solution is performed by submersing the pre-mix in said first aqueous solution.

According to the invention, a skin part of the pre-mix shape is cured by contacting the pre-mix shape from the outside with the first aqueous solution. The dimensions of the skin part may depend on the duration of the first contact time and other factors, such as the rate of diffusion of the first aqueous solution into the pre-mix shape. In a useful embodiment, a method is provided wherein the skin part of the skin-cured pre-mix shape in at least one crosssection comprises at most 50% of the at least one cross-sectional area of the skin-cured pre-mix shape, more preferably at most 40%, more preferably at most 30%, even more preferably from 0.1 to 20%, yet even more preferably from 0.5 to 10%, and yet even more preferably from 1 to 5% of the at least one cross-sectional area of the skin-cured pre-mix shape. More preferably, a substantial amount and even more preferably all of the cross-sections of the skin-cured pre-mix shape comprise a skin part of at most 50% of the at least one cross-sectional area of the skin-cured pre-mix shape, more preferably at most 40%, more preferably at most 30%, even more preferably from 0.1 to 20%, yet even more preferably from 0.5 to 10%, and yet even more preferably from 1 to 5% of the at least one cross-sectional area of the skin-cured pre-mix shape

As mentioned hereinbefore, both the skin-cured pre-mix shape and the individual shapes have a skin part and a core part, wherein the skin part and the core part are mutually exclusive, and together form the complete crosssection of the skin-cured pre-mix shape or the individual shapes. When the skin part of the skin-cured pre-mix shape or the individual shapes comprises at most 50% of a cross-sectional area of the pre-mix shape or individual shapes, then the core part comprises at least 50%. When the skin part of the skin- cured pre-mix shape or the individual shapes comprises at most 40%, then the core part comprises at least 60%, and so forth.

In yet another embodiment, the present invention provides a method as defined herein, wherein the core part of the skin-cured pre-mix shape or of the individual shapes in at least one cross-section thereof comprises at least 50% of the cross-sectional area of the skin-cured pre-mix shape or the individual shapes, more preferably at least 60%, more preferably at least 70%, even more preferably from 80 to 99.9%, yet even more preferably from 90 to 99.5%, and yet even more preferably from 95 to 99% of the average cross-sectional area of the skin-cured pre-mix shape or the individual shapes.

In a useful embodiment, in step d) of the method according to the invention, the formation of the individual shapes from the skin-cured pre-mix shape is occurring while preserving the cured skin part. Forming individual shapes from the skin-cured pre-mix shape while preserving the skin part means that individual shapes are formed from the skin-cured pre-mix shape such that at least 50% of the skin of the formed individual shapes consists of cured skin part of the skin-cured pre-mix shape. Preferably at least 75 wt.%, more preferably at least 80 wt.%, most preferably at least 90 wt.%, and up to 100 wt.% of the skin of the formed individual shapes consists of cured skin part of the skin-cured pre-mix shape.

In step e) of the invented method, the individual shapes are further cured which means that the core part of the individual shapes is cured to some extent. It is not necessary that the complete cross-sectional area of the core part is cured, and some uncured core part may remain in the individual shapes. In a preferred embodiment, however, the individual shapes are substantially completely cured during the second contact time, preferably both in terms of geometry and degree of cure.

The further curing of the individual shapes in step e) can lead to desired sensory characteristics of the food product, such as, but not limited to, appearance, texture, taste and bite. Embodiments wherein the individual shapes are substantially completely cured usually provide the most desirable sensory characteristics.

In order to obtain a desired degree of cure, preferably a full cure, the duration of the second contact time may be varied. In suitable embodiments, the presently claimed method is provided such that the second contact time is at least 15 min, more preferably at least 30 min, even more preferably at least 1 hour, preferably from 4 to 48 hours, more preferably from 6 to 36 hours, even more preferably from 8 to 30 hours, yet even more preferably from 10 to 26 hours, yet even more preferably from 16 to 20 hours.

Curing of the individual shapes typically may take significantly longer than the formation of the cured skin part of the pre-mix shape on the outside thereof. As the curing of the individual shapes may depend on diffusion of the aqueous calcium solution into the individual shapes, larger and thicker individual shapes or pieces tend to need longer second contact times than smaller and thinner individual shapes.

Similar to step c), contacting the individual shapes with the second aqueous calcium solution in step e) may be performed in several different ways, such as, but not limited to, by spraying, pouring, submersing, and other methods available to the killed person. Preferably, contacting the individual shapes with the second aqueous calcium solution is performed by submersing the individual shapes in said second aqueous solution.

In yet another embodiment, the present invention provides a method as defined herein, wherein the individual shapes are contacted with the second aqueous solution comprising calcium at a temperature of at most 25°C, preferably at most 15°C, more preferably from 3 to 10°C, even more preferably from 5 to 8°C. As mentioned hereinbefore, the further curing process of step e) may be dependent on diffusion of the calcium solution into the individual shapes. While the further curing process may proceed faster at elevated temperatures, there also could be a higher risk for microbiological contamination and growth. It is therefore preferred to perform the further curing process of step e) at lower temperatures, such as typical refrigeration temperatures. The further curing process at these lower temperatures has the added benefit of further texture development associated with mycoproteins.

In yet another embodiment, the present invention provides a method wherein forming the individual shapes from the skin-cured pre-mix shape, while substantially preserving the cured skin, is performed by cutting, tearing, pulling, or any combinations thereof. It has been found that the method in another embodiment wherein the individual shapes are formed by pulling or tearing the pre-mix, leads to a food product with a more desirable natural and appealing appearance. The method of the invention is suited to provide meat substitute products having a somewhat larger size than minced beef products, such as provided by pieces of chicken, beef chunks, and the like.

While it is possible to form individual shapes from the skin-cured pre-mix shape by any suitable means, it is desirable to use shaping techniques that indeed allow for a more natural appearance of the food product according to the invention. This more natural appearance, for instance for meat substitute products having a somewhat larger size, such as pieces of chicken, beef chunks, and the like, may be produced in an embodiment of the method by using processing equipment that allows to impart onto the skin-cured pre-mix shape a combination of tearing and cutting forces simultaneously.

In an embodiment of the present invention, a method is provided wherein forming the individual shapes in step d) is carried out by tearing apart and/or cutting apart the skin-cured pre-mix shape.

The pre-mix shape may have different geometries, and the invention is not limited to a particular geometry of the pre-mix shape. The geometry may be regular or may be irregular. A useful embodiment however provides a method wherein the pre-mix shape has an elongated appearance, and the individual shapes are formed by tearing apart and/or cutting apart the skin-cured pre-mix shape in a longitudinal direction thereof. The pre-mix elongated appearance may for instance be provided by extruding the pre-mix to provide a continuous elongated pre-mix shape. This can for instance be achieved by continuously pushing the pre-mix through a circular opening, thereby providing a pre-mix in the elongated shape, contacting the elongated pre-mix shape from the outside with a first calcium solution, and having a rotor provided with a series of irregularly shaped blades mounted thereon, one after the other in a radial direction of the rotor, tearing and/or cutting apart the individual shapes from the skin-cured pre-mix shape. Other methods of obtaining the individual shapes may however be used, such as shredding, cutting and/or portioning, and the invention is not limited to a particular method of obtaining the individual shapes.

In yet another embodiment, the present invention provides a method wherein the individual shapes from the skin-cured pre-mix shape are formed while the pre-mix shape is in contact with the first or second aqueous solution comprising calcium. By contacting the skin-cured pre-mix shape with a calcium solution while the individual shapes are formed, any new surface of the skin- cured pre-mix shape that is being created through the forming or shaping process is immediately exposed to the calcium solution, resulting in a new cured skin outer layer on the skin-cured pre-mix shape being formed into the individual shapes. This embodiment has the advantage that the process is less sensitive to the dimensions of the pre-mix shape or the individual shapes, and/or breaking of the cured skin of the skin-cured pre-mix shape. It is also possible to cure the skin part of the pre-mix shape by contacting the pre-mix shape from the outside with the first aqueous solution, then form the individual shapes from the skin-cured pre-mix shape without contacting with any of the first and second aqueous solutions, and then further cure the individual shapes by contacting the individual shapes with the second aqueous solution.

The concentration of the calcium in the first and/or second solution may be varied, depending on the desired textural properties, such as firmness and hardness for instance. In an embodiment of the present invention, a method is provided wherein the concentration of calcium in the first and/or the second aqueous solution comprising calcium is at least 0.2 wt%, preferably from at least 0.5 wt%, more preferably at least 0.7 wt%, and at most 3.0 wt%, more preferably at most 1 .5 wt%.

