WO2025029138A1

WO2025029138A1 - A method for manufacturing a textured protein product, a reactor for use therewith and a product manufactured therewith

Info

Publication number: WO2025029138A1
Application number: PCT/NL2023/050414
Authority: WO
Inventors: Jan Michael BÜHLER; Robin Stanley Stefan HAAKMAT; Emanuele Joanna Maria VAN WIJLEN; David WULFF
Original assignee: Vivera BV
Current assignee: Vivera BV
Priority date: 2023-08-02
Filing date: 2023-08-02
Publication date: 2025-02-06
Anticipated expiration: 2026-02-02

Abstract

The invention relates to a method for manufacturing a textured material based on a protein starting material, for instance a plant based protein starting material, comprising the use of a device comprising a container with an inner cylindrical space with an outer wall defining the cylindrical space on the outer circumference, characterized in that the device comprises a scraping stirring element placed in said space, the scraping stirring element moving along the outer wall for inducing shear forces on the protein starting material and for forming the textured material.

Description

A METHOD FOR MANUFACTURING A TEXTURED PROTEIN PRODUCT , A REACTOR

FOR USE THEREWITH AND A PRODUCT MANUFACTURED THEREWITH

The present invention relates to a method for manufacturing a textured material based on a protein starting material , for instance a vegetable protein starting material , according to the preamble of claim 1 . The invention also relates to an apparatus for use with the method and to a product obtained with the apparatus or with the method .

Such a method is known in the art . In particular , it is known to use so-called shear reactors , for instance designed as a coneplate shear reactor or as a couette reactor , in which a composition with a protein starting material , as known in the art , is subj ected at high temperature to shear forces , to obtain a composition comprising the protein material having the textured structure . For example , the textured structure may be fibrous or layered . A detailed theoretical explanation of the underlying technique and examples of starting materials to be used and the structures to be obtained, determined among other things by means of an anisotropic index value , is described in Georgios A . Krintiras et al , "On the use of the Couette Cell technology for large scale producti on of textured soy-bean meat replacers" , J . Food Eng . 169 , ( 2016 ) , 205-213 . The information therein is hereby incorporated into this specification by reference . As protein starting material , for example , soybean protein isolate ( SPI ) or vital wheat gluten (WG) can suitably be used .

Such a method using a shear reactor is difficult to scale up . Although Krintiras mentions that scaling up is easy, practice in the meantime has shown otherwise . The gap size as well as the rotation speed, diameter and material properties are all critical factors when performing the process , as applied by Krintiras . Since the process depends on all these parameters in combination it is very difficult to scale up this known shear reactor . Furthermore , the operation of such an apparatus is difficult as such . In particular, filling the shear reactor is a laborious process . Furthermore , it is difficult to achieve a consistently defined structure of the textured protein material from the method .

Therefore , there is a need in the art for another method of manufacturing a textured protein material .

In particular, there is a need for a method that can be easily scaled up .

In addition, there is a need for a method in which the reactor can be simply filled and emptied .

There is also a need for a method by which a protein product with consistent properties can be obtained .

The invention has for its first obj ect to provide an alternative method of the type mentioned in the preamble .

The invention also has for its obj ect to provide an improved method of the type mentioned in the preamble .

In particular, the invention has for its obj ect to provide a method of the type mentioned in the preamble which offers simple scalability .

Another obj ect of the invention is to provide a method with which a plant based protein starting material can be converted into a denatured protein material with a structure like that of meat or which approaches a structure of meat very well .

In order to obtain at least one of the aforementioned advantages , the invention according to a first embodiment provides a method comprising the features of claim 1 . This method has the effect that it can be easily scaled up while preserving the predictability of the structure , more in particular the denatured structure , of the formed product .

It has also been found that the method offers a better controllability of the temperature . Such a synergistic effect is a great advantage .

The invention therefore relates to a method for manufacturing a textured material based on a protein starting material , for instance a plant based protein starting material , comprising the use of a device comprising a container with an inner substantially cylindrical space with an outer wall , defining the substantially cylindrical space on the outer circumference , and in that the device comprises a scraping stirring element placed in said space , the scraping stirring element moving along the outer wall for inducing shear forces on the protein starting material and for forming the textured material . Because the stirring element keeps the wall of the substantially cylindrical space substantially free from material and because of the fact that the material is mixed by the stirrer , excellent heat transfer is achieved, resulting in a more consistent conversion of the starting material . The method according to the invention produces a material that can be accurately defined .

It is preferred that the method comprises the use of a device wherein in the substantially cylindrical space a substantially cylindrical inner body is placed concentrically with respect to the outer wall , wherein a surface of the inner body that is positioned inside the said space forms an inner wall of the space and wherein both the inner wall and outer wall are held mutually stationary . The presence of the inner body improves the efficiency of the stirring element , in particular because a higher shear force is induced .

In this invention, the term "substantially cylindrical" means that the said shape may be exact cylindrical wherein both ends of the cylindrical shape have the same diameter, but also relates to conical cylindrical shapes wherein a first end has another diameter than the other end . The scraping stirring elements are positioned such that they keep the walls substantially free from material . Within the scope of the present invention, other shapes also fall within the scope of the present claims , such as free-form walls as long as the body is rotationally symmetric around a rotation axis of the scraping stirring elements .

It is especially preferred that the method comprises the step of moving the stirring element along the inner wall to induce shear forces on the protein starting material and to form the textured material . This also keeps the inner wall free from material . The inner wall can therefore also be used very efficiently as a heat-exchanging surface for converting or even reacting the starting materials and/or for cooling the textured material formed .

It is particularly preferred that the invention comprises the step of forming an anisotropic textured material during the meth- od, preferably with a fibrous and/or layered structure . