WO2024249471A1 - Plant-based minced meat mimics - Google Patents

Abstract

The invention relates to the field of plant-based proteins, in particular wheat proteins, used in vegan or vegetarian food products to mimic minced meat. The invention also relates to the process for making such vegan minced meat mimics. Finally, the invention also covers the use of the wheat proteins to make minced meat mimics or the use of the wheat proteins in meat extenders.

Description

PLANT-BASED MINCED MEAT MIMICS

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of European Application No. EP23176621.3, filed June 1, 2023, which is incorporated by reference herein in its entirety.

FIELD OF THE INVENTION

[0002] The present invention relates to novel wheat gluten products and food products comprising such wheat gluten products. The invention also relates to processes for transforming highly viscoelastic vital wheat gluten into devitalized wheat gluten in the form of coarse particles.

BACKGROUND OF THE INVENTION

[0003] With the world population set to reach 8 billion in the next few years, the demand for animal proteins for human consumption continues to grow. However, there is a growing trend of a shift in diets towards more plant-based foods. Trends include flexitarianism, characterized by only occasionally consuming meat, vegetarianism, characterized by excluding animal-containing food but consuming dairy and egg, and finally veganism, characterized by excluding both animalcontaining food and animal by-products (including dairy and egg). Over the last decade, increasing investment has been directed towards creating meat alternative or substitute products with ever closer organoleptic properties to meat.

[0004] A major use of gluten in non-bakery foods is as a meat replacement in vegan and vegetarian foods. Due to the growing concerns around the sustainability of high levels of meat consumption, an increasing number of consumers are looking for meatless alternatives. Pure wet wheat gluten can be seasoned, shaped, and cooked by boiling in a broth into dense sliceable loaves, steaks etc. This seasoned product is also widely known as “seitan”. However, this is generally sold and used by consumers as a wet product in slabs with seasoning.

[0005] It is also known that vital wheat gluten can also be extruded under low moisture together with other ingredients such as starches and flours into textured products that mimic the mouthfeel, chew, and taste of meat. Alternative meat products created by this process are suitable for vegetarian burgers, sandwich fillings, pizza toppings etc. However, extrusion processes to make textured proteins are rather costly.

[0006] Devitalized wheat gluten fine powders made by wet processing followed by high temperature flash drying techniques are known. However, such fine powders cannot be used as vegan or vegetarian minced meat alternatives. They do not have the necessary structure and texture. [0007] WO 1999003359 Al teaches a food product comprising soy protein concentrate and/or isolated soya protein, texturized soya protein and/or soya protein concentrate, wheat gluten, water and other ingredients.

[0008] US20120156355 teaches a method of producing a meat analogue product by extruding and drying a mixture of ingredients including at least one vegetable protein, a dough conditioner, and water.

[0009] GB1335596A discloses rolling dough of workable vegetable protein (such as soy protein and wheat protein) into sheets and cutting the sheet to form fiber-like strands.

[0010] US20060105098A1 discloses a method of manufacturing a texturized proteinaceous meat analogue product, said product having a relative water activity of lower than about 0.8, said method comprising inter alia the step of extruding a mixture containing about 20 to 80% by weight edible proteinaceous materials selected from the group consisting of predetermined mixtures of defatted soy flour, soy meal, soy concentrate, cereal gluten and egg white powder and up to about 5% by weight of edible mineral binding and cross-linking compounds; and up to about 50% by weight of an edible humectant system consisting of a mixture of glycerol and glucose in a predetermined ratio, to provide a meat-analogue product similar to shredded or flaked meats (i.e. not mince).

[0011] US2022030911 Al discloses a food composition which include a myceliated high-protein food product and methods to make such compositions, which are mixtures of myceliated high- protein food products and other edible materials. These compositions are prepared by extrusion in an extruder.

[0012] US20050287267A1 discloses in Example 30 a wheat protein isolate powder that is extruded in a twin -screw extruder.

[0013] US20040052923 Al discloses textured proteinaceous food product that can be produced in a controlled and safe manner by adding an endogenous gas-forming agent to a protein substrate and subjecting the protein substrate with the gas-forming agent in the presence of water to a heat treatment.

[0014] W0200205657A1 discloses textured proteinaceous food product that can be produced in a controlled and safe manner by adding a starter culture composed of one or more selected gasforming food-grade microorganisms to a protein substrate, fermenting the protein substrate with said culture in the presence of water, and subjecting the fermented protein substrate to a heat treatment. [0015] Riaz M.N. in Chapter 15 "Texturized vegetable proteins" (pages 395-418) in the "Handbook of food proteins", published 9 September 2011, discusses textured soy and other vegetable proteins.

[0016] Lin Quanquan et al (Food Hydrocolloids vol. 130 (2022) 107694) discusses protein digestibility of textured-wheat-protein (TWP) -based meat analogues.

[0017] EP1014806B1 discloses a fibrous food product and method and device for its production. [0018] Thus, there is a need to provide additional wheat protein in a devitalized form, which can be used as a minced meat substitute, whilst having good and rapid enough water absorption capacity.

[0019] There is a need to provide additional wheat protein in a devitalized form, which can be used as a minced meat substitute, with a good integrity, in particular when used in sauces, in particular in acidic sauces, like a tomato sauce.

[0020] There is furthermore a need to provide additional plant-based protein for food, which is obtained from more sustainable sources and represents a reduced carbon dioxide footprint, which is currently an unmet need in the industry.

[0021] There is furthermore a need to provide a coarse devitalized wheat gluten composition prepared by more energy efficient means with improved properties compared to extruded wheat gluten compositions.

SUMMARY OF THE INVENTION

[0022] The invention covers a coarse devitalized wheat gluten composition wherein at least 80wt% of the composition has a particle size of at least 0.8mm, preferably from 0.8mm to 4mm, or from 1mm to 4mm, or from 1mm to 3mm, comprising at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt%. Such a composition is preferably a non-extruded composition.

[0023] The invention also covers a process for preparing such a coarse devitalized wheat gluten composition comprising the following steps: a) Heating (optionally with agitation) a vital wheat gluten composition comprising

- at most 50wt% dry substance, preferably at most 35wt%, more preferably at most 30wt%,

- at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt%,

- and at least 50wt% water, preferably at least 65wt%, more preferably at least 70wt%, to obtain a devitalized wheat gluten composition, b) Passing the devitalized wheat gluten composition through a particle size reducer (e.g. knives, plates, cutter, mixer, mincer, grinder, shredder, lump breaker, mill or any combination thereof) to reduce the particle size to obtain a wet coarse devitalized wheat gluten composition, and c) Drying the wet coarse devitalized wheat gluten composition down to a water content of at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%; wherein the process for preparing the coarse devitalized wheat gluten, preferably, does not comprise any extrusion steps, or wherein at no point in the process is a wheat gluten-containing composition processed through an extruder.

[0024] The invention also covers a coarse devitalized wheat gluten composition obtained or obtainable from this process (i.e. directly from step c) wherein at least 80wt% of the composition has a particle size of at least 0.8mm, or at least 0.9mm, or at least 1mm, or preferably from 0.8mm to 4mm, or from 1mm to 4mm, or from 1mm to 3mm. Such a composition is a non-extruded composition.

[0025] Furthermore, the invention also covers a process for preparing a minced meat mimic product wherein the coarse devitalized wheat gluten composition according to the invention above is mixed with one or more other food ingredients, such as other plant-based ingredients, for instance other plant proteins. The invention thus also covers a minced meat mimic product comprising the coarse devitalized wheat gluten composition according to the invention above and one or more other food ingredients, such as other plant-based ingredients, for instance other plant proteins.

[0026] The invention also covers a meat extender product comprising the coarse devitalized wheat gluten composition according to the invention above and one or more meat-derived ingredients.

[0027] Finally, the invention also covers the use of the coarse devitalized wheat gluten composition according to the invention above as a minced meat mimic or in a meat extender. FIGURES

[0028] Figures 1 to 3 show the sensory results of various plant protein sources compared with devitalized wheat gluten composition according to the invention.

[0029] Figures 4 and 5 show the viscoelasticity results obtained on various wheat gluten samples using the Mixolab® “Gluten 1” protocol.

DETAILED DESCRIPTION OF THE INVENTION

1. The raw material vital wheat gluten

[0030] Vital wheat gluten (also called elastic gluten) is the water-insoluble protein fraction extracted from wheat flour by a wet process. The main proteins in vital wheat gluten are gliadin and glutenin. The wheat flour is washed with water until all or a majority of the starch has been removed, leaving the sticky insoluble gluten as an elastic mass. To obtain vital wheat gluten powder, the mass can be dewatered and gently dried whilst maintaining the vitality of the wheat gluten.

[0031] According to the process of the invention vital wheat gluten powder may be used as the starting material to prepare the vital wheat gluten composition in step (a). However, more preferably, to avoid the need of an additional drying step, a wet vital wheat gluten composition obtained directly from the starch removal washing steps can be used.

[0032] A vital wheat gluten composition as required in step (a) comprises:

- at most 50wt% dry substance, preferably at most 35wt%, more preferably at most 30wt% dry substance,

- at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt% protein on a dry weight basis,

- and at least 50wt% water, preferably at least 65wt%, more preferably at least 70wt% water. The above preferred amounts can be combined in all possible ways for all three features.

The protein content as disclosed herein is always measured according to the AOAC 990.03 method (DUMAS) and using a 6.25 protein factor.

[0033] The vital wheat gluten composition preferably essentially consists of vital wheat gluten and water. The vital wheat gluten in the composition essentially consists of protein. However, there may also be some remaining/residual fat, fiber, starch and minerals present in the vital wheat gluten. Preferably, the vital wheat gluten in the composition is comprised of (or essentially consists of): at least 75wt% on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt% of protein, most preferably at least 90wt% of protein, optionally less than 5wt% on a dry weight basis, preferably from 0.01 to 5wt%, more preferably from 0.1 to 4wt%, most preferably from 0.2 to 3.5wt% of fat and optionally less than 5.0wt% on a dry weight basis, preferably from 0.01 to 5wt%, more preferably from 0.01 to 4wt%, most preferably from 0.01 to 2wt% of fiber, and optionally less than 10wt% on a dry weight basis, preferably from 0.01 to 10wt%, more preferably from 0.01 to 9wt%, most preferably from 0.01 to 8wt% of starch, and optionally less than 2wt% on a dry weight basis, preferably from 0.001 to 2wt%, more preferably from 0.01 to 2wt%, most preferably from 0.1 to 2wt% of minerals.

The above preferences can be combined in all possible ways for all the features mentioned.

[0034] The dry substance and water content of the vital wheat gluten composition is measured by i. weighing 5g of sample, ii. air drying the 5g of sample in an oven for 2 hours at 130°C, iii. and determining the amount of moisture lost by reweighing the sample after drying.

The protein content is measured according to the AO AC 990.03 method (DUMAS method) and using a 6.25 protein factor.

2. The heating step (a)

[0035] The vital wheat gluten composition is heated according to step (a). This can be done in any heating device suitable for devitalizing vital wheat gluten. The heating may occur with agitation.

[0036] The vital wheat gluten is thus devitalized by heat denaturation of the proteins in the composition. The composition obtained after this heating step is a devitalized wheat gluten composition. Most preferably, the wheat gluten in the devitalized wheat gluten composition obtainable from step (a) has lost all of its viscoelastic properties i.e. it is considered a devitalized wheat gluten according to the CODEX STAN 163-187 definition.

[0037] The heating temperature is between 90°C to 120°C, preferably 95°C to 115°C.

[0038] The vital wheat gluten composition is heated for a duration necessary to devitalize preferably all the wheat gluten.

[0039] The vital wheat gluten composition can be heated with heated air or heated water or steam, microwave, radio frequency heating, or direct electrical heating (for instance a worm screw conveyor heated by a low voltage current), or a similar heating method.

[0040] More preferably, the vital wheat gluten composition is heated in a surface scrape heat exchanger. The vital wheat gluten composition can be heated indirectly in a surface scrape heat exchanger with steam. However, the heating device is not an extruder nor a pelletizer (also known as a pellet mill). The heating device is also not a flash-dryer e.g. not a high-temperature flashdryer.

[0041] Heating can occur together with agitation.

3. The particle size reduction step (b)

[0042] Before drying, the devitalized wheat gluten composition is size reduced. However, the objective is not to reduce the particle size down to a (fine) powder, but down to a coarse material, such that after the drying step (c) at least 80wt% of the composition has a particle size of at least 0.8mm, or at least 0.9mm, or at least 1mm, or from 0.8 to 4mm, or from 0.9 to 4mm, or from 1 to 4mm, or from 1mm to 3mm, or from 0.8 to 2mm.

[0043] The particle size and particle size distribution can be measured by sieving and mechanical shaking, for instance with a Retsch Sieve Shaker.

[0044] It has been observed that the coarse material (in particular made starting from the wet vital wheat gluten) is easier to produce, handle and transport than devitalized wheat gluten powder.

[0045] Particle size reduction can be carried out using any known device suitable for reducing the particle size of a solid material. This can be for instance, static knives and plates, a cutter, a mixer, a lump breaker (to de-cake or crumble), a shredder, a mincer, a spaghetti plate (with holes), a grinder, a mill or any combination thereof. Preferably, the particle size reduction device in this invention is carried out with a lump breaker to de-cake and/or crumble the material.

[0046] Alternatively, the particle size reduction device in this invention is a cutter situated at the exit of the surface scrape heat exchanger.

[0047] The particle size can also be managed by fractionation e.g. by sieving alone or in combination with one of the size reduction techniques mentioned above.

[0048] The particle size reduction device is not part of an extruder nor a pelletizer (also known as a pellet mill).

4. The drying step (c)

[0049] The coarse devitalized wheat gluten composition obtained from step (b) is then dried down to a water content of at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%.

[0050] The drying temperature, i.e. the temperature within the drying chamber, is from 68°C to 130°C, preferably from 70°C To 120°C, more preferably 70°C to 110°C.

[0051] The drying step can be carried out in a dryer, such as a contact dryer or an air-steam dryer. [0052] The contact dryer is preferably a vacuum dryer, more preferably a vacuum disc dryer. The contact dryer (including a vacuum dryer, preferably a vacuum disc dryer) with an energy recovery system as described in WO2021042016 can be used. This renders the drying step considerably more energy efficient.

[0053] Alternatively, the contact dryer is a fluidized bed dryer.

[0054] The drying device is not part of an extruder nor a pelletizer (also known as a pellet mill). The drying device is also not a flash-dryer e.g. not a high-temperature flash-dryer.

[0055] The drying duration depends on the temperature. The vital wheat gluten composition is heated for a duration necessary to dry the composition down to a water content of at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%. Some minor amounts of water may remain e.g. at least 0.1 wt%, or at least 0.5wt%, or at least lwt% or at least 1.5wt% or at least 2wt%.

[0056] In a separate embodiment, the drying step can also be omitted in order to prepare a different kind of devitalized wheat gluten composition ingredient. Omitting the drying step means the composition remains in the wet state and is used as an ingredient in a wet state.

[0057] Furthermore, the process of the invention is substantially free of any addition of gasforming agents and/or gas-forming micro-organisms.

5. The dried coarse devitalized wheat gluten composition

[0058] The coarse devitalized wheat gluten composition obtained from step (c) can then be easily packaged or transferred to containers or bags or into tanks ready for transport, in particular for transportation to customers for further processing or directly to retailers. All of the disadvantages observed with transporting powdered devitalized wheat gluten, in particular dusting and explosion dangers, are thereby avoided.

[0059] The coarse devitalized wheat gluten composition preferably essentially consists of devitalized wheat gluten and optionally water. The water content is preferably at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%.

[0060] At least 80wt% of the coarse devitalized wheat gluten composition, preferably obtainable from the process according to the invention, has a particle size of at least 0.8mm, or at least 0.9mm, or at least 1mm, or from 1mm to 4mm, and comprises at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt%. [0061] The above preferences can be combined in all possible ways for all the features.

[0062] The particle size and particle size distribution can be measured by sieving and mechanical shaking, for instance with a Retsch Sieve Shaker.

[0063] The coarse devitalized wheat gluten composition after drying may thus still have some amounts of water remaining in the composition. The coarse devitalized wheat gluten composition after drying can still comprise some water as described above e.g. at least 0.1 wt%, or at least 0.5wt%, or at least lwt%, or at least 1.5wt% or at least 2wt% of water, and/or at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%.

[0064] The coarse devitalized wheat gluten composition preferably essentially consists of devitalized wheat gluten and optionally water. The water content is preferably at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%. The content of devitalized wheat gluten is preferably at least 86wt%, or at least 90wt%, or at least 92wt%, or at least 93wt%, or at least 94wt%, or at least 95wt%.

[0065] Preferably, the devitalized vital wheat gluten in the devitalized wheat gluten composition obtained from the process according to the invention has (or essentially has) the same or similar nutrient profile as the vital wheat gluten in the vital wheat gluten composition used in step (a) and described above.

[0066] The main difference is the nature of the wheat gluten, which changes from vital to devitalized.

[0067] The devitalization means herein that the wheat gluten has lost most or all of its viscoelastic properties. The devitalization can be measured using the Mixolab® device from Chopin technologies. More specifically using the standard Mixolab® protocol “Gluten 1”. This protocol developed by Chopin and described in the Mixolab® handbook entitled “Mixolab applications handbook - Rheological and Enzymatic Analysis” published by Chopin Technologies (created September 2006, Updated July 2009), provides a simple, effective and repeatable solution for evaluating wheat gluten behavior.

[0068] When the rheological behavior of the starting material (i.e. vital wheat gluten) is evaluated according to the protocol, this will typically lead to a maximum torque response of around 2Nm or more. When the rheological behavior of an extruded wheat gluten is evaluated according to the protocol, this will typically lead to a maximum torque response of less than 0.6Nm. When the rheological behavior of the coarse devitalized wheat gluten composition obtained according to the invention is measured according to the protocol, the maximum torque response is from 0.6Nm to 1.7Nm. Preferably the maximum torque response is more than 0.6Nm and up to 1.7Nm, or from 0.7Nm to 1.5Nm, or from 0.7Nm to 1.2Nm, or from 0.8 to l.ONm.

[0069] The capacity of the product to absorb and retain water is measured and described as water binding capacity. Devitalized wheat gluten in its coarse form can absorb more water than vital wheat gluten or devitalized wheat gluten in powder form.

[0070] Water binding capacity is measured as of the amount of water that the product can retain e.g. 1g H2O per g product. Product is added on a centrifuge tube and soaked in water for a period of time. After a resting time, the mix is centrifuged and the supernatant is removed. The differences in weigh resulted in the amount of water captured by the material.

[0071] The process for preparing the dried coarse devitalized wheat gluten composition does not comprise an extrusion step or a flash-drying step. No extruder or pelletizer (pellet mill) or flashdryer (e.g. high temperature flash dryer) is used in this process.

[0072] Furthermore, the dried coarse devitalized wheat gluten is substantially free of gas-forming agents and/or gas-forming micro-organisms.

6. Process for preparing the minced meat mimic product

[0073] The invention also covers a process for preparing a minced meat mimic product wherein coarse devitalized wheat gluten composition is prepared according to steps (a) to (c) above, followed by a step (d) wherein the coarse devitalized wheat gluten composition is then mixed with one or more other food ingredients, preferably selected from one or more of:

- plant-based protein isolates and concentrates, such as from soy, com, pea, rapeseed, or sunflower;

- plant-based flours, for instance whole wheat flour, refined wheat flour or legume flours, such as faba flour or whole pea flour;

- fats;

- starches;

- flavoring agents;

- minerals;

- vitamins;

- lecithin;

- pigments;

- binders, such as blends of hydrocolloids;

- water.

[0074] By “minced meat mimic product” it is meant a product that resembles minced meat by visual and/or sensory means, but which does not contain any animal-derived components. The minced meat mimic product can be used as substitute for or as an alternative to products containing animal-derived minced meat.

[0075] The minced meat mimic product may essentially consist of the coarse devitalized wheat gluten composition according to the invention.

[0076] The coarse devitalized wheat gluten composition, used to prepare the minced meat mimic product, has a particle size distribution wherein at least 80wt% of the composition has a particle size of at least 0.8mm, or at least 0.9mm, or at least 1mm, or from 1mm to 4mm. The composition comprises at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt% protein. The composition may comprise at most 14wt% water, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt% water.

[0077] The minced meat mimic product can be used as a pizza topping or in a sauce. The sauce can be for instance a tomato sauce to mimic a ragou or bolognese type of sauce. The sauce can also be a cheese- or cream-based sauce. The cheese or cream can also be a cheese or cream vegan mimic.

[0078] The minced meat mimic product can also be shaped into balls to mimic meatballs or shaped into patties to mimic hamburgers. This can be done optionally with the help of known binders, for instance blends of hydrocolloids.

[0079] The coarse devitalized wheat gluten composition can also be used in a meat extender food product partially comprising the devitalized wheat gluten composition according to the invention and partially comprising meat-derived ingredients. A meat extender food product is referred to herein as a food product that contains less meat-derived ingredients compared to its full meat- derived version, wherein a portion of the meat-derived ingredients are substituted with plant-based ingredients. A meat extender food product comprising the coarse devitalized wheat gluten according to the invention and meat-derived ingredients (such as meat from beef, lamb, chicken or turkey) can be selected from minced meat, burgers, meatballs, sausages and the like.

EXAMPLES

[0080] Example 1

Preparation of a coarse DWG (devitalized wheat gluten) according to the invention a). Heating step:

1320 g of a vital wheat gluten composition consisting of:

• 30wt% of a commercially available vital wheat gluten comprising a protein content of 82 wt% on a dry weight basis (measured using the AOAC 990.03 method and using a 6.25 protein factor) and

• 70wt% water was heated for Ihl 5 in a stainless steel tray placed in boiling water at regular atmospheric pressure to obtain a devitalized wheat gluten composition. Before boiling, vital wheat gluten and water are mixed to develop a dough which is then stretched to cover the whole surface of the tray. b.) Mincing and decaking step

Heated material was cut into bands with a maximum of 3 cm width and then minced in a kitchen mincer. The composition was also decaked by manual disintegration before grinding. d). Drying step:

The wet coarse devitalized wheat gluten composition was then dried in a fluidized bed dryer.

The temperature of the air in a fluidized bed dryer was set to 70°C.

The water content of the wet coarse devitalized wheat gluten composition was then reduced down to 6wt%. e). Sieving

Sieving the dried coarse devitalized wheat gluten through a sieve so that at least 80wt% of the final coarse devitalized wheat gluten composition had a particle size of from 0.8mm to 4mm.

[0081] Example 2

Comparative examples: Preparation of conventional alternative plant protein based products, namely minced soy (also known as soy grits) and seitan

1. The alternative products with 30% dry substance were hydrated with demi water at room temperature and let to hydrate for 10 minutes.

2. Once the alternative protein product was hydrated, excess water was removed using a strainer.

3. The moisture content of the hydrated protein was measured.

4. The hydrated proteins were cut using a standard kitchen mincer in order to obtain regular product particle sizes.

5. The sample was transferred onto a fluidized bed dryer with its temperature set to 70°C.

6. Caking of the product was avoided by manually disintegrating it. Caking was avoided so that particles or crumbles do not stick to each other, which would otherwise interfere with an effective drying step.

7. The product was dried until a dry matter of 6wt% was achieved.

8. Dried material was then sieved on a 1mm sieve using following vibrating sieve conditions: amplitude of 2.00 (mm/g) for 5 mins.

[0082] Example 3

Properties of the samples from Examples 1 and 2

3, 1, Measuring moisture loss upon mechanical stress using a Texture Analyzer:

Devitalized wheat gluten and other alternative protein products can be mechanically stressed in a standardized way to determine their capacity to keep moisture.

1. Equipment and Supplies

Analytical Balance Two 1000 mL beaker (for rehydration)

50 mL beakers

Timer

Stir bar and stir plate

Filter paper

Fine mesh kitchen strainer and bowl

Fixture: TA-245 Ottawa cell frame plunger and TA.HD.Plus Texture Analyzer with Exponent software Reagents

Room temperature demineralized water Texture Analyzer (TA) Setup and Calibration

1. With the TA instrument turned off, a 30 kg load cell was installed. The instrument was turned on and the Exponent software was loaded.

2. The TA fixture was installed, making sure the top piston could slide smoothly through the column before tightening down the bottom plate. A filter paper was added to the bottom plate.

3. The top piston was lowered until there was only a slight gap between it and the screen. Then the probe height was calibrated and set at a return distance of 130 mm. It was ensured that the top plate was at the proper return distance prior to beginning every test. Sample Preparation

1. 30g of dry sample product were weighed and the weight recorded as ‘Dry Weight’ [Wl],

2. 250g demineralized water at room temperature (17-21 °C) was added to a 1000 mL beaker with a magnetic stirrer.

3. The speed on the stir plate was set and the sample product was added to the water. The product was rehydrated for 30 minutes under constant agitation.

4. The sample was drained through a fine mesh strainer. The sample was left to sit and drain for 10 minutes. 5. Texture Anaylzer Procedure

1. See below for the Texture Analyzer program and relevant parameters.

2. 20g of rehydrated sample product was weighed out into a beaker. Weight was recorded as pre-compression (W3).

3. All the sample was put in the cell .

4. The Probe height was set to 130 mm.

5. The test was run.

6. The sample was removed from the cell by opening the trap, the filter paper was removed. Any pieces that dropped into the drip plate were recovered. The sample product was put in the 50ml dry and clean beaker.

7. The beaker on previously tared scale was weighed and the weight was recorded as post compression weight (W4).

6. Calculations

1. To calculate Water removal = W3-W4/W3

2. Each sample analysis was replicated 3 times

[0083] When performing the Texture Analyzer test on the 3 alternative protein products following results were obtained:

[0084] Devitalized wheat gluten was also assessed on sensory attributes using a protocol to assess sensory attributes of the 3 samples by a sensory panel:

[0085] The panelists were experienced tasters. They were selected based on their ability to taste and smell, discriminate, use a rating scale and describe what they perceive. Most have been active as panelists for more than 2 years. For the evaluation of the samples a descriptive analysis protocol was used (see e.g. Sensory Evaluation Practices. Stone, Bleibaum and Thomas. 2020. Pages 253- 281). Samples were offered blind, with 3-digit codes. They were offered in a randomized order. 2 or 3 replicates were used according to the ANOVA model. Panelist was taken as a random factor. An LSD (“'least significant difference”) post hoc test was used.

Step 1 :

[0086] Attributes generation. Attributes needed to describe differences between the samples of interest were generated by the panelists. A broad set of samples was used to ensure all relevant characteristics were found. Attributes refer to appearance, aroma, taste, mouthfeel, aftertaste, and afterfeel.

Step 2:

[0087] Alignment. Panelists were trained to use the attributes in the same way and scale them in the same way. Panel performance was tested to ensure panel was sufficiently trained (taking into account agreement, repeatability and discrimination).

Step 3 :

[0088] Measurement. All samples were rated on all attributes using 100mm linescales.

Step 4:

[0089] Data analysis. To determine whether differences exist between the samples on any of the attributes ANOVA is used. The model considered for the ANOVA is:

Attribute~Product+Panelist+Replica+Product*Panelist+Product*Replica.

When performing such test on the 3 alternative protein product samples following results, as also shown in Figure 1, Figure 2 and Figure 3 were obtained:

Flavour attributes:

Differences between samples tested with Anova. Attributes with * show significant differences between the samples: ***• p <= 0.01; **: p <= 0.05; *: p < = 0.1

At 95% confidence level **

Bitter:

DWG was less bitter than soy mince

DWG scored similar to seitan on bitterness

Sour:

DWG was less sour than seitan

DWG scored similar to soy mince on sourness

Salty:

DWG was less salty than seitan

DWG scored similar to soy mince on saltiness

Umami:

DWG had less umami flavour than seitan

DWG scored similar to soy mince on umami flavour

Flavour descriptions

Texture attributes: Differences between samples tested with Anova. Attributes with * show significant differences between the samples: ***: p <= 0.01; **: p <= 0.05; *: p <= 0.1

At 95% confidence level **

Hardness:

DWG harder than soy mince

Springiness:

DWG more springiness than soy mince

Moistness:

No significant differences of DWG compared to Seitan and Soy mince

Chewability:

DWG less chewability than soy mince

Rest:

DWG had more “rests” in the mouth than soy mince

Sour aftertaste:

DWG had less sour aftertaste compared to seitan

Lingering:

DWG has less lingering aromas compared to seitan.

No significant differences between DWG and Soy mince.

Texture descriptions

[0090] Results demonstrate that DWG is the solution with the lowest impact on basic sensory attributes, thus making it more suitable than soy mince and seitan for mimicking minced meat. It can also be noted that soy mince has significantly lower hardness than DWG.

Example 4

[0091 ] Properties of the DWG after heat treatment in an acidic sauce

Among the various applications of DWG as meat alternatives, one of them would be its use in a vegan “Bolognese” type of sauce (i.e. DWG used as a vegan minced meat alternative in a tomato sauce) where conditions are harsh due to an acidic environment and a high temperature heat treatment such as sterilization needs to be carried out on the sauce. Such conditions require ingredients to demonstrate a certain stability and integrity to control a pleasant eating experience for end consumers.

[0092] Protocol to mimic conditions of use of alternative protein products in heat treated acidic sauce, such as Bolognese type:

1. The ini tai pH of tinned fine tomato puree (Elvea® brand) was measured at 4.2.

2. 350g of the tinned tomato puree was mixed with each of the 3 alternative protein products and water as follows:

53.83g of non-hydrated alternative protein products 118.47g of tomato fine puree from the tins 177.69g of water

3. The mixture was put into tinned cans.

4. 5 cans per alternative protein product were sterilized for 1 hour at 121 °C.

