WO2025027137A1

WO2025027137A1 - Device and method for preparing an edible non-animal-based fibrous product

Info

Publication number: WO2025027137A1
Application number: PCT/EP2024/071817
Authority: WO
Inventors: Ton KLOS; Jos HUGENSE
Original assignee: Meatless BV
Current assignee: Meatless BV
Priority date: 2023-08-03
Filing date: 2024-08-01
Publication date: 2025-02-06
Anticipated expiration: 2026-02-03

Abstract

Disclosed is device comprising first conduit (301) for supplying aqueous alginate-containing slurry; first pressurizing means (302) configured for sustaining flow of aqueous alginate-containing slurry through an outlet (304) of first conduit, wherein outlet comprises a flow distributor having at least one aperture (305) through which flow of the aqueous alginate-containing slurry exits; supply (306) for aqueous calcium-containing solution connected to outlet of first conduit to, in operation, contact aqueous alginate-containing slurry exiting the at least one aperture and cure at least a skin part of alginate-containing slurry to obtain a skin-cured shape; dividing element (307) having at least one dividing blade (308) configured to pass over the at least one aperture of the flow distributor at defined distance and divide skin-cured shape exiting the at least one aperture into number of skin-cured pieces thereby forming non-animal- based fibrous product; and receptacle (309) for receiving non-animal-based fibrous product. Method is also disclosed.

Description

DEVICE AND METHOD FOR PREPARING AN EDIBLE NON-ANIMAL- BASED FIBROUS PRODUCT

The present invention relates to a device and a method for preparing an edible non-animal-based fibrous product.

Consumers are increasingly leaning towards ways to reduce, eliminate or substitute products originating from livestock in their diets, thereby moving towards vegetarian or even vegan products. The increasing demand for non- animal-based 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 provide the desired sensory characteristics, such as appearance, texture, smell, taste and the like. Meat products for instance are especially challenging, given their characteristic fibrous texture, which is difficult to obtain from non-animal-based proteins.

NL1008364 discloses a process for obtaining non-animal-based products having a fibrous texture. An emulsion of plant-based proteins, alginate and water, i.e. an aqueous alginate-containing slurry comprising non-animal proteins, is brought into contact with a solution of calcium chloride in water, i.e. an aqueous calcium-containing solution, while stirring for a certain amount of time and at a certain stirring speed. A fibrous product is formed, whereby the choice of a low or high stirring speed determines the size of the fiber.

It would be desirable to be able to provide an industrial process allowing to prepare a non-animal based fibrous product in a more efficient way, i.e. in a continuous production process and/or with limited cleaning operations and/or limited loss of product or ingredients during the production process. Furthermore, it would be desirable to be able to provide a process that is able to better control the desired sensory characteristics of the non-animal based fibrous product and more specifically, obtain a fibrous texture of non-animal- based product that is better controllable and reproducible in terms of size and shape.

It is therefore an object of the present invention to provide a device and method for preparing in an efficient, reproducible and flexible way such fibrous nonanimal based product.

According to the invention, a device for preparing a non-animal-based fibrous product is provided, the device comprising:

- a first conduit (101 , 201 , 301 , 501 ) for supplying an aqueous alginate- containing slurry that further comprises non-animal-based proteins and/or starch;

- first pressurizing means (102, 202, 302) configured for sustaining a flow of the aqueous alginate-containing slurry from an inlet (103, 203, 303) to an outlet (104, 204, 304, 504) of the first conduit (101 , 201 , 301 , 501 ), wherein the outlet comprises a flow distributor having at least one aperture (105, 205, 305, 505) through which aperture the flow of the aqueous alginate-containing slurry exits and, optionally, is redistributed;

- a supply (106, 206, 306) for an aqueous calcium-containing solution fluidly connected to the outlet of the first conduit to, in operation, contact the aqueous alginate-containing slurry exiting the at least one aperture and cure at least a skin part of the alginate-containing slurry to obtain a skin-cured shape;

- a dividing element (107, 207, 307, 407, 507) having at least one dividing blade (108, 208, 308, 408, 508) configured to pass over the at least one aperture of the flow distributor at a distance (518) from 0.5 to 20 mm thereof and divide the skin-cured shape exiting the at least one aperture into a number of skin-cured pieces thereby forming the non-animal-based fibrous product; and

- a receptacle (109, 209, 309) for receiving the non-animal-based fibrous product. It was found that a device as defined herein allows to provide a non-animal- based fibrous product having the desired properties in terms of sensorial characteristics, shape and size. It was moreover found that the device according to embodiments of the invention is particularly suited for a continuous production process providing the non-animal-based fibrous product in large quantities in a reproducible and efficient way.

Figures 1 to 5 are examples of a device or parts thereof in accordance with the teachings of the present invention.

Figure 1 schematically represents a cross-sectional view of the device according to an embodiment of the invention, whereby the supply is in the form of a second conduit.

Figure 2 schematically represents a cross-sectional view of the device according to an embodiment of the invention, whereby the supply is in the form of a vessel. Figure 3 schematically represents a cross-sectional view of the device according to an embodiment of the invention, whereby the receptacle is in the form of a vessel.

Figure 4 schematically represents a part of the device according to the invention, i.e. a rotating knife having 6 knife blades.

Figure 5 schematically represent a cross-sectional view of a part of the device according to an embodiment of the invention, i.e. the rotational knife and the flow distributor at the outlet of the first conduit.

In the figures, each item is indicated with a reference number that is made out of 3 digits, XYZ. The first digit, X, refers to the number of the figure in which the item is represented. The second and third digit, YZ, form a number that is referring to the items listed here below:

- 01 : first conduit for supplying an aqueous alginate-containing slurry;

- 02: first pressurizing means configured for sustaining a flow of the aqueous alginate-containing slurry;

- 03: inlet of the first conduit;

- 04: outlet of the first conduit comprising a flow distributor; - 05: at least one aperture through which aperture the flow of the aqueous alginate-containing slurry exits and, optionally, is redistributed;

- 06: supply for an aqueous calcium-containing solution

- 07: dividing element;

- 08: at least one dividing blade;

- 09: receptacle for receiving the non-animal-based fibrous product.

- 10: second pressurizing means configured for sustaining a flow of the aqueous calcium-containing solution;

- 11 : inlet of the second conduit;

- 12: outlet of the second conduit;

- 13: vessel as part of the receptacle;

- 14: screw conveyor;

- 15: outlet conduit of the vessel as part of the receptacle

- 16: rotating knife shaft

- 17 : diameter of a rotating knife

- 18: distance between dividing blade (08) and aperture (05).

When the device is in operation, an aqueous alginate-containing slurry comprising non-animal proteins and/or starch is pumped from the inlet (103, 203, 303) to the outlet (104, 204, 304, 504) of the first conduit (101 , 201 , 301 , 501 ), and injected through the at least one aperture (105, 205, 305, 505) of a flow distributor, into a calcium containing solution. When the aqueous alginate- containing slurry is contacting calcium ions from the calcium-containing solution, a thin layer of cured alginate-containing slurry is quickly formed on the outside of the alginate-containing slurry leading to a mass having a skin-cured shape, also called briefly “a skin-cured shape”. The skin-cured shape is subsequently divided, for instance cut, into skin-cured pieces that form the non-animal-based fibrous product. The flow of the formed non-animal-based fibrous product surrounded by the aqueous calcium-containing solution is received in the receptacle.

The device according to the present invention comprises a first conduit (101 , 201 , 301 , 501 ) that is suitable for transporting an aqueous alginate-containing slurry. The first conduit is equipped with a pressurizing means (102, 202, 302) configured for sustaining a flow of the aqueous alginate-containing slurry from the inlet (103, 203, 303) to the outlet (104, 204, 304, 504) of the first conduit (101 , 201 , 301 , 501 ). The pressurizing means (102, 202, 302) may be a pump that is suitable for transporting an aqueous alginate-containing slurry having a dynamic viscosity at room temperature in a range of from 500 to 20000 mPas, preferably from 1000 to 15000 mPas, more preferably from 1500 to 10000 mPas, and even more preferably from 2000 to 5000 mPas.

The outlet (104, 204, 304, 504) of the first conduit (101 , 201 , 301 , 501 ) of the device according to the present invention is in the form of a flow distributor. The flow distributor may be embodied in different ways, provided that it allows for a continuous throughput of the aqueous alginate-containing slurry from the first conduit. It was found that it may be beneficial for the throughput of the process, and for the properties and/or for the consistency of the non-animal-based fibrous product, to have a plurality of apertures (105, 205, 305, 505) present in the distributor, to have a closed end face with one or more apertures in a perimeter edge of the flow distributor (104, 204, 304, 504), to have a closed perimeter edge with one or more apertures in an end face of the flow distributor and/or any suitable combination thereof. In useful embodiments of the invention, the flow distributor has a closed end face, and the at least one aperture (105, 205, 305, 505) is provided along a perimeter edge of the flow distributor (104, 204, 304, 504). In further useful embodiments of the invention, the flow distributor has a closed perimeter edge, and the at least one aperture is provided in an end face of the flow distributor. In particular embodiments, the present invention provides a device as defined herein, wherein the flow distributor (104, 204, 304, 504) comprises a plurality of apertures (105, 205, 305, 505). In other particular embodiments, the present invention provides a device as defined herein, wherein the flow distributor (104, 204, 304, 504) is detachably connected to the first conduit. In a specific embodiment of the invention, the flow distributor (104, 204, 304, 504) has a closed end face, and the plurality of apertures (105, 205, 305, 505) are provided along a perimeter edge of the flow distributor (104, 204, 304, 504) or the flow distributor has a closed perimeter edge, and the plurality of apertures are provided in an end face of the flow distributor. In a more specific embodiment, the present invention provides a device as defined herein, wherein the flow distributor has one or more apertures along a perimeter edge of the flow distributor, and one or more apertures in an end face of the flow distributor. In another more specific embodiment, the present invention provides a device as defined herein, wherein the flow distributor has a closed end face and a single aperture that is extending along the full perimeter edge of the flow distributor, and forming a thin gap, such as from 0.5 to 5.0 mm, preferably from 1.0 to 4.0 mm, more preferably from 1.5 to 3.0 mm, between the end face and the perimeter edge of the flow distributor.

It has been found that the apertures (105, 205, 305, 505) of the flow distributor (104, 204, 304, 504) may have any suitable cross-sectional shape or size for obtaining a non-animal-based fibrous product of different shapes and/or sizes. The apertures of the flow distributor may have a circular, ellipsoidal, squared, rectangular, triangular, and even irregular cross-sectional shapes. Preferably, the apertures (105, 205, 305, 505) of the flow distributor (104, 204, 304, 504) have a circular, or substantially circular cross-sectional shape. The apertures (105, 205, 305, 505) may have a cross-section in a range of from 0.04 to 3.0 cm², preferably from 0.1 to 2.0 cm², more preferably from 0.3 to 1 .0 cm².

It has been found that a flow distributor (104, 204, 304, 504) having a plurality of round apertures (105, 205, 305, 505) with a small cross-section, such as 0.04 to 0.3 cm², may be applied for obtaining non-animal-based fibrous product having small, short fibers. It has further been found that a flow distributor (104, 204, 304, 504) having a plurality of rectangular apertures (105, 205, 305, 505) with a large perimeter, such as 1 .0 to 3.0 cm², may be applied for obtaining nonanimal based fibrous product having chunky form, even a substantially rectangular or cubic form.