Apart from contact time and temperature, in particular for the further curing step e), the concentration of calcium in the aqueous solution(s) can have an influence on the curing of the skin part and of the individual shapes comprising alginate. A higher concentration of calcium may lead to a faster curing process, which can be specifically advantageous for the first calcium solution, where smaller volumes of calcium solution may be used, and a short curing time is preferred. Due to possibly higher volumes of second aqueous solution needed for the further curing step e), it may be advantageous to use higher calcium concentrations in the aqueous solution to obtain a faster further curing process, but lower calcium concentrations in view of having a lower cost of resources. Therefore, similar to the temperature, a trade-off needs to be selected in terms of efficacy and economics of the process. Applicant has found that a calcium concentration in the first and/or second aqueous solution from 0.2 to 3 wt% may lead to a suitable process and product in accordance with the desired sensory properties.

Suitable salts to be used in the first and/or second aqueous solution comprise soluble metal salts, preferably soluble calcium salts, such as, but not limited to, calcium acetate, calcium orthophosphate, calcium carbonate, calcium lactate, calcium ascorbate, calcium propionate, calcium sulfate, calcium chloride, or any combinations thereof. Adding the calcium salt to water will provide the calcium ions.

An embodiment of the present invention provides a method wherein the first and/or second aqueous solution comprising calcium is substantially free from chloride, preferably wherein the concentration of chloride is below 0.5 wt%, preferably below 0.2 wt%, even more preferably below 0.1 wt%, relative to the total weight of the aqueous solution.

Preferred calcium salts are those allowed for food applications, such as, but not limited to, calcium acetate, calcium orthophosphate, calcium carbonate, calcium lactate, calcium ascorbate, calcium propionate, calcium sulfate, and/or any combinations thereof.

According to the invention, the pre-mix should contain mycoprotein. The amount of mycoprotein in the pre-mix may be varied. In suitable embodiments of the method the pre-mix contains at least 5 wt% mycoprotein, preferably at least 10 wt%, more preferably at least 15 wt% of mycoprotein, and at most 97 wt%, more preferably at most 78 wt%, and even more preferably at most 75 wt% of mycoprotein, such as 23.4 wt.%, 60.0 wt.% or 74.2 wt.%, expressed as dry weight of mycoprotein on total dry weight of the pre-mix.

Mycoprotein is a form of single-cell protein, also known as fungal protein, derived from fungi for human consumption. Fungi belong to the group of eukaryotic organisms that includes microorganisms such as yeasts and molds, as well as the more familiar mushrooms. These organisms are classified as a kingdom, separately from the other eukaryotic kingdoms, which by one traditional classification may include Plantae, Animalia, Protozoa, and Chromista. The mycoprotein is preferably treated according to well-known practice to make it suitable for human consumption, i.e. to make the mycoprotein edible. Preferably also, the mycoprotein is non-viable. The mycoprotein has preferably been treated to lower the level of RNA which they contain. Thus, the level of RNA in the mycoprotein used is preferably less than the level in an identical fungus when in a viable state. The level of RNA may be reduced as described in W095/23843 for instance.

It was found that different sources of edible mycoprotein are suitable to be used in the method according to the invention. Non-limiting examples of strains known in the art to provide edible mycoprotein are Fusarium, Rhizopus, Rhizomucor, Mucor, Mortierella, Neurospora, Aspergillus, Trichoderma, Pleurotus, Ganoderma, Inonotus, Cordyceps, Ustilago, Tuber, Pennicillium, Xylaria, Trametes. Suitable fungi of the genus Fusarium include Fusarium venenatum. Suitable fungi of the genus Rhizopus include Rhizopus stolonifer, Rhizopus arrbizus, Rhizopus miehei, Rhizopus pusillus, Rhizopus oligosporus and, Rhizopus oryzae. Edible mycoprotein from Fusarium, and Rhizopus are particularly preferred.

The mycoprotein may be provided in any physical form, for instance as a paste or solid. It may also be provided in particulate or powder form by milling or slashing the mycoprotein to promote mixing with the other ingredients of the pre-mix. In a suitable embodiment, the present invention provides a method wherein the mycoprotein is provided as particles with an average particle size of from 4 to 30 mm, more preferably from 6 to 25 mm, even more preferably from 8 to 20 mm, and most preferably from 10 to 15 mm. Reducing the size of the mycoprotein particles to within the claimed preferred ranges, before mixing them with the plant protein source, the alginate, and water to provide the premix, has a beneficial effect on the properties of the food product. Smaller mycoprotein particles may lead to a finer and firmer structure of the food product.

According to the invention, the pre-mix also contains a plant protein source. Plant proteins originate from plant sources such as, but not limited to, edible legumes, nuts, seeds, grains and the like. Examples of edible legumes are lentils and beans, such as faba beans, kidney, pea and soy beans. Examples of grains are rice and wheat. The plant proteins may be added to the pre-mix in the form of a plant protein source, such as flour containing said proteins, a protein isolate, a protein concentrate or any combination thereof. Preferred plant proteins are selected from pea protein, faba bean protein, rice protein, flour containing said proteins, or any combinations thereof. To obtain a food product having a desired nutritional profile, it is preferred to use sources rich in proteins.

The amount of plant protein in the pre-mix may also be selected within wide limits. Suitable embodiments provide a method as defined herein, wherein the pre-mix contains at least 2 wt% plant protein source, preferably at least 3 wt%, more preferably at least 4 wt%, even more preferably at least 5 wt% of plant protein source, and at most 94 wt%, more preferably at most 57 wt%, and most preferably at most 55 wt% of plant protein source, such as 10.7 wt.%, 24.7 wt.% or 53.8 wt.%, expressed as dry weight of plant protein source on total dry weight of the pre-mix. Furthermore, suitable embodiments provide a method as defined herein, wherein the pre-mix contains at least 1 wt% plant protein, preferably at least 2 wt%, more preferably at least 3 wt%, even more preferably at least 4 wt% of plant protein, and at most 55 wt%, more preferably at most 50 wt%, and most preferably at most 45 wt% of plant protein, such as 8.6 wt.%, 19.7 wt.% or 43.0 wt.%, expressed as dry weight of plant protein on total dry weight of the pre-mix.. In a preferred embodiment, the present invention provides a method as defined herein, wherein the plant protein source is selected from pea protein and faba bean protein.

In a more particular embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains from 5 to 55 wt% plant protein source, expressed as dry weight of plant protein source on total dry weight of the pre-mix, and wherein the plant protein is pea protein.

The amount of alginate in the pre-mix may be selected within wide limits, for instance in function of the water content of the pre-mix, the desired texture of the food product, processability of the pre-mix, and/or any combinations thereof. Suitable embodiments provide a method as defined herein, wherein the pre-mix contains at least 1 wt% alginate, preferably from 1 .5 to 10.0 wt%, more preferably from 2.0 to 9.5 wt%, and most preferably from 2.5 to 9.0 wt%, such as 3.9 wt.%, 5.0 wt.% or 8.7 wt.%, expressed as dry weight of sodium alginate equivalent on total dry weight of the pre-mix.

In order to avoid premature curing of the pre-mix comprising the alginate before contacting it from the outside with the first calcium solution, it is desirable in an embodiment to use a source of alginate that is limited in calcium. Suitable embodiments provide a method as defined herein, wherein the alginate is characterized in that the concentration of calcium (on dry matter) is below 1 .0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 or even 0.1 wt%; most preferably, the alginate is essentially free of calcium. In a specific embodiment, the present invention provides a method as defined herein, wherein the alginate is sodium alginate.

In a particular embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains at least 1 wt% alginate, preferably from 1 .5 to 10.0 wt%, more preferably from 2.5 to 9.5 wt%, even more preferably from 3.0 to 9.0 wt%, such as 3.9 wt.%, 5.0 wt.% or 8.7 wt.%, expressed as dry weight of alginate on total dry weight of the pre-mix; and wherein the alginate is sodium alginate.

It was further found that mixing the plant protein source, the alginate and the water separately, thereby providing a slurry, and subsequently mixing the slurry with the (optionally milled) mycoprotein may have a beneficial effect on the properties of the food product. Mixing the plant protein source, the alginate and water before mixing with the mycoprotein may lead to a more homogeneous pre-mix, and/or to less energy needed to mix all ingredients at the same time, which may deteriorate the fibrous structure of the mycoprotein. Suitable embodiments provide a method as defined herein, wherein the plant protein source, the alginate and the water are provided as a slurry by first mixing them separately, before mixing with the mycoprotein.

During the development of the invention, it was found that the ratio of the amount of the mycoprotein and the amount of the plant protein source can have an effect on the texture of the food product. When the relative amount of the mycoprotein, compared to the amount of plant protein source, is lower, it can provide for a smoother texture of the food product, while a higher relative amount of the mycoprotein can lead to a food product with a firmer texture.

In a preferred embodiment, the present invention provides a method as defined herein, wherein the dry weight ratio of mycoproteins over plant protein source in the pre-mix is in a range of from 0.1 to 40, preferably from 0.2 to 25, more preferably 0.3 to 15, such as 0.4, 2.4 or 6.9. In another a preferred embodiment, the present invention provides a method as defined herein, wherein the dry weight ratio of mycoproteins over plant protein in the pre-mix is in a range of from 0.1 to 80, preferably from 0.2 to 40, more preferably 0.3 to 20, such as 0.5, 3.0 or 8.6.

In a specific embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains at least 5 dry wt% mycoprotein, preferably at most 97 dry wt%, more preferably from 10 to dry 78 wt%, even more preferably from 15 to 75 dry wt%; wherein the pre-mix contains at least 2 dry wt% plant protein source, preferably from 3 to 94 dry wt%, more preferably from 4 to 57 dry wt%, even more preferably from 5 to 10 dry wt%, expressed on total dry weight of the pre-mix; wherein the plant protein source is selected from pea protein, faba bean protein, rice protein, flour containing said proteins, isolate containing said proteins, concentrate containing said proteins, or any combinations thereof; wherein the pre-mix contains at least 1 wt% alginate, preferably from 1 .5 to 10.0 wt%, more preferably from 2.0 to 9.5 wt%, even more preferably from 2.5 to 9.0 wt%, expressed on total dry weight of the pre-mix; and wherein the concentration of calcium in the alginate is below 1.0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 wt%.

In a another specific embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains at least 5 dry wt% mycoprotein, preferably at most 97 dry wt%, more preferably from 10 to dry 78 wt%, even more preferably from 15 to 75 dry wt%; wherein the pre-mix contains at least 2 dry wt% plant protein source, preferably from 3 to 94 dry wt%, more preferably from 4 to 57 dry wt%, even more preferably from 5 to 10 dry wt%, expressed on total dry weight of the pre-mix; wherein the plant protein source is selected from pea protein, faba bean protein, rice protein, flour containing said proteins, isolate containing said proteins, concentrate containing said proteins, or any combinations thereof; wherein the pre-mix contains at least 1 wt% alginate, preferably from 1 .5 to 10.0 wt%, more preferably from 2.0 to 9.5 wt%, even more preferably from 2.5 to 9.0 wt%, expressed on total dry weight of the pre-mix; and wherein the concentration of calcium in the alginate is below 1.0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 wt%; and wherein the alginate is sodium alginate.

In a more specific embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains 15 to 75 dry wt% mycoprotein; wherein the pre-mix contains at least 5 to 55 dry wt% plant protein source, expressed on total dry weight of the pre-mix; wherein the plant protein source is selected from pea protein, faba bean protein, rice protein, flour containing said proteins, isolate containing said proteins, concentrate containing said proteins, or any combinations thereof; wherein the pre-mix contains from 2.5 to 9.0 wt% alginate expressed on total dry weight of the pre-mix; and wherein the concentration of calcium in the alginate is below 1 .0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 wt%.

In a another more specific embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains 15 to 75 dry wt% mycoprotein; wherein the pre-mix contains at least 5 to 55 dry wt% plant protein source, expressed on total dry weight of the pre-mix; wherein the plant protein source is selected from pea protein, faba bean protein, rice protein, flour containing said proteins, isolate containing said proteins, concentrate containing said proteins, or any combinations thereof; wherein the pre-mix contains from 2.5 to 9.0 wt% alginate expressed on total dry weight of the premix; and wherein the concentration of calcium in the alginate is below 1 .0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 wt%; and wherein the alginate is sodium alginate.

In an even more specific embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains 15 to 75 dry wt% mycoprotein; wherein the pre-mix contains at least 5 to 55 dry wt% plant protein source, expressed on total dry weight of the pre-mix; wherein the plant protein source is pea protein, or flour, concentrate, or isolate containing pea protein; wherein the pre-mix contains from 2.5 to 9.0 wt% alginate, expressed on total dry weight of the pre-mix; and wherein the concentration of calcium in the alginate is below 1.0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 wt%.

In another even more specific embodiment, the present invention provides a method as defined herein, wherein the pre-mix contains 15 to 75 dry wt% mycoprotein; wherein the pre-mix contains at least 5 to 55 dry wt% plant protein source, expressed on total dry weight of the pre-mix; wherein the plant protein source is pea protein, or flour, concentrate, or isolate containing pea protein; wherein the pre-mix contains from 2.5 to 9.0 wt% alginate, expressed on total dry weight of the pre-mix; and wherein the concentration of calcium in the alginate is below 1 .0 wt%, preferably below 0.5 wt%, even more preferably below 0.2 wt%; and wherein the alginate is sodium alginate.

The water content of the mycoprotein before adding it to the pre-mix or to part of the pre-mix may vary from 0 wt% to 80 wt% and more. Preferred water contents of the mycoprotein may range from 10-80 wt%, more preferably from 15-60 wt%, even more preferably from 20-50 wt% and most preferably from 25-40 wt%, relative to the total weight of the mycoprotein. A higher water content of the mycoprotein may enhance the further curing during the second contact time, in particular may enhance the essentially full curing of the core.

In a useful embodiment, the present invention provides a method as defined herein, wherein the pre-mix has a dry matter content in a range of from 10 to 40 wt.%, preferably from 15 to 35 wt.%, more preferably from 20 to 30 wt.%, expressed on total weight of the pre-mix.

In a useful embodiment, the present invention provides a method as defined herein, wherein the pre-mix has a moisture content in a range of from 60 to 90 wt.%, preferably from 65 to 85 wt.%, more preferably from 70 to 80 wt.%, expressed on total weight of the pre-mix.

According to step d) of the invention, individual shapes are formed from the skin-cured pre-mix shape whereby the skin-cured pre-mix shape may be finite in length, or, alternatively, may be almost infinite, meaning that it comprises a continuously formed string, ribbon or wire shape of pre-mix. The dimensions of the individual shapes may be varied according to the specific application they are used for. The method according to embodiments of the invention allows for a wide variation in lengths of the individual shapes, such as a length of 5 mm, of 10 mm, of 25 mm, of 50 mm, of 60 mm, of 75 mm, of 100 mm, of 150 mm, of 200 mm, of 250 mm, up to lengths of 1000 mm, and even more if needed. It is however desirable to have a length considered natural in the field of meat, and meat substitutes. In embodiments of the invention, the food product has a length of at least 5 mm, preferably of at most 500 mm, more preferably of from 10 to 250 mm, even more preferably from 50 to 150 mm.

The method according to embodiments of the invention allows for a wide variation in widths, such as a width of 5 mm, of 10 mm, of 25 mm, of 50 mm, of 60 mm, of 75 mm, of 100 mm, of 150 mm, of 200 mm, of 250 mm, up to widths of 1000 mm, and even more if needed. It is however desirable to have a width considered natural in the field of meat, and meat substitutes. In embodiments of the invention, the food product has a width of at least 5 mm, preferably of at most 500 mm, more preferably of from 10 to 250 mm, even more preferably from 50 to 150 mm.

In yet other embodiments of the invention, the food product has an aspect ratio (length/width) of at least 0.1 , preferably at most 10, even more preferably from 0.1 to 5.

In particular embodiments of the invention, the food product may be subjected to further processing steps including but not limited to rinsing the food product; submersing the food product in a sodium chloride solution; adjusting the pH of the food product; treating the food product at elevated temperatures, such as pasteurization; cooling the food product; freezing the food product; reducing the size of the food product; combining several pieces of food product into a semi-finished or finished food product, such as patties, balls, fillet, meat-like cuts, and the like; and any combinations thereof.

In other particular embodiments of the invention, the food product may be prepared under clean room conditions to avoid or minimize microbial contamination.

In embodiments of the invention, the composition of the food product can comprise, further to the mycoprotein, the plant protein source, alginate, calcium ions, counter ions and water, other compounds, such as, but not limited to, vegetable fats or oils, emulsifiers, preservatives, colorants, flavorants, and the like. These other compounds can be suitably added during any of the steps of the method according to embodiments of the invention.

In yet another embodiment, the present invention provides a method wherein the food product is heat-treated at an elevated temperature of at least 60°C, preferably at most 100°C, more preferably below 80°C, even more preferably from 65 to 75°C in order to avoid or further avoid or minimize microbial contamination. The food product preferably is subsequently cooled down to freezing temperatures of below 0°C, preferably between -10°C and -40°C, more preferably between -30 and -40°C.

The above heat-treatment at an elevated temperature may be conducted for a suitable period, such as for at least 5 min, more preferably from 10 to 60 min, even more preferably from 20 to 30 min.

The present invention also provides a food product obtainable by the invented method and embodiments thereof, the food product comprising a calcium content lower than known in the art, preferably between 5 and 2000 ppm, more preferably between 50 and 1500 ppm, even more preferably between 100 and 1000 ppm, even more preferably between 150 and 600 ppm, and most preferably between 200 and 450 ppm. The calcium content is relative to the total weight of the food product, preferably after having treated the individual shapes at elevated temperatures to individual shapes to remove any microbial contamination, as disclosed hereinabove. The food product obtainable by the invented method surprisingly contains a relatively low calcium content while at the same time having a relatively high degree of cure, preferably a complete cure.

In yet another aspect of the invention, a device for preparing a food product comprising mycoprotein is provided. The device comprises the following components, in the order of i) to v): vi. a feeding unit for providing a pre-mix comprising at least a mycoprotein, a plant protein source, an alginate, and water; vii. shaping means for shaping the pre-mix to form a pre-mix shape; viii. a curing unit for curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; ix. a forming unit for forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; x. a further curing unit for further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time, thereby providing the food product.

With ‘in the order of i) to v)’ is meant that each component ii) to v) processes the output of a component listed before each component ii) to v). As an example, component ii) processes the output of component i), component iii) processes the output of component ii), and so on, with finally component v) processing the output of component iv). Preferably, no additional components are positioned between subsequent components i) to v).

The device may be operated in batch mode, which requires the output of at least one component to be transferred in batch to the subsequent component in the claimed order. A preferred embodiment however provides a device as claimed, wherein the components are fluidly connected to each other for continuous production of the food product and the device comprises pumping means for advancing at least one of the premix, the premix shape, and the skin-cured premix shape through the device. Preferably, the pumping means are arranged for advancing the premix, the premix shape, and the skin-cured premix shape through the device. In these embodiments, a continuous stream is provided whereby each component is provided more downstream than a component listed before that component.

A useful embodiment provides a device as claimed, that is further comprising prior to the feeding unit a mixing unit for preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water. The mixing unit may be any suitable mixer, such as for example, but not limited to, a paddle mixer.

The feeding unit (i) is suitable for providing a pre-mix comprising at least a mycoprotein, a plant protein source, an alginate, and water. Suitable feeding units include vacuum fillers, extruders and pumps, without being limited thereto. For continuous operation, pumping means are typically provided for advancing the premix towards the shaping means. The pumping means is preferably configured to produce an output of at least 1 kg/min, more preferably of at least 5 kg/min, even more preferably of at least 15 kg/min, most preferably of at least 25 kg/min. In principle the output is not particularly limited but for practical purposes the pumping means is preferably configured to produce an output of at most 100 kg/min, more preferably of at most 90 kg/min, even more preferably of at most 80 kg/min, even more preferably of at most 70 kg/min.

It is preferred to use a feeding unit that is able to provide at least a partial vacuum during mixing, such as, but not limited to, a vacuum filler. A very suitable feeding unit is the one disclosed in US 6,309,293B1 , which is incorporated herein in its entirety, in particular as disclosed in figures 1 to 3 and the corresponding description in columns 3 to 6 thereof. The preferred feeding unit comprises in combination a vane-type conveying mechanism having a housing including a rotor forming vane cells, wherein a vacuum opening which communicates through a vacuum channel with a vacuum source is arranged on said housing of said conveying mechanism, and a negative pressure can be produced through said vacuum opening in a region of said vane-type conveying mechanism for supporting the intake of the premix into said vane-type conveying mechanism. A closure element may be present for at least partly opening and closing said vacuum opening. The rotor of the conveying mechanism is arranged eccentrically within the housing such that the volume of successive vane cells changes, thereby creating a pressure change between the successive vane cells. It should be understood that the feeding unit according to this embodiment may comprise another mixer provided upstream of the vane-type conveying mechanism, such as an agitated tank for instance. In this embodiment, the vane-type conveying mechanism acts as the pumping means for advancing the premix towards the shaping means.

The created vacuum helps in feeding in the ingredients or a pre-mix in the first place. Secondly, the created vacuum may be instrumental is controlling the porosity of the premix as it enters the shaping means.

According to the invention, the device further comprises shaping means (ii) for shaping the pre-mix to form a pre-mix shape. The shaping means may conveniently be formed by tubing, an inlet of which is connected to an outlet of the feeding unit for accepting the premix. The premix is pumped through the tubing under the action of the pumping means forced through an outlet of the tubing. In continuous operation, a string, ribbon or wire shape may hereby be formed.

The shaping of the premix into the premix shape is defined by the size and/or shape of the outlet of the tubing. The outlet of the tubing may have a shape that is or is substantially circular, oval, square, rectangular or may have any irregular or flattened, shape. The outlet of the tubing may have a perimeter in a range of from 0.5 to 12.0 cm, preferably from 1.0 to 10.0 cm, more preferably from 2.0 to 9.0 cm. In one embodiment, the tubing outlet is shaped as one or more relatively small orifices, such as having a perimeter in a range of from 0.5 to 2.5 cm, preferably from 1 .0 to 2.0 cm, more preferably from 1 .2 to 1 .8 cm, to form wires that look like ground meat. In another embodiment, the tubing outlet may be shaped as one orifice, that will produce a relatively large premix ribbon or string, such as having a perimeter in a range of from 4.0 to 12.0 cm, preferably from 5.0 to 10.0 cm, more preferably from 6.0 to 9.0 cm. Preferably, the one orifice has a flattened shape. The flattening may be in a horizontal or in a vertical plane, or may be in a slanted plane, if desired.

The tubing may consist of one tube only, or may bifurcate in a plurality of tubes, preferably extending about parallel to each other. Each of the plurality of tubes may have an outlet orifice with the same or different shape and/or size as the other tubes. As shown, each outlet orifice may be shaped differently and/or irregularly. In this embodiment it becomes possible to produce a plurality of premix shapes simultaneously.

The invented device further comprises a curing unit (iii) for curing a skin part of the pre-mix shape by contacting for a first contact time the pre-mix shape from the outside with a first aqueous solution comprising calcium to obtain a skin- cured pre-mix shape.

The curing unit may be a receptacle for the first aqueous solution comprising calcium, such as a container, a vessel, and the like. A useful embodiment allowing continuous operation comprises a curing unit that is fluidly connected to the outlet of the tubing of the shaping means. According to an embodiment, the curing unit comprises an elongated closed or open tray - or runnel - into which the outlet of the tubing of the shaping means is extending to discharge its content. One tray may be enough but other embodiments provide a plurality of trays, positioned next to each other, preferably in a parallel arrangement.

When the device is in operation, the premix shape exiting the shaping means is advanced through the curing unit, for instance through the tray in an embodiment thereof, where it is allowed to contact the first calcium-containing solution present in the curing unit. During this contact, a thin layer on the outside of the premix shape is cured leading to a skin-cured shape. This cured skin part may reduce or prevent, or at least hinder, any sticking of parts of the mycoprotein-containing food product to one or more parts of the device, such as the one or more orifices of the shaping means, or parts of the forming unit. The cured skin part of the skin-cured shape envelops an uncured core part of the skin-cured shape. This is because the curing is effectuated from the outside with the first calcium-containing solution. In this process, the first calcium-containing solution may diffuse into the premix shape from the outside towards the inside, over some distance. This distance may influence the thickness of the cured skin part.

To obtain curing of at least a skin part of the premix shape, thereby providing a skin-cured shape, it was found that the aqueous calcium-containing solution may be supplied by any suitable means to the curing unit. In useful embodiments, the aqueous calcium-containing solution is supplied by a calcium-containing solution conduit and a second pumping means configured for sustaining a flow towards the outlet of the calcium-containing solution conduit. According to an embodiment, the curing unit comprises an elongated closed or open tray into which the outlet of the calcium-containing solution conduit debouches to discharge the aqueous calcium-containing solution into the curing unit or tray. This may cause a sustained flow of the aqueous calcium-containing solution through the curing unit, preferably through the tray.

Another useful embodiment provides a curing unit in the form of an elongated open or closed tray whereby the tray is positioned under a non-zero angle with the horizontal, such that it slants down from a leading end towards a trailing end of the tray. Suitable non-zero angles may be selected within a wide range, such as between 1 -10 degrees, preferably between 2-8 degrees.

The premix-shape that becomes skin-cured during advancement within the curing unit, preferably the tray, is forced to flow from the leading end to the trailing end of the tray by at least one of the slanted positioning of the tray, the pressure under which the premix shape is forced through the tubing, and the sustained flow of the aqueous calcium solution within the tray.

Preferably, the outlet of the calcium-containing solution conduit debouches in the tray at a position that is upstream of the position where the outlet of the shaping means debouches into the tray. This ensures that the calcium- containing solution will contact the premix shape exiting the shaping means at all times. The supply of the aqueous calcium-containing solution may be regulated such that sufficient calcium solution is provided at any given time in the curing unit to allow curing of at least an outer layer or skin part of the premix shape exiting the tubing and entering the curing unit.

The device according to the invention further comprises a forming unit (iv) for forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part. In an embodiment adapted for continuous operation, the forming unit is positioned downstream of the curing unit, such as the tray, and fluidly connected thereto.

The forming unit may be embodied in different ways, as long as it is able to provide individual pieces of the skin-cured shape that is formed during contact of the premix shape exiting the tubing with the supplied aqueous calcium- containing solution. The individual pieces may for instance be formed by a cutting motion, a tearing motion, a pulling motion, or any combination thereof. A tearing motion is preferred. In useful embodiments of the invention, the forming unit comprises two or more blades (denoted as a blade unit), such as 2, 3, 4, 5, 6, or even more, blades provided on a rotatable central shaft. The one of more blades extend radially outward from the rotatable central shaft. In a specific embodiment, the blades are regularly distributed around the rotatable central shaft.

In operation the rotatable central shaft is positioned such that each blade contacts the skin-cured premix shape with a radially outward edge (also denoted a tip end) of the blade. The skin-cured premix shape in the form of an elongated ribbon, string or wire in operation extends about perpendicular to a plane of each blade, and preferably also to the direction in which the rotatable central shaft extends.

In order to increase production volume, more than one blade unit may be employed, each provided with its own shaft, or using a common shaft. The blade units may operate in one tray of the curing unit, or they may each operate in their own tray.

In an embodiment wherein the curing unit comprises an elongated tray, the rotatable central shaft of the forming unit preferably extends about perpendicular to the elongation of the tray. Obviously, in this embodiment, each blade will extend from the rotatable central shaft over a radial distance that is shorter than the distance from the rotatable central shaft to a bottom part of the tray, in order to avoid direct contact with said bottom part.

According to a useful embodiment, the radially outward edge or tip end of each blade, or at least of some blades, is not straight but shows a curvature or undulation. This will help in forming individual pieces with varying shapes showing some irregularity, as desired. The minimum distance between such radially outward edge and the bottom part of the tray which is within reach of the forming unit may typically be between 0.1 and 3 cm, more preferably between 0.2 and 2 cm, even more preferably between 0.4 and 1 .5 cm, and most preferably between 0.5 and 1 cm. This distance may be instrumental in shaping the individual pieces of the skin-cured shape.

In an embodiment, at least one of the blades, or each blade of the forming unit is planar. In another, more preferred embodiment, at least one of the blades, or each blade of the forming unit is undulated out of the plane of the at least one blade or each blade. This undulation may extend (or progress) in a transverse direction of the at least one blade, or of each blade, or may extend in a longitudinal direction of the at least one blade, or of each blade, or may extend in both said directions. The undulation may also extend in a direction that differs from the longitudinal and the transverse direction of the at least one blade or each blade. The longitudinal direction of a blade extends about perpendicular to the rotatable central shaft. The above-disclosed embodiments having a blade with undulations helps in increasing variability between the shapes of the individual pieces.

Although the forming unit may be equipped with blades of equal shape, preferred embodiments of the forming unit comprise blades having different shapes. This further increases variability in shapes of the individual pieces.

In operation the rotatable central shaft of the forming unit is brought in rotation by a suitable drive, such as an electric motor. Any drive suitable for the purpose may be used. Preferably, the rotation of the rotatable central shaft will be selected in the direction of advancement of the skin-cured shape. This will help in obtaining a tearing action on the skin-cured shape. This effect is even enhanced by having the rotatable central shaft rotate at a rotation speed that yields a blade tip speed exceeding the speed of advancement of the skin- cured shape in the curing unit.

The dimensions of the forming unit may be selected within large limits, depending on the desired production rate of the device. For instance, the curing unit in an embodiment using the elongated tray, may have a width that is at least the same as the with of the outlet of the feeding unit. The curing unit in an embodiment using the elongated tray, may have a width of 1 to 15 cm, more preferably 2 to 14 cm, more preferably 4 to 13 cm. The curing unit in an embodiment using the elongated tray, may have a length of 0.1 to more than 1 .5 m, such as a length of 0.2 to 1.2 m, preferably 0.3 to 1 .0 m, more preferably 0.4 to 0.8 m. In an embodiment using a centrally provided rotatable shaft provided with a number of radially extending blades as forming unit, the diameter of the apparatus from blade tip to tip may be from 10 to 50 cm, more preferably from 20 to 40 cm. Larger diameters are however possible. Such an embodiment may produce blade tip end speeds of over 1 m/sec up to 10 m/sec and higher, depending on the rotation speed of the rotatable central shaft. Such rotation speed may for instance range from 100 to 500 rpm, without however being limited thereto. The depth of the elongated tray may be selected such that the premix shape may be fully or substantially fully submersed by the calcium-containing solution.

The length of the individual pieces may be varied by the shape of the outlet of the shaping means, such as the width of the flattened outlet, the dimensions of the blades of the forming unit, and the dimension of the tray. The width of the individual pieces may be varied the rotation speed of the rotatable central shaft, the number of blades provided on the rotatable central shaft of the forming unit, but also by the speed of advancement of the skin-cured shape in the tray. The thickness of the individual pieces may be varied by the shape of the outlet of the shaping means, but also by the distance between the tip of the blades of the forming unit and the bottom part of the tray which is within reach of the forming unit. One skilled in the art will be able to select these parameters to obtain the desired dimensions, length, width and thickness, of each individual piece.

According to a particularly preferred embodiment, the individual pieces hit a retaining wall when exiting the forming unit. The exit of the individual pieces from the forming unit, in particular in an embodiment using a rotatable central shaft provided with radially extending blades, can occur at high speed, taking into account the typical speeds of the tip ends of the blades in operation. Indeed, the individual pieces tend to be ejected from the forming unit at relatively high exit speeds that conform to the typical blade tip end speeds mentioned hereinabove and hit against the retaining wall. This embodiment can produce individual pieces that tend to have a ribbed surface, not unlike the fibrous muscle structure of animal pieces, such as chicken pieces.

According to the invention, the individual pieces when exiting the forming unit, preferably via falling from the retaining wall, end up in a further curing unit (v) for further curing the individual shapes by contacting for a second contact time the individual shapes with a second aqueous solution comprising calcium, thereby providing the food product. The pieces may be collected by the further curing unit directly after exiting the forming unit. However, the individual pieces are preferably collected by the further curing unit after they hit the optional retaining wall. Part of the retaining wall can, to this end, extend under a nonzero angle with the vertical direction. Individual pieces that hit the retaining wall of this embodiment will be forced to fall down into the further curing unit, particularly when embodied by a container.

Indeed, the further curing unit in an embodiment of the invention comprises a container, positioned downstream of the forming unit in an embodiment allowing a continuous operation. The container is adapted to receive the formed food product and contact said food product with a further aqueous calcium-containing solution in order to further cure the individual pieces, preferably to a substantially full cure.

The further aqueous calcium-containing solution may be provided in the container or may be supplied to it. In a particularly preferred embodiment, the device comprises a feedback conduit, provided with a pumping means, for recirculating the further aqueous calcium-containing solution from the container to the calcium-containing solution conduit. In this embodiment, the feedback conduit is fluidly connected to an inlet of the calcium-containing solution conduit, or forms one integral conduit with it. This embodiment is environmentally friendly since it saves calcium-containing solution.

To reduce or remove any microbial contamination, the invented device may if desired be provided with a temperature-regulating unit wherein the food product is preferably heat-treated at an elevated temperature to form an edible food product. The temperature-regulating unit may be provided downstream of the forming unit. The temperature-regulating apparatus is preferably adapted to heat-treat the individual pieces, either skin-cured or substantially fully cured, such as by heating to a temperature above 60°C for at least 5 min, as well as cooling the heat-treated food product, such as to freezing temperatures.

In a specific embodiment, the invention provides a method and a device as defined herein for preparing a food product comprising mycoprotein, the method comprising the steps of: a) preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate and water, and providing the pre-mix by means of a feeding unit i) of the device; b) shaping by the shaping means ii) of the device the pre-mix to form a pre-mix shape; c) curing in a curing unit iii) of the device a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; d) forming in a forming unit iv) of the device individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; and e) further curing in a further curing unit v) of the device the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time. The invention will now be described by reference to the below Examples and to the drawings attached to this application, without being limited thereto. In the drawings:

Figure 1 A shows the appearance of the food product according to example 2;

Figure 1 B shows the appearance of the individual shapes according to comparative example A;

Figure 1 C shows the appearance of the individual shapes according to comparative example B;

Figure 1 D shows the appearance of the individual shapes according to comparative example C;

Figure 2 shows firmness values of examples 2 and 4, and comparative examples A and B;

Figure 3 shows toughness values of examples 2 and 4, and comparative examples A and B;

Figure 4 schematically shows a device for preparing a food product comprising mycoprotein according to an embodiment of the invention;

Figure 5 schematically shows a detail of the device showing the mutual positioning of the aqueous calcium-containing conduit and the premix tubing at an entrance of the curing unit in the form of a tray, according to an embodiment of the invention;

Figures 6A to 6C schematically show several embodiments of premix tubing;

Figure 7 schematically shows a forming unit according to an embodiment of the invented device; while

Figures 8A and 8B schematically show frontal views of a forming unit blade, according to some embodiments of the invention.

EXAMPLES

Materials

Pea protein concentrate having a protein content of about 80 wt.% protein on total dry matter was sourced from Windmill (Meelunie). The pea protein concentrate was in powder form, having a dry matter content of about 90%. Sodium alginate was sourced from Shandong Jiejing Group Corporation. Mycoprotein from the strain Fusarium venenatum was sourced from either the company Marlow Foods - brand name Quorn - or from the company Enough; as is known, these mycoproteins have been treated to lower the level of RNA which they contain. The mycoprotein sourced from Enough had a solids content of 25 wt%. The Quorn mycoprotein had a solids content of 35 wt.%. Mycoproteins were sourced in frozen form. After thawing, mycoproteins had a paste-like texture. Chicken flavor was sourced from Griffith Foods.

Methods

General procedure A: Firmness & Toughness

Sensorial properties of the individual shapes were analysed through a standard Texture Profile Analysis using a Stable Microsystems TA.HD plus equipped with a Meullenet Owens Razor Shear Blade and guillotine block. The starting position was set at 20 mm, the test speed was 2 mm/s, and the test distance was 20 mm. The deformation curve of the sample was obtained, from which the parameter Force 1 (g) was determined in function of time (s), according to the manufacturer's protocol.

From these parameters, the following properties were calculated: Firmness = peak force (g) of Force 1 ;

Toughness = area (g.s) below the curve; i.e. Force 1 x time

General procedure B: Determination of calcium content

The sample (mass approx. 10 gram) was prepared by ashing, and subsequently dissolving the ash in hydrochloric acid. The calcium content finally was determined in the hydrochloric acid solution using a flame photometer (Kriiss FP 8801 ) based on a calibration curve that is established every working day. General procedure C: Determination of dry matter

To determine the relative amount of dry matter, a sample was exposed to vacuum and elevated temperature in a vacuum oven. Briefly, a sample was first reduced in size, for instance by mixing. Subsequently, a dry metal crucible is weighed (P1 ), and an amount of sample (less than 1 cm thickness) was subsequently weighed (P2) into the crucible. The crucible was put in the vacuum oven at 70 °C, and the pressure of the oven was slowly lowered to a pressure of 35 mbar or lower. After 20 hours, the vacuum was slowly removed, and the crucible was put in an exicator to allow it to cool down to room temperature. After cooling down, the crucible was once more weighed (P3).

The dry matter content (wt%) was finally determined by ((P3-P1 )/(P2-P1 )) x 100. Conversely, the water content (wt%) is 100 minus the dry matter content.

Example 1 - Preparation of a pre-mix

A slurry was prepared by mixing 400 gram of pea protein concentrate, 25 gram of sodium alginate, and 2065 gram of water. The mycoprotein, as received from Quorn, was milled at 13 mm. Subsequently 482 gram of milled mycoprotein, 482 gram of the slurry (a 50:50 ratio of mycoprotein fraction and plant protein source fraction), 7 gram sodium alginate, and 29 gram of chicken flavor were mixed until a homogeneous pre-mix was obtained (“pre-mix Quorn”).

The composition of the resulting pre-mix is shown in Table 1 . Table 1. Composition data according to Example 1

Example 2 - Preparation of individual shapes

Individual shapes were prepared by adding the pre-mix of example 1 to a retention bath containing a 4% solution of calcium lactate in water. Directly after this additional step, the pre-mix was flattened, thereby becoming fully submersed in the calcium lactate solution, and individual shapes were formed by tearing pieces from the pre-mix. After all the pieces were tom, the individual shapes were kept submersed in the calcium solution in the retention bath overnight during 18 hours at a temperature of 7°C. To remove any microbial contamination, the food product was heated in a water bath at 75°C for 25 min. Finally, the food product was allowed to cool down to room temperature and frozen to minus 18°C. Example 3 to 6 demonstrate the preparation of alternative pre-mixes according to the process of the invention. Example 3

A pre-mix was prepared having the same final composition as example 1 , but by adding the pea protein concentrate, the sodium alginate, and the water directly to the milled mycoprotein, together with the chicken flavor and mixing all ingredients at the same time until a homogeneous pre-mix is obtained.

Finally, a food product was prepared according to the method of example 2.

Example 4

A pre-mix was prepared according to example 1 , but with mycoprotein sourced from Enough (“pre-mix Enough”).

Finally, a food product was prepared according to the method of example 2.

Example 5

In accordance with example 1 , while however using mycoprotein from Enough, 771.2 gram of milled mycoprotein, 192.8 gram of the slurry (a 80:20 ratio of mycoprotein fraction and plant protein source fraction), 7 gram sodium alginate, and 29 gram of chicken flavor were mixed until a homogeneous premix was obtained.

The composition of the resulting pre-mix is shown in Table 2.

Table 2. Composition data according to Example 5

Finally, a food product was prepared according to the method of example 2. Example 6

In accordance with example 1 , while however using mycoprotein from Enough, 192.8 gram of milled mycoprotein, 771.2 gram of the slurry (a 20:80 ratio of mycoprotein fraction and plant protein source fraction), 7 gram sodium alginate, and 29 gram of chicken flavor were mixed until a homogeneous pre- mix was obtained.

The composition of the resulting pre-mix is shown in Table 3. Table 3. Composition data according to Example 6

Finally, a food product was prepared according to the method of example 2. Comparative example A to C are processes for preparing individual shapes that are not according to the invention. Comparative examples A to C are compared with the process of example 2. The effect of the order of process steps is demonstrated. Comparative example A - Fully curing of pre-mix prior to shaping of individual pieces

The pre-mix of example 1 was added to a retention bath containing a 4% solution of calcium lactate in water. In contrast to example 2, after the pre-mix was flattened, and becoming fully submersed, the flattened pre-mix was first kept submersed in the calcium solution in the retention bath overnight (18 hours) at a temperature of 7 °C (in the refrigerator). Subsequently, individual shapes were prepared by breaking, rather than tearing, individual shapes from -M- the pre-mix. Finally, the individual shapes were heated and frozen according to example 2.

Comparative example B - Shaping of individual pieces prior to skin curing of pre-mix

In contrast to example 2, individual shapes were prepared from the pre-mix of example 1 first by tearing/forming pieces from the sticky pre-mix first, and adding the individual shapes to a retention bath containing a 4% solution of calcium lactate in water. The individual shapes were kept further submersed in the calcium solution in the retention bath overnight (18 hours) at a temperature of 7 °C (in a refrigerator). Finally, the individual shapes were heated and frozen according to example 2.

Comparative example C - Curing simultaneous with pre-mix preparation

A pre-mix already containing calcium ions was prepared by adding 50 gram of a 4% solution of calcium lactate to the pre-mix of example 1 , and further mixing until a homogeneous mixture was obtained. Individual shapes were subsequently prepared by tearing/forming pieces from the mixture. The pieces were then cooled overnight (18 hours) at a temperature of 7 °C (in a refrigerator). Finally, the individual shapes are heated according to example 2.

When qualitatively comparing the appearance and sensorial feeling of the food product or individual shapes prepared according to example 2 (FIG 1 A), examples 3 to 6, and comparatives examples A, B and C (FIG 1 B-1 D), it becomes apparent that the food product prepared according to the method of the invention has the most desirable characteristics for a meat-like food product, such as chicken pieces, or beef chunks.

Figures 1 A-1 D show a picture of the appearance of the food product according to example 2, and of individual shapes of comparatives examples A, B and C, respectively. Table 4 provides an overview of a qualitative assessment of the different food products or individual shapes in terms of 1 ) overall appearance, 2) shape, 3) surface smoothness, 4) fibrous appearance, and 5) touch. The qualitative assessment is scored from undesirable (-), over sufficient (+), to desirable (+++)■

Table 4. Results of qualitative assessment

The food product prepared according to the method of the invention was found to have the most desirable overall appearance, including fibrous textural appearance, a meat-like shape resembling chicken pieces or beef chunks, a smooth surface and a non-sticky firmness when touched. In contrast, the individual shapes according to comparative example A, i.e. where the shapes are formed after the pre-mix has been allowed to cure overnight in a calcium solution in the refrigerator, have a more synthetic appearance, with smooth edges, and no fibrous textural appearance. The individual shapes according to comparative example B, i.e. where the individual shapes are formed first, before adding them to the calcium solution, and allowing them to further cure overnight, have a more lumpy appearance, an unsmooth surface, and only have a limited fibrous textural appearance. The individual shapes according to comparative example C, i.e. where the individual shapes are formed from a pre-mix to which calcium ions were already added, are very sticky and have only limited firmness. They moreover lack a meat-like appearance and even disintegrate when heated in a water bath at 75 °C.