5. They were then allowed to cool down to room temperature. [0093] The pH of the tomato sauce with alternative protein products was measured in the can.

The pH of the tomato sauce prior to the vegan Bolognese preparation: 4.2

[0094] Using a strainer (with sieve from 1 to 2 mm) the sauce was separated from solid particles and this sauce was kept aside for protein/moisture/ash analysis with results below:

Ash content of the native tomato puree: 2,4%

Dry matter content of the native tomato puree: 27,4%

Protein content of the native tomato puree: 4,6%

[0095] Rinsing: The sterilized tomato sauces with the 3 alternative protein products were passed through a sieve for separation. The collected solid contents were then gently stirred for less than 5 minutes with 200mL water. After stirring, the solid material was again separated from the water using the sieve. This rinsing step was performed 7 times, until the rinsing water became clear.

-Final material kept on the strainer was weighed and moisture content was measured

(Measured at 105 °C until weight stabilized)

[0096] As the tables show, the amount of soy mince material retrieved from the sieve is much lower than the other alternative protein samples demonstrating a poorer integrity of soy mince in keeping its coarse shapes and sizes in harsher environments.

[0097] Devitalized wheat gluten and other alternative protein products can be mechanically stressed in a standardized way to see their capability to keep moisture as described above. The same test as described above was applied on material separated from the sieve after the 7 steps rinsing process:

[0098] Results after sterilization in acidic conditions:

[0099] This can be compared with the results presented previously with alternative protein products freshly hydrated without having undergone sterilization in an acidic environment (as shown already above):

[0100] Results with soy mince shows an increase in water release after sterilization compared to before. This may lead to a poorer eating experience for the consumer.

[0101] Results with DWG demonstrates a decrease in water release after sterilization compared to before. This may lead to a better eating experience for the consumer.

[0102] The sensory test as described above was also carried out on the washed material after and after separation on sieve after the 7 steps rinsing process.

[0103] It is to be noted that in this sensory test a different set of attributes were selected, as these were deemed more relevant.

[0104] Differences between samples tested with Anova. Attributes with * show significant differences between the samples: ***: p <= 0.01; **: p <= 0.05; *: p <= 0.1 At 95% confidence level **

Overall Odor Intensity:

No significant difference between soy mince and DWG

Brothy Taste

No significant difference between DWG and soy mince.

Overall Taste Intensity:

DWG has less taste intensity compared to seitan. No significant difference between DWG and soy mince.

Hardness:

DWG is less hard than soy mince.

No significant difference between DWG and seitan.

Moistness:

DWG is more moist compared to soy mince.

No significant difference between DWG and seitan.

Rest:

No significant difference between DWG and soy mince.

Descriptions

[0105] Results demonstrate that Seitan has high overall taste and odor intensity versus DWG and Soy mince. It can also be noted that soy mince has now the highest hardness, contrary to example 3 and which illustrate its poorer stability.

Example 5: Comparison of devitalized wheat gluten of different particle sizes.

[0106] Example 1 was repeated, except in step (e), the dried gluten was separated into two parts. Each part was sieved in order to obtain two different samples A and B of different particle sizes:

Sample A was created by sieving the product to a particle size according to the invention so that at least 80wt% of the final coarse devitalized wheat gluten composition had a particle size of from 0.8mm to 4mm (same as Example 1).

Sample B was created by sieving the product to a particle size so that at least 80wt% of the final coarse devitalized wheat gluten composition had a particle size of less than 0.8mm. [0107] Moisture loss upon mechanical stress was determined using the Texture Analyzer and following the protocol as provided by Example 3 Section 3.1.

[0108] The following results were obtained as an average of 3 measurements for each sample:

Sample A according to the invention shows less moisture loss than Sample B.

Example 6: Comparison of devitalized wheat gluten according to the invention and extruded TVP

[0109] Samples Al to A6 were made by preparing 75g doughs using the DWG sample made according to Example 1 with different amounts of vital wheat gluten (e.g. Gluvital® 21020) and water as shown in the table below:

Preparation

[0110] Comparative Samples Bl to B6 were made by preparing 75g doughs using a commercial sample of extruded textured wheat gluten (referred to herein as “TVP”, made by processing vital wheat gluten through an extruder) with different amounts of vital wheat gluten (e.g. Gluvital® 21020) and water as shown in the table below:

Preparation

[0111] The viscoelastic behavior of Samples Al to A6 and Bl to B6 were measured using the Mixolab® device from Chopin Technologies, and in particular by using the standard Mixolab® protocol “Gluten 1”. This protocol developed by Chopin and described in the Mixolab® handbook provides a simple, effective and repeatable solution for evaluating wheat gluten properties.

[0112] The parameters of the Gluten 1 protocol are provided in the following table:

[0113] Since the devitalized wheat gluten obtained using the process of the invention is in the form of a coarse product, the product was milled to obtain a particle size of less than 500 microns (i.e. so that all particles passed through a 500 micron sieve) prior to analysis to minimize damage to the device.