The device according to the present invention also comprises a dividing element (107, 207, 307, 407, 507). As is demonstrated in Figure 5, the dividing element (507) is configured to pass over the at least one aperture (505) of the flow distributor (504) at a distance (518) of from 0.5 to 20.0 mm, preferably from 0.7 to 15.0 mm, more preferably from 1.0 to 10.0 mm. The dividing element (507) may be embodied in different ways, as long as it is able to form individual pieces of the skin-cured shape that is formed during contact of the aqueous alginate- containing slurry exiting the at least one aperture of the flow distributor with the supplied aqueous calcium-containing solution. The individual pieces may for instance be obtained by a cutting motion, a tearing motion, a pulling motion, or any combination thereof. In useful embodiments of the invention, the dividing element comprises two or more dividing blades (508), such as 2, 3, 4, 5, 6, or even more, dividing blades. In a preferred embodiment, as is demonstrated in Figure 4, the present invention provides a device as defined herein, wherein the dividing element (407) comprises a rotating knife having a plurality of knife blades (408) positioned on a knife shaft (416). The number of knife blades (408) may depend on the size of the rotating knife. The size of the rotating knife may be determined by the perimeter, and thus the diameter (417), of the flow distributor. In other words, the amount of knife blades (408) on the rotating knife can be expressed as a ratio of knife blades (408) per cm perimeter of the flow distributor. In a useful embodiment of the invention, the dividing element comprises a rotating knife having a plurality of knife blades (408) positioned on a knife shaft (416), wherein the ratio of knife blades (408) per cm perimeter of the flow distributor is in a range of from 1 blade per 2 cm to 1 blade per 15 cm, preferably from 1 blade per 2.5 cm to 1 blade per 12 cm, more preferably from 1 blade per 3 cm to 1 blade per 10 cm. Preferably the blades are regularly distributed around the knife shaft (416). In a specific embodiment, the present invention provides a device as defined herein, wherein the dividing element comprises a rotating knife having a plurality of knife blades (408) positioned on a knife shaft (416), wherein the knife preferably has from 2 to 8 knife blades (408), preferably from 3 to 7 knife blades (408), more preferably from 4 to 6 knife blades (408), and the blades are regularly distributed around the knife shaft (416). In a further specific embodiment, the present invention provides a device as defined herein, wherein the dividing element (407) comprises a rotating knife having a plurality of knife blades (408) positioned on a knife shaft (416), wherein the knife has 4 knife blades regularly distributed around the knife shaft.

The device according to the present invention further comprises a supply (106, 206, 306) for an aqueous calcium-containing solution. It was found that the supply (106, 206, 306) for an aqueous calcium-containing solution may be any suitable means as long as sufficient calcium solution is provided at any given time in the volume between the one or more apertures (105, 205, 305) of the flow distributor (104, 204, 304, 504) and the one or more dividing blades (108, 208, 308, 508) of the dividing element (107, 207, 307, 507), to allow curing of at least an outer layer or skin part of the aqueous alginate-containing slurry exiting the at least one aperture (105, 205, 305) of the flow distributor (104, 204, 304, 504) before it reaches the dividing element (107, 207, 307, 507). The supply (106, 206, 306) for the aqueous calcium-containing solution may be a vessel (as is demonstrated in Figure 2, i.e. 206) or a second conduit (as is demonstrated in Figure 1 , i.e. 106). In useful embodiments the aqueous calcium-containing solution is supplied by a second conduit and second pressurizing means configured for sustaining a flow towards the outlet of the second conduit. In a particular embodiment, as is demonstrated in Figure 3, the present invention provides a device as defined herein, wherein the supply for the aqueous calcium-containing solution comprises a second conduit (306) for supplying the aqueous calcium-containing solution and second pressurizing means (310) configured for sustaining a flow of the aqueous calcium-containing solution from an inlet (311 ) to an outlet (312) of the second conduit.

It may be beneficial that the first conduit extends into the second conduit, as is demonstrated in Figure 3. The excess of aqueous calcium-containing solution present in the second conduit may thereby engulf the aqueous alginate- containing slurry exiting the one or more apertures (305) of the flow distributor (304), leading to fast curing of at least an outer layer of skin part of the slurry, thereby providing a skin-cured shape. It may further be desirable that the first conduit (301 ) extends into the second conduit (306) at most up to the outlet of the second conduit to allow, or at least facilitate, curing of the aqueous alginate- containing slurry exiting the at least one aperture (305) of the flow distributor (304). In useful embodiments of the invention, the first conduit (301 ) extends into the second conduit (306). In a more particular embodiment, the present invention provides a device as defined herein, wherein the first conduit (301 ) extends into the second conduit (306) at most up to the outlet (312) of the second conduit. In a more particular embodiment, the present invention provides a device as defined herein, comprising a second conduit (306) for supplying the aqueous calcium-containing solution and second pressurizing means (310) configured for sustaining a flow of the aqueous calcium-containing solution from an inlet (311 ) to an outlet (312) of the second conduit (306), wherein the first conduit (301 ) extends into the second conduit (306) at most up to the outlet (312) of the second conduit (306).

The device according to the present invention further comprises a receptacle (109, 209, 309). The receptacle and the supply for the aqueous calcium- containing solution are fluidly connected to each other. It was found that the supply and the receptacle may be partly or may even be completely part of a single physical entity of the device according to the present invention. As demonstrated in Figure 1 , the supply (106) may be in the form of a second conduit and the receptacle (109) fluidly extends in the receptacle, that is also in the form of a conduit. In other words, the supply (106) and the receptacle (109) may form part of one physical entity, i.e. a conduit, whereby the supply area ends where the aqueous calcium-containing solution is brought in contact with the aqueous alginate-containing slurry that is exiting the first conduit, leading to fast curing of at least an outer layer of skin part of the slurry and thereby providing a non-animal-based fibrous product; and whereby the receptacle area starts where non-animal-based fibrous product is removed along with a flow of aqueous calcium-containing solution. Alternatively, as demonstrated in Figure 2, supply (206) for the aqueous calcium-containing solution and the receptacle (209) may be both in the form of one single physical entity of a vessel having an inlet and an outlet. Through the inlet of the vessel, a flow of the aqueous calcium- containing solution is provided such that the aqueous calcium-containing solution is brought in contact with the aqueous alginate-containing slurry that is exiting the first conduit. The vessel is also acting as receptacle for the formed non-animal-based fibrous product that is removed through the outlet of the vessel together with a flow of aqueous calcium-containing solution. The aqueous calcium-containing solution may be provided to the receptacle by the second conduit and/or any further conduit comprising pressurizing means configured for sustaining a flow of the aqueous calcium-containing solution towards the outlet of the conduit. In useful embodiments of the invention, the aqueous calcium- containing solution is provided in the vicinity of the at least one aperture of the flow distributor by spraying, pouring, filling, or any combination thereof. In another particular embodiment of the invention, the receptacle is filled, at least partially, with the aqueous calcium-containing solution and the calcium solution is replenished by the second conduit and/or any further conduit.