The food product according to example 3 was found to have a similar overall appearance to the food products according to example 2.

To perform a quantitative assessment of the sensorial properties of the food product or individual shapes of the different examples and comparative examples, 10 individual samples of examples 2 and 4, and comparative examples A and B were selected with a similar length (50-60 mm), width (35- 40 mm), height (9-14 mm), and weight (11 -14 gram). These samples were subsequently tested with a Meullent Owens Razor Shear Blade according to general procedure A. The results of the quantitative assessment are shown in Figure 2 and Figure 3 for firmness and toughness of the tested samples, respectively.

Comparative example B, whereby individual pieces were prepared by tearing/forming pieces from the sticky pre-mix, resulted in a high amount of pre-mix that remained sticking to the equipment after the process was finalized. The process of Comparative example B resulted in more loss of premix and required more efforts, in terms of water usage and cleaning time, to clean the equipment after completion of the process, compared to the process of Example 2.

To determine the amount of calcium ions in the food product or individual shapes, already present from the raw materials used to prepare the individual shapes and/or accumulated during curing or further curing in a calcium solution, test samples were subjected to general procedure B. The amount of calcium in each of the tested samples is shown in Table 5. Table 5. Results of calcium measurements

To determine the dry matter content, or conversely the water content, test samples were subjected to general procedure C. The dry matter content and water content in each of the tested samples is shown in Table 6.

Table 6. Results of dry matter measurements

Example 7 - Device

The above disclosed food products may be prepared by a device according to one aspect of the invention. An embodiment of such a device will now be described, without however limiting the invented device thereto. The embodiment is mainly used to illustrate the invented device.

Referring to figure 4, a device 1 for preparing a food product comprising mycoprotein according to an embodiment of the invention is schematically shown. The device 1 comprises a feeding unit 2 for preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water, shaping means 3 for shaping the pre-mix to form a pre-mix shape, a curing unit 4 for curing a skin part of the pre-mix shape by contacting for a first contact time the pre-mix shape from the outside with a first aqueous solution comprising calcium to obtain a skin-cured pre-mix shape, a forming unit 5 for forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part, and a further curing unit 6 for further curing the individual shapes by contacting for a second contact time the individual shapes with a second aqueous solution comprising calcium, thereby providing the food product.

It will be understood that the shaping means 3 processes the output of the feeding unit 2, the curing unit 4 processes the output of the shaping means 3, the forming unit 5 processes the output of the curing unit 4, and the further curing unit 6 finally processes the output of the forming unit 5. In the shown embodiment, all components 2 to 6 of the device 1 are fluidly connected to each other, in order to allow for a continuous operation. The device 1 may however also be operated in batch mode, which requires the output of at least one component 2 to 5 to be transferred in batch to another component in the claimed order.

The device 1 comprises pumping means in the form of a pump 20 of the feeding unit 2 for advancing at least one of the premix, the premix shape, and the skin-cured premix shape through the device 1 . In the embodiment shown, a continuous stream is provided whereby each component 3 to 6 is provided more downstream than a component 2 to 5 listed before that component 3 to 6.

The feeding unit 2 is suitable for preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water. A suitable feeding unit include vacuum mixer 21 , provided with an inlet hopper 22 for entering the premix to arrow 23. The embodiment shown in figure 4 uses a feeding unit 2 that is able to provide at least a partial vacuum during mixing. This is provided by a vane-type conveying mechanism 24 having a housing including a rotor forming vane cells. A detailed description of such a mechanism is disclosed in US 6,309,293B1 , which is incorporated herein in its entirety, in particular as disclosed in figures 1 to 3 and the corresponding description in columns 3 to 6 thereof. In this embodiment, the vane-type conveying mechanism 24 also acts as a pumping means for advancing the premix through the device 1 .

According to the embodiment shown, the device 1 further comprises shaping means 3 for shaping the pre-mix to form a pre-mix shape. The shaping means 3 are formed by tubing 30, an inlet 31 of which being connected to an outlet 25 of the feeding unit 2 for accepting the premix. The premix is pumped through the tubing 30 in the direction of arrow 33 under the action of the pump 20 and forced through an outlet 32 of the tubing 3. In continuous operation, a string, ribbon or wire shape may hereby be formed, schematically shown in figure 1 as string 10.

The shaping of the premix into the premix shape is defined by the shape of the outlet 32 of the tubing 3. As shown in figure 6A, in one embodiment, the tubing outlet 32 is shaped as one or more relatively small orifices 320, for instance two orifices 320, having an exemplary diameter of about 0.5 cm, in other words a perimeter of 1 .57 cm. Such an outlet 32 will form wires 10 that look like ground meat. In another embodiment, shown in figure 6B, the tubing outlet 32 may be shaped as one flattened orifice 321 . Such an orifice 320 will produce a relatively large, flattened premix ribbon or string 10. The flattening may be in a horizontal plane, as shown, bur may also be in a vertical plane, or may be in a slanted plane, if desired.

The tubing 30 may consist of one tube only or may bifurcate in a plurality of tubes (30a, 30b, 30c), preferably extending about parallel to each other, as shown in figure 6C. In this embodiment it becomes possible to produce a plurality of strings, wires or ribbons 10 simultaneously, i.e. from one inlet 31 and each exiting from outlet orifices 322a, 322b and 322c. As shown, each outlet orifice may be shaped differently and/or irregularly. The invented device 1 further comprises a curing unit 4 for curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside for a first contact time with a first aqueous solution 40 comprising calcium to obtain a skin-cured pre-mix shape 10b in the form of a wire, string or ribbon, or a plurality of these.

The curing unit 4 in the embodiment shown comprises an elongated open tray 40 into which the outlet 32 of the tubing 30 is fluidly connected to discharge its content. One tray 40 may be enough but other embodiments provide a plurality of trays 40, positioned next to each other, preferably in a parallel arrangement.

When the device is in operation, the premix shape exiting the tubing 30 is advanced through the tray 40, where it is allowed to contact the first calcium - containing solution present in the tray 40. During this contact, a thin layer on the outside of the premix shape 10a exiting the tubing 30 is cured leading to a skin-cured shape 10b.

To obtain curing of at least a skin part of the premix shape 10a, thereby providing a skin-cured shape 10b, the aqueous calcium-containing solution 11 in the tray 40 may be supplied thereto by any suitable means. Referring to figures 4 and 5, a possible arrangement comprises a calcium-containing solution conduit 41 through which the aqueous calcium-containing solution 11 is supplied by a second pump 42 configured for sustaining a flow towards the outlet 410 of the calcium-containing solution conduit 41 , according to the arrows 43. According to this embodiment, the outlet 410 of the calcium- containing solution conduit 41 debouches in the elongated open tray 40 to discharge the aqueous calcium-containing solution 11 into the tray 40. This causes a sustained flow of the aqueous calcium-containing solution 11 through the tray 40, as indicated by the arrow 43. As shown in figure 4, the elongated open tray 40 is positioned under a nonzero angle 44 with the horizontal, such that the tray 40 slants down from a leading end 45a towards a trailing end 45b of the tray 40.

The premix-shape 10a exiting the tubing 30 that becomes a skin-cured shape 10b during advancement within the tray 40, is forced to flow from the leading end 45a to the trailing end 45b of the tray 45 by the slanted positioning of the tray 45, which provides a gliding surface, the pressure under which the premix shape 10a is forced through the tubing 30, and the sustained flow of the aqueous calcium solution 11 within the tray 40.

As shown in figure 5, the outlet 410 of the calcium-containing solution conduit 41 debouches in the tray 40 at a position that is upstream of the position where the outlet 32 of the tubing 30 debouches into the tray 40. In other words, there is a non-zero distance 46 between the outlets 410 and 32. This ensures that the calcium-containing solution 11 will contact the premix shape 10a exiting the tubing 30.

Referring to figures 4 and 7, the device 1 according to the shown embodiment further comprises a forming unit 5 for forming individual shapes 10c from the skin-cured pre-mix shape 10b while substantially preserving the cured skin part. In an embodiment adapted for continuous operation, the forming unit 5 is positioned downstream of the tray 40, or at least of a large part thereof, and fluidly connected thereto.