[0114] When the rheological behavior of vital wheat gluten, such as Gluvital® 21020 (which does not require milling for the analysis since it already has a particle size of less than 500 microns), is evaluated under the adapted protocol, this led to a torque response of above 2Nm.

[0115] When plotting the Mixolab® results obtained from the “Gluten 1” protocol for Samples Al to A6 and Bl to B6 onto graphs (Figures 4 and 5), the difference in rheological behavior was clearly observed. Thus, the difference in elasticity and binding capabilities were clearly demonstrated for the devitalized wheat gluten according to the invention whereby elasticity was lost compared to the “vital” starting material. Going from Sample Al (100% vital wheat gluten) to Sample A6 (100% DWG) the maximum torque response decreased from above 2Nm down to about 0.8Nm. Similarly, from Sample Bl (100% vital wheat gluten) to B6 (100% TVP) the maximum torque response decreased much further down to about 0.5Nm. Sample A6 therefore is devitalized compared to vital wheat gluten, but still has more residual viscoelasticity compared to Sample B6. Therefore, the coarse devitalized wheat gluten according to the invention is unexpectedly different from extruded wheat gluten, as they have different viscoelastic behaviours. This difference helps preserve a certain level of chewiness in the inventive DWG that is sought after in certain meat analogue and meat extender products.

[0116] The Mixolab® graphs are shown in Figures 4 for Samples Al to A6 and in Figure 5 for Samples Bl to B6.

Claims

1. A coarse devitalized wheat gluten composition wherein at least 80wt% of the composition has a particle size of at least 0.8mm and comprising at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt%.

2. The composition according to claim 1 wherein the composition is a non-extruded composition.

3. The composition according to claim 1 or 2 wherein the composition has a maximum torque response of more than 0.6Nm and up to 1.7Nm measured according to the Mixolab® Gluten 1 protocol.

4. The composition according to any one of claims 1 to 3, wherein the composition essentially consists of devitalized wheat gluten and optionally water, preferably at most 14wt% water, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt% water.

5. A process for preparing a coarse devitalized wheat gluten composition comprising the following steps: a) Heating a vital wheat gluten composition comprising

- at most 50wt% dry substance, preferably at most 35wt%, more preferably at most 30wt%,

- at least 75wt% protein on a dry weight basis, preferably at least 80wt%, more preferably at least 82wt%, most preferably at least 90wt%,

- and at least 50wt% water, preferably at least 65wt%, more preferably at least 70wt%, to obtain a wet devitalized wheat gluten composition, b) Reducing the particle size of the devitalized wheat gluten composition in a particle size reducer to obtain a wet coarse devitalized wheat gluten composition, and c) Drying the wet coarse devitalized wheat gluten composition down to a water content of at most 14wt%, or at most 10wt%, or at most 8wt%, or at most 7wt%, or at most 6wt%, to obtain a coarse devitalized wheat gluten composition.

6. The process according to claim 5 wherein the process does not comprise any extrusion step and/or does not comprise a flash-drying step.

7. The process according to any one of claims 5 to 6 wherein in step (a) the heating step is carried out using heated air or heated water or steam, microwave, radio frequency heating, or direct electrical heating.

8. The process according to any one of claims 5 to 7 wherein the particle size reducer is a static knives and plates, a cutter, a mixer, a lump breaker, a shredder, a mincer, a spaghetti plate, a grinder, a mill or any combination thereof.

9. The process according to any one of claims 5 to 8 wherein at least 80wt% of the coarse devitalized wheat gluten composition obtained from step (c) has a particle size of at least 0.8mm, preferably 1mm to 4mm.

10. The process according to any one of claims 5 to 9 wherein in step (c) the drying is carried out in a contact dryer or in an air-stream dryer or in a fluidized bed drier, preferably in a contact dryer, more preferably a vacuum dryer, most preferably a vacuum disc dryer.

11. A coarse devitalized wheat gluten composition obtainable from the process of any one of claims 5 to 10.

12. A minced meat mimic product comprising the coarse devitalized wheat gluten composition according to any one of claims 1 to 3 or claim 11 and one or more other food ingredients, wherein the product is free of any animal-based and/or animal -derived components.

13. A vegan or vegetarian food product selected from: minced meat, ready-meals, ready-made sauces, for instance tomato sauces, pizza toppings, pizzas, quiches, flans, filled puff pastries burgers, meatballs, sausages, and comprising the minced meat mimic product according to any one of claims 1 to 3 or claim 11.

14. Use of the coarse devitalized wheat gluten composition according to any one of claims 1 to 3 or claim 11 in a vegan or vegetarian food product to mimic minced meat.

15. A meat extender food product comprising the devitalized wheat gluten composition according to any one of claims 1 to 3 or claim 11 and meat-derived ingredients.

16. Use of the coarse devitalized wheat gluten composition according to any one of claims 1 to 3 or claim 11 in a meat extender food product further comprising meat-derived ingredients.