Different embodiments of the receptacle may be applied, provided that the receptacle is configured to receive the skin-cured pieces resulting from the division of the skin-cured shape as described hereinbefore, and preferably also the excess of aqueous calcium-containing solution. In embodiments of the invention, as is demonstrated in Figure 3, the receptacle (309) comprises a vessel (313). In preferred embodiments of the invention, the receptacle (309) comprises a vessel (313) which is configured for transporting (314) the skin- cured pieces to an outlet conduit of the vessel (315). In specific embodiments, the present invention provides a device as defined herein, wherein the receptacle (309) comprises a vessel (313) to which the outlet (304) of the first conduit (301 ) is fluidly connected. In additional specific embodiments, the present invention provides a device as defined herein, wherein the receptacle (309) comprises a vessel (313) to which the outlet (312) of the second conduit (306) is fluidly connected. In a more particular embodiment, the present invention provides a device as defined herein, wherein the receptacle (309) comprises a vessel (313) to which the outlet (304) of the first conduit (301 ) and the outlet (312) of the second conduit (306) is fluidly connected to an outlet (315) conduit of the vessel (313).

In useful embodiments of the invention, the present invention provides a device as defined herein, wherein the vessel (313) comprises transport means for the skin-cured pieces. In a preferred embodiment, the present invention provides a device as defined herein, wherein the vessel (313) comprises a screw conveyor (314) configured to transport the skin-cured pieces. In a particular embodiment, the present invention provides a device as defined herein, wherein the receptacle (309) comprises a vessel (313) to which the outlet (304) of the first conduit (301 ) and the outlet (312) of the second conduit (306) is fluidly connected, which vessel is configured for transporting (314) the skin-cured pieces to an outlet (315) conduit of the vessel (313).

In a preferred embodiment, the present invention provides a device as defined herein, the device comprising:

- a first conduit (301 , 501 ) for supplying an aqueous alginate-containing slurry that further comprises non-animal-based proteins and/or starch;

- first pressurizing means (302) configured for sustaining a flow of the aqueous alginate-containing slurry from an inlet (303) to an outlet (304, 504) of the first conduit (301 , 501 ), wherein the outlet (304, 504) comprises a flow distributor having at least one aperture (305, 505) through which aperture the flow of the aqueous alginate-containing slurry exits and, optionally, is redistributed;

- a supply (306) for an aqueous calcium-containing solution fluidly connected to the outlet of the first conduit to, in operation, contact the aqueous alginate-containing slurry exiting the at least one aperture and cure at least a skin part of the alginate-containing slurry to obtain a skin- cured shape; and wherein the supply of the aqueous calcium-containing solution comprises a second conduit (306) for supplying the aqueous calcium-containing solution and a second pressurizing means (310) configured for sustaining a flow of the aqueous calcium-containing solution from an inlet (311 ) to an outlet (312) of the second conduit;

- a dividing element (307, 407, 507) having at least one dividing blade (308, 408, 508) configured to pass over the at least one aperture of the flow distributor at a distance (518) from 0.5 to 20 mm thereof and divide the skin-cured shape exiting the at least one aperture into a number of skin- cured pieces thereby forming the non-animal-based fibrous product; and wherein the dividing element (407, 507) comprises a rotating knife having a plurality of knife blades (408, 508) positioned on a knife shaft (416, 516), wherein the ratio of knife blades per cm perimeter of the flow distributor is in a range of from 1 blade per 4 cm to 1 blade per 24 cm, and the blades are preferably regularly distributed around the knife shaft (416, 516); and

- a receptacle (309) for receiving the non-animal-based fibrous product, wherein the receptacle (309) comprises a vessel (313) to which the outlet (304) of the first conduit (301 ) and the outlet (312) of the second conduit (306) are fluidly connected, which vessel (313) is configured for transporting (314) the skin-cured pieces to an outlet (315) conduit of the vessel.

In a particularly preferred embodiment, the vessel (313) of the device comprises a screw conveyor (314).

As mentioned hereinbefore, further curing of the non-animal-based fibrous product may lead to improved textural properties. To allow for this further curing of the non-animal-based fibrous product, the device according to the invention may further comprise a container, downstream of the receptacle. In useful embodiments of the invention, the device further comprises a container downstream of the receptacle, wherein the container is adapted to receive the formed non-animal-based fibrous product, and an aqueous calcium-containing solution. Said non-animal-based fibrous product are contacted with aqueous calcium-containing solution, i.e. a further aqueous calcium-containing solution and/or the aqueous calcium-containing solution from the supply and/or the receptacle. In preferred embodiments of the invention, the container is configured to convey the non-animal-based fibrous product from an inlet to an outlet of the container. According to a particular embodiment, the present invention provides a device as defined herein, further comprising a container downstream of the receptacle, wherein the container comprises a conveyor system adapted to convey the non-animal-based fibrous product from an inlet to an outlet of the container.

The non-animal-based fibrous product that is obtained at the outlet of the receptacle or at the outlet of the container, may be further separated from the aqueous calcium containing solution. The device may comprise a recirculation conduit for recirculation of the aqueous calcium containing solution into the supply for aqueous calcium containing solution and said supply may comprise an inlet for recirculated aqueous calcium containing solution.

To reduce or remove any microbial contamination, the non-animal-based fibrous product is preferably heat-treated at an elevated temperature to form an edible non-animal-based fibrous food product. To allow for such a heat treatment, the device according to the invention may further comprise a temperature-regulating apparatus provided downstream of the receptacle, and optionally downstream of the optional container. The temperature-regulating apparatus is preferably adapted to heat-treat the non-animal-based fibrous food product. The heat treatment may be a pasteurization or a sterilization, or the like. The heattreatment of the non-animal-based fibrous food product may occur by heating to a temperature above 68°C, such as from 70 to 135°C, from 75 to 130°C, for at least 30 seconds. Preferably, the heat-treatment of the non-animal-based fibrous food product may occur at a temperature of from 70 to 85°C for 10 to 35 minutes. Alternatively, the heat-treatment of the non-animal-based fibrous food product may occur at a temperature from 90 to 135°C for 30 seconds to 15 minutes. The temperature-regulating apparatus is preferably adapted as well to cooling treatment of the heat-treated non-animal-based fibrous food product, such as to freezing temperatures. In a particular embodiment, the present invention provides a device as defined herein, further comprising a temperature- regulating apparatus provided downstream of the receptacle, and optionally downstream of the optional container, and adapted to heat-treat the non-animal- based fibrous food product by heating to a temperature above 68°C for at least 5 min and optionally cooling down the heated fibrous food product to freezing temperatures.

The non-animal-based fibrous product may also be dried alternative to, prior to, or subsequently to, cooling it to freezing temperature. Removal of moisture may improve the microbial properties and/or storage stability of the non-animal- based fibrous food product. In particular embodiments, the present invention provides a device as defined herein, further comprising a drying apparatus provided downstream of the receptacle, and optionally downstream of the optional container, and optionally downstream of the optional heat-treating apparatus.

The device according to the present invention allows to deliver a continuous supply of an aqueous alginate-containing slurry and inject it into an aqueous calcium-containing solution. The device further allows to deliver a continuous removal of a flow of formed non-animal-based product into the calcium- containing solution. The device thus allows for a continuous production that is more efficient than a batch production. By injecting the aqueous alginate- containing slurry into the aqueous calcium-containing solution, and thus forming a skin-cured shape, the device according to the present invention may reduce, prevent, or at least hinder, any sticking of parts of the alginate-containing slurry and/or the non-animal-based fibrous product to each other or to one or more parts of the device, such as the one or more apertures of the flow distributor, the one or more dividing blades of the dividing element, and/or the receptacle. This may result in a more efficient process using a device that is easier to clean and/or having a higher yield due to less ingredient and/or product losses.

Furthermore, the device according to the present invention allows to deliver in a reproducible way non-animal-based product having a fibrous texture of a pre- determined size and/or shape. The device offers flexibility to adapt said length and/or shape.

The invention further provides a method of preparing a non-animal-based fibrous product, the method comprising the steps of: a) supplying an aqueous alginate-containing slurry that further comprises non-animal-based proteins and/or starch; b) sustaining a flow of the aqueous alginate-containing slurry by a first pressurizing means (102, 202, 302) from an inlet (103, 203, 303) to an outlet (104, 204, 304, 504) of a first conduit (101 , 201 , 301 , 501 ), and distribute the flow through at least one aperture (105, 205, 305, 505) of a flow distributor comprised in the outlet (104, 204, 304, 504); c) supplying an aqueous calcium-containing solution and contacting the aqueous calcium-containing solution during 0.1 to 10 sec with the aqueous alginate-containing slurry exiting the at least one aperture (105, 205, 305, 505) of the outlet (104, 204, 304) of the first conduit (101 , 201 , 301 , 501 ), thereby curing at least a skin part of the alginate-containing slurry to obtain a skin-cured shape; d) dividing the skin-cured shape exiting the at least one aperture (105, 205, 305, 505) with a dividing element (107, 207, 307, 407, 507) having at least one dividing blade (108, 208, 308, 408, 508) configured to pass over the at least one aperture of the flow distributor at a distance from 0.5 to 20 mm thereof, thereby forming the non-animal-based fibrous product, i.e. shortened skin-cured pieces in a medium of aqueous calcium- containing solution; e) optionally further curing the non-animal-based fibrous product from step d); f) removing from the aqueous calcium-containing solution the non-animal- based fibrous product obtained from step d) or, optionally from step e); and g) optionally recycling the aqueous calcium-containing solution obtained from step f) into step c). In step a) of the method of the present invention, an aqueous alginate-containing slurry that further comprises non-animal-based proteins and/or starch is provided. The alginate-containing slurry further comprising non-animal-based proteins and/or starch may be prepared by mixing suitable amounts of an alginate, non-animal-based proteins and/or starch, and water. Alginates are the metal salts of alginic acid, a naturally occurring, edible polysaccharide found in 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. When alginates are contacted with calcium ions, for instance in the form of a calcium solution, the alginate polymer chains become linked by the calcium ions, leading to gelation. This linking process is referred to as ‘curing’ or ‘further curing’ in the present application. Suitable alginates may for instance comprise sodium, potassium, without being limited thereto. Alginate may be obtained in filamentous, granular, or powdered form.

In the context of the current invention, “non-animal-based proteins” are meant to encompass plant proteins, mycoproteins, algal proteins, or mixtures thereof. Plant proteins are based on 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. Preferred plant proteins are selected from pea protein, faba bean protein, rice protein, wheat protein or any combinations thereof. The plant proteins may be in the form of a flour containing said proteins, a protein isolate, a protein concentrate or any combination thereof.

Mycoproteins also known as fungal proteins, are 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.

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 aqueous alginate-containing slurry.

In embodiments of the invention, the aqueous alginate-containing slurry contains at least 2 wt.% non-animal-based protein, preferably from 3 to 20 wt.%, more preferably from 4 to 15 wt.%, even more preferably from 5 to 10 wt.% plant protein, expressed on total weight of the aqueous alginate-containing slurry.

In the context of the current invention, “non-animal-based starches” are meant to encompass starches based on plant sources such as, but not limited to, rice, com, pea, potato, wheat, tapioca and any combination of two or more thereof. Preferably, the starch in the aqueous alginate-containing slurry that further comprises non-animal-based proteins is selected from the group consisting of rice, com, pea, wheat, tapioca, faba and any combination of two or more thereof. More preferably, the starch is selected from the group consisting of rice, com, pea, faba and any combination of two or more thereof. Most preferably, the starch is obtained from rice, faba or any combination thereof. The non-animal- based starch may be in the form of a flour containing said starch, the starch a such, i.e. isolated from its source, or a combinations thereof.

In embodiments of the invention, the aqueous alginate-containing slurry contains at least 2 wt.% of starch, preferably from 3 to 25 wt.%, more preferably from 4 to 20 wt.%, even more preferably from 5 to 15 wt.% starch, expressed on total weight of aqueous alginate-containing slurry.

The alginate-containing slurry may comprise non-animal-based ingredients that offer a source of proteins as a well starch, such as, but not limited to, rice flour, pea flour, or faba bean flour, or mixtures thereof. Preferably, the aqueous alginate-containing slurry comprises rice flour, faba bean flour or combinations thereof.

In embodiments of the invention, the aqueous alginate-containing slurry contains a combined content of protein and starch of at least 4 wt.%, preferably in a range of from 5 to 30 wt.%, more preferably from 7 to 28 wt.%, even more preferably from 10 to 25 wt.%, expressed on total weight of the alginate- containing slurry.

In embodiments of the invention, the aqueous alginate-containing slurry contains at least 0.1 wt.% alginate, preferably from 0.2 to 2.0 wt.%, more preferably from 0.3 to 1.5 wt.%, even more preferably from 0.5 to 1.0 wt.% alginate, expressed on total weight of the aqueous alginate-containing slurry.

It was found that it may be beneficial for the properties and/or consistency of the non-animal-based fibrous product, that the first pressurizing means (102, 202, 302) in step b) of the method of the present invention, provides a continuous flow of the aqueous alginate-containing slurry further comprising non-animal- based proteins and/or starch. In useful embodiments, the first pressurizing means (102, 202, 302) provides a continuous flow of the aqueous alginate- containing slurry. In a particular embodiment, the present invention provides a method as defined herein, wherein the flow rate of the aqueous alginate- containing slurry through the first inlet (101 , 201 , 301 , 501 ), expressed as the amount of slurry in litre per minute and per square centimetre cross section of the first conduit, is from 0.5 to 5 l/min/cm², preferably from 1 to 4 l/min/cm², more preferably 1 .5 to 3 l/min/cm² such as 2.0 l/min/cm².

In step c) of the method of the present invention, an aqueous calcium-containing solution is provided. Throughout the application, an “aqueous calcium- containing solution”, an “aqueous calcium solution”, 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, leading to dissociation of the calcium salt. While the calcium solution can contain any suitable calcium salt to have a curing effect, it may be desirable to use calcium chloride. Non-limiting examples of preferred calcium salts, which are allowed for food applications, are calcium chloride, calcium acetate, calcium orthophosphate, calcium carbonate, calcium lactate, calcium ascorbate, calcium propionate, calcium sulfate, or any combination thereof.

The concentration of calcium in any calcium solution as used throughout the application may be varied, depending on the desired textural properties, such as for instance firmness and hardness of the resulting non-animal-based fibrous product. In useful embodiments of the invention, the concentration of calcium in the aqueous calcium-containing solution, or any other calcium solution as defined herein, is at least 1 wt.%, preferably from 2 to 10 wt.%, more preferably from 3 to 5 wt.%. In particular embodiments of the invention, the aqueous calcium-containing solution, or any other calcium solution as defined herein, comprises a calcium salt selected from calcium chloride, calcium acetate, calcium orthophosphate, calcium carbonate, calcium lactate, calcium ascorbate, calcium propionate, calcium sulfate, or any combination thereof. In a preferred embodiment, the aqueous calcium-containing solution comprises calcium chloride.

It was further found to be possibly beneficial for the properties and consistency of the non-animal-based fibrous product, that the second pressurizing means provides a continuous flow of the aqueous calcium-containing solution. In useful embodiments, a second pressurizing means (310) provides a continuous flow of the aqueous calcium-containing solution. In a particular embodiment, the present invention provides a method as defined herein, wherein the flow rate of the aqueous calcium-containing solution through the supply (306), expressed as the amount of solution in litre per minute and per square centimetre cross section of the second conduit, is from 0.5 to 5 l/min/cm², preferably from 1 to 4 l/min/cm², more preferably 1 .5 to 3 l/min/cm², such as 2.0 l/min/cm².

By contacting the alginate-containing slurry with the calcium-containing solution in step c) of the method of the present invention, a thin layer of cured alginate- containing slurry is formed on the outside of the alginate-containing slurry leading to a mass having a skin-cured shape.

In step d) of the method of the present invention, the skin-cured shape that is obtained in step c) is divided, for instance cut by means of a dividing element (107, 207, 307, 407, 507). Skin-cured pieces that form the non-animal-based fibrous product are obtained in step d). In a useful embodiment of the invention, the dividing element (107, 207, 307, 407, 507) in step d) of the method according to the invention comprises a rotating knife having a plurality of knife blades (408, 508) positioned on a knife shaft (416, 516), whereby the rotation speed of the knife shaft is in a range of from 300 to 1000 rpm, preferably from 400 to 900 rpm, more preferably from 500 to 800 rpm (rpm = revolutions per minute). The rotating knife may have a rotation speed in a range of from 0.8 to 2.3 m/s (meter per second), preferably from 1 .0 to 2.1 m/s, more preferably from 1 .2 to 1 .9 m/s.

To allow the non-animal-based fibrous product to further develop its textural properties, it was found that it may be beneficial to allow the non-animal-based fibrous product obtained in step d) of the method as defined herein to be in further contact with an aqueous calcium-containing solution, i.e. an optional step e). This further contact may result in further curing of the non-animal-based fibrous product. With the wording ‘further curing' is meant that the core parts of the non-animal-based fibrous product, or pieces thereof, are allowed to also cure at least over part of their cross-sectional area, preferably over essentially all of their cross-sectional area.

When the method according to the present invention is occurring in a device having a receptacle (309) for receiving the non-animal-based fibrous product from step d), whereby said receptacle (309) comprises a vessel (313) to which the outlet (304) of the first conduit (301 ) and the outlet (312) of the second conduit (306) is fluidly connected to an outlet (315) conduit of the vessel (313), and said vessel comprises a screw conveyer (314) as transport means for the skin-cured pieces, the further curing in step e) may occur in said vessel. It was found that further curing in step e) occurring in a vessel comprising a screw conveyer to transport the non-animal-based fibrous product may further benefit to the fibrous form of the product. The rotation axis of the screw conveyor (314) may have a rotation speed in a range of from 300 to 1000 rpm, preferably from 400 to 900 rpm, more preferably from 500 to 800 rpm (rpm = revolutions per minute).

Alternatively, or in addition to, a further curing in a vessel comprising a screw conveyer, the further curing of the non-animal-based fibrous product in step e) may occur in a device having a container positioned downstream of the receptacle (309).

The aqueous calcium-containing solution for the further curing of the non- animal-based fibrous products may be the same or different than the aqueous calcium-containing solution provided in step c) of the method as defined herein. It may for instance have the same or different calcium salt dissolved in the solution, or the same or different concentration of calcium ions.

In embodiments of the invention, the non-animal-based fibrous product is further cured in step e) with an aqueous calcium-containing solution 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.

In step f) of the method of the present invention, removal of the formed fibrous product from the aqueous calcium-containing solution may be performed by any technique known in the art, such as filtration, decantation, and the like.

Removal of the non-animal-based fibrous product from the aqueous calcium- containing solution may take place after the initial curing step d), after the further curing step e), or any combination thereof.

Optionally, the aqueous calcium-containing solution obtained in step f) of the method of the present invention, may be recirculated or partially recirculated into step c) of the method.

In a preferred embodiment, the invention provides a method comprising the steps of: a) supplying an aqueous alginate-containing slurry that further comprises non-animal-based proteins and/or starch; b) sustaining a flow of the aqueous alginate-containing slurry by a first pressurizing means (302) from an inlet (303) to an outlet (304, 504) of a first conduit (301 , 501 ), and distribute the flow through at least one aperture (305, 505) of a flow distributor comprised in the outlet (304, 504); c) supplying an aqueous calcium-containing solution though supply comprising a second conduit (306) for supplying the aqueous calcium- containing solution and a second pressurizing means (310) configured for sustaining a flow of the aqueous calcium-containing solution from an inlet (311 ) to an outlet (312) of the second conduit, and contacting the aqueous calcium-containing solution during 0.1 to 10 sec with the aqueous alginate-containing slurry exiting the at least one aperture (305, 505) of the outlet (304) of the first conduit (301 , 501 ), thereby curing at least a skin part of the alginate-containing slurry to obtain a skin-cured shape; d) dividing the skin-cured shape exiting the at least one aperture (305, 505) with a dividing element (307, 507) having at least one dividing blade (308, 508) configured to pass over the at least one aperture of the flow distributor at a distance from 0.5 to 20 mm thereof, and wherein the dividing element (407, 507) comprises a rotating knife having a plurality of knife blades (408, 508) positioned on a knife shaft (416, 516), wherein the ratio of knife blades per cm perimeter of the flow distributor is in a range of from 1 blade per 4 cm to 1 blade per 24 cm, and the blades are preferably regularly distributed around the knife shaft (416, 516), thereby forming the non-animal-based fibrous product, i.e. shortened skin-cured pieces in a medium of aqueous calcium-containing solution; and whereby the formed the non-animal-based fibrous product is received in a receptacle (309) comprising a vessel (313) to which the outlet (304) of the first conduit (301 ) and the outlet (312) of the second conduit (306) are fluidly connected and which vessel (313) is configured for transporting (314) the skin-cured pieces to an outlet (315) conduit of the vessel; e) optionally further curing the non-animal-based fibrous product from step d); f) removing from the aqueous calcium-containing solution the non-animal- based fibrous product obtained from step d) or, optionally from step e); and g) optionally recycling the aqueous calcium-containing solution obtained from step f) into step c).

In a particularly preferred embodiment, the formed non-animal-based fibrous product is received in the vessel (313) comprising a screw conveyor (314).

The dimensions of the skin-cured pieces forming the non-animal-based fibrous product may be varied according to the desired application, for instance by variation of the flow distributor in terms of number, size and form of apertures, of the flow rate of the aqueous alginate-containing slurry, the flow rate of the aqueous calcium-containing solution, the distance of the dividing element from the apertures of the flow distributor, or any combination therefore. The method according to embodiments of the invention allows for a wide variation in lengths and width or thickness of the individual shapes. For instance an average length of 1 mm, of 2 mm, of 5 mm, of 10 mm, of 15 mm, of 25 mm, of 50 mm, of 60 mm, of 75 mm, up to lengths of 100 mm, and even more if needed. It is however desirable to have a length considered natural in the field of food products, i.e. resembling the fibrous muscle tissue of meat or fish products. In embodiments of the invention, the non-animal-based fibrous product has an average length from 1 to 100 mm, preferably from 2 to 75mm, more preferably from 5 to 50 mm, most preferably from 10 to 25 mm.