The forming unit 5 in the embodiment shown comprises a blade unit in the form of a plurality of blades 50, such as 16 blades 50, provided on a rotatable central shaft 51 . Each blade extends radially outward from the rotatable central shaft 51 . The blades 50 may be regularly distributed around the rotatable central shaft 51 , as shown. In operation the rotatable central shaft 51 is positioned such that each blade

50 contacts the skin-cured premix shape 10b with a radially outward edge (also denoted a tip end) 500 of the blade 50. The skin-cured premix shape 10b in the form of an elongated ribbon, string or wire in operation extends about perpendicular to a plane of each blade, and preferably also to the direction in which the rotatable central shaft 51 extends. As shown, the rotatable central shaft 51 of the forming unit 5 extends about perpendicular to the elongation 47 of the tray 40.

As shown in figure 7, each blade 50 will extend from the rotatable central shaft

51 over a radial distance 52 that is shorter than the distance 53 from the rotatable central shaft 51 to a bottom part 48 of the tray 40, in order to avoid direct contact with said bottom part 48. As further shown in figures 8A and 8B, the radially outward edge or tip end 500 of each blade 50, or at least of some blades 50, may be straight (figure 8A) or may show a curvature or undulation (figure 8B). The latter embodiment may help in forming individual pieces 10c with varying shapes showing some irregularity, as may be desired. The minimum distance 501 between a radially outward edge 500 and the bottom part 48 of the tray 40 may typically be between 0.1 and 3 cm, more preferably between 0.2 and 2 cm, even more preferably between 0.4 and 1 .5 cm, and most preferably between 0.5 and 1 cm. This distance may be instrumental in shaping the individual pieces of the skin-cured shape.

At least one blade 50, or each blade 50 of the forming unit 5 may be planar. At least one blade 50, or each blade 50 may also be undulated out of the plane of such blade 50. As shown in figure 7, the undulation extends in a transverse direction of the blades 50, but it may also extend in a longitudinal direction of the blades 50 (not shown), or even may extend in both said directions (not shown). As further shown in figure 7, the forming unit 5 may comprise blades 50 having different shapes. This increases variability in shapes of the individual pieces 10c. In operation the rotatable central shaft 51 of the blade unit is brought in rotation by an electric motor 54 for instance. Referring to figure 4, the rotation direction 55 of the rotatable central shaft 51 is typically selected in the direction of advancement 49 of the skin-cured shape 10b. This may be instrumental in in obtaining a tearing action on the skin-cured shape 10b. This effect is even enhanced by having the rotatable central shaft 51 rotate at a rotation speed that yields a blade tip speed exceeding the speed of advancement of the skin- cured shape 10b in the tray 40.

As further shown in figure 4, the individual pieces 10c when exiting the forming unit 5 are withheld by a retaining wall 56. The exit of the individual skin-cured pieces 10c from the forming unit 5 comprising a rotatable central shaft 51 provided with radially extending blades 50 occurs at high speed, taking into account the typical speeds of the tip ends of the blades 50 in operation. The individual skin-cured pieces 10c therefore tend to be projected with force from the forming unit 5 to hit against the retaining wall 56. This embodiment has been proven to produce individual skin-cured pieces 10c that tend to have a ribbed surface. The individual skin-cured pieces 10c projected against the retaining wall 56 finally end up in a further curing unit 6 for further curing the skin-cured individual shapes 10c by contacting for a second contact time the skin-cured individual shapes 10c with a second aqueous solution 12 comprising calcium, thereby providing the food product, which consist of substantially fully cured individual pieces 10d. As shown in figure 4, a part 56a of the retaining wall 56 extends under a non-zero angle 57 with the vertical direction. Skin-cured individual pieces 10c that hit the retaining wall 56, and in particular part 56a thereof, will be forced to fall down into the further curing unit, for instance embodied by a container 60, having a bottom 60b and side walls 60a. The container 60 is positioned downstream of the forming unit 5 allowing continuous operation. The further aqueous calcium-containing solution 12 may be provided in the container 60 or may be supplied to it (not shown). As shown in figure 4, a feedback conduit 61 , optionally provided with a pump (the pump 42 may serve as such) may be provided for recirculating the further aqueous calcium-containing solution 12 from the container 60 to the calcium-containing solution conduit 41 . The feedback conduit 61 is fluidly connected to an inlet of the calcium-containing solution conduit 11 , or to an inlet of the pump 42 to fluidly connect with the conduit 41. In this way, the aqueous calcium-containing solution 11 and the further aqueous calcium- containing solution 12 may be the same solution. In order to suck in the further aqueous calcium-containing solution 12 into the conduit 61 in accordance with arrow 13, a filter 62 may be provided to prevent substantially fully cured individual pieces 10d or other material from entering the feedback conduit 61.

Claims

1 . A method for preparing a food product comprising mycoprotein, the method comprising the steps of: a) preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water; b) shaping the pre-mix to form a pre-mix shape; c) curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; d) forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; e) further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time, thereby providing the food product.

2. Method according to claim 1 , wherein the skin part of the skin-cured pre-mix shape in at least one cross-section comprises at most 50% of the at least one cross-sectional area of the skin-cured pre-mix shape, more preferably at most 40%, more preferably at most 30%, even more preferably from 0.1 to 20%, yet even more preferably from 0.5 to 10%, and yet even more preferably from 1 to 5% of the at least one cross-sectional area of the skin- cured pre-mix shape.

3. Method as claimed in any one of the preceding claims, wherein the individual shapes are contacted with the second aqueous solution comprising calcium at a temperature of at most 25 °C, preferably at most 15 °C, more preferably from 3 to 10 °C, even more preferably from 5 to 8 °C.

4. Method as claimed in any one of the preceding claims, wherein forming the individual shapes in step d) is carried out by tearing apart or cutting apart the skin-cured pre-mix shape. 5. Method as claimed in any one of the preceding claims, wherein the individual shapes are formed from the skin-cured pre-mix shape while the skin- cured pre-mix shape is in contact with the first or second aqueous solution comprising calcium.

6. Method as claimed in any one of the preceding claims, wherein the concentration of calcium in the first and/or second aqueous solution comprising calcium is at least 0.2 wt%, preferably from 0.5 to 3 wt%, more preferably from 0.7 to 1 .5 wt%.

7. Method as claimed in any one of the preceding claims, wherein the first and/or second aqueous solution comprising calcium comprises a calcium salt selected from calcium acetate, calcium orthophosphate, calcium carbonate, calcium lactate, calcium ascorbate, calcium propionate, calcium sulfate, or any combinations thereof.

10. Method as claimed in any one of the preceding claims, wherein the premix contains at least 5 wt% mycoprotein, preferably at most 97 wt%, more preferably from 10 to 78 wt%, even more preferably from 15 to 75 wt% expressed as dry weight of mycoprotein on total dry weight of the pre-mix.

11 . Method as claimed in any one of the preceding claims, wherein the mycoprotein is sourced from Fusarium and/or Rhizopus.

12. Method as claimed in any one of the preceding claims, wherein the premix contains at least 2 wt% plant protein source, preferably from 3 to 94 wt%, more preferably from 4 to 57 wt%, even more preferably from 5 to 55 wt%, expressed as dry weight of plant protein source on total dry weight of the premix.

13. Method as claimed in any one of the preceding claims, wherein the plant protein source is derived from faba beans, pea and/or rice.

14. Method as claimed in any one of the preceding claims, wherein the premix contains at least 1 wt% alginate, preferably from 1 .5 to 10.0 wt%, more preferably from 2.0 to 9.5 wt%, even more preferably from 2.5.0 to 9.0 wt%, expressed as dry weight of sodium alginate equivalent on total dry weight of the pre-mix.

15. A food product comprising mycoprotein obtainable by the method according to any one of claims 1 to 14, the food product comprising a calcium content between 5 and 2000 ppm, more preferably between 50 and 1500 ppm, even more preferably between 100 and 1000 ppm, even more preferably between 150 and 600 ppm, and most preferably between 200 and 450 ppm.

16. A device for preparing a food product comprising mycoprotein, the device comprising the following components, in the order of i) to v): i. a feeding unit for preparing a pre-mix by mixing at least a mycoprotein, a plant protein source, an alginate, and water; ii. shaping means for shaping the pre-mix to form a pre-mix shape; iii. a curing unit for curing a skin part of the pre-mix shape by contacting the pre-mix shape from the outside with a first aqueous solution comprising calcium for a first contact time to obtain a skin-cured pre-mix shape; iv. a forming unit for forming individual shapes from the skin-cured pre-mix shape while substantially preserving the cured skin part; v. a further curing unit for further curing the individual shapes by contacting the individual shapes with a second aqueous solution comprising calcium for a second contact time, thereby providing the food product.

17. Device as claimed in claim 16, wherein the components are fluidly connected to each other for continuous production of the food product.