To reduce or remove any microbial contamination, the non-animal-based fibrous product obtained from step f) of the method according to the inventions may preferably be heat-treated at an elevated temperature. Such a treatment may for instance comprise heating the food product in a water bath at a temperature above 68°C, between 70°C and 135°C, more preferably between 75°C and 130°C for at least 30 seconds. Preferably, the heat-treatment of the non-animal- based fibrous food product may comprise heating at a temperature of from 70 to 85°C for 10 to 35 minutes. Alternatively, the heat-treatment of the non-animal- based fibrous food product may comprise heating at a temperature from 90 to 135°C for 30 seconds to 15 minutes. Preferably, the heat-treating 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 is preferably dried at elevated temperatures, cooled to freezing temperatures, or any combination thereof, to allow storage and transport of the non-animal-based fibrous product under hygienic conditions. The freezing temperatures are below 0°C, preferably between -10°C and -30°C.

The present invention also provides a non-animal-based fibrous product obtainable by the invented method and its embodiments described herein having novel specific properties.

Claims

1. A device for preparing a non-animal-based fibrous product, the device comprising:

- a receptacle (109, 209, 309) for receiving the non-animal-based fibrous product.

2. Device as claimed in claim 1 , wherein the supply of the aqueous calcium- containing solution comprises a second conduit (306) for supplying the aqueous calcium-containing solution and a second pressurizing means (310) configured for sustaining a flow of the aqueous calcium-containing solution from an inlet (311 ) to an outlet (312) of the second conduit.

3. Device as claimed in claim 2, wherein the first conduit (301 ) extends into the second conduit (306) at most up to the outlet of the second conduit (312).

4. Device as claimed in any one of the preceding claims, wherein the flow distributor (104, 204, 304, 504) has a closed end face and the at least one aperture (105, 205, 305, 505) is provided along a perimeter edge of the flow distributor or the flow distributor has a closed perimeter edge and the at least one aperture is provided in an end face of the flow distributor.

5. Device as claimed in any one of the preceding claims, wherein the flow distributor comprises a plurality of apertures (105, 205, 305, 505).

6. Device as claimed in anyone of the preceding claims, wherein the flow distributor is detachably connected to the first conduit.

7. Device as claimed in any one of claims 2-6, wherein the receptacle (309) comprises a vessel (313) to which the outlet (304) of the first conduit (301 ) and the outlet (312) of the second conduit (306) are fluidly connected, which vessel

(313) is configured for transporting (314) the skin-cured pieces to an outlet (315) conduit of the vessel.

8. Device as claimed in claim 7, wherein the vessel comprises transport means

(314) for the skin-cured pieces.

9. Device as claimed in claim 8, wherein the transport means comprise a screw conveyor (314).

10. Device as claimed in any one of the preceding claims, wherein the dividing element (407, 507) comprises a rotating knife having a plurality of knife blades (408, 508) positioned on a knife shaft (416, 516), wherein the ratio of knife blades per cm perimeter of the flow distributor is in a range of from 1 blade per 4 cm to 1 blade per 24 cm, and the blades are preferably regularly distributed around the knife shaft (416, 516).

11 . Device as claimed in any one of the preceding claims, further comprising a container provided downstream of the receptacle, and adapted to receive the formed non-animal-based fibrous product, and an aqueous calcium-containing solution from the supply, and contact said non-animal-based fibrous product with aqueous solution comprising calcium to further cure said non-animal-based fibrous product, thereby providing a non-animal-based fibrous product.

12. Device as claimed in claim 11 , wherein the container comprises a conveyor system adapted to convey the non-animal-based fibrous product from an inlet to an outlet of the container.

13. Device as claimed in any one of the preceding claims, further comprising a temperature-regulating apparatus provided downstream of the receptacle, and optionally downstream of the optional container, and adapted to heat-treat the non-animal-based fibrous product by heating to a temperature above 68°C for at least 5 min and optionally cooling down the heat-treated non-animal-based fibrous product to freezing temperatures.

14. A method of preparing a non-animal-based fibrous product, the method comprising the steps of: a) supplying an aqueous alginate-containing slurry that further comprises non-animal-based proteins and/or starch; b) sustaining a flow of the aqueous alginate-containing slurry by first pressurizing means (102, 202, 302) from an inlet (103, 203, 303) to an outlet (104, 204, 304, 504) of a first conduit (101 , 201 , 301 , 501 ), and distribute the flow through at least one aperture (105, 205, 305, 505) of a flow distributor comprised in the outlet (104, 204, 304, 504); c) supplying an aqueous calcium-containing solution and contacting the aqueous calcium-containing solution during 0.1 to 10 sec with the aqueous alginate-containing slurry exiting the at least one aperture (105, 205, 305, 505) of the outlet (104, 204, 304, 504) of the first conduit (101 , 201 , 301 , 501 ) and cure at least a skin part of the alginate-containing slurry to obtain a skin-cured shape; d) dividing the skin-cured shape exiting the at least one aperture (105, 205, 305, 505) with a dividing element (107, 207, 307, 507) having at least one dividing blade (108, 208, 308, 508) configured to pass over the at least one aperture of the flow distributor at a distance from 0.5 to 20 mm thereof, thereby forming the non-animal-based fibrous product, i.e. shortened skin-cured pieces in a medium of aqueous calcium-containing solution, and whereby the formed the non-animal-based fibrous product is received in a receptacle (109, 209, 309); e) optionally further curing the non-animal-based fibrous product from step d); f) removing from the aqueous calcium-containing solution the non-animal- based fibrous product obtained from step d) or, optionally from step e); and g) optionally recycling the aqueous calcium-containing solution obtained from step f) into step c).

15. Method as claimed in claim 14, carried out by a device as claimed in any one of claims 1 -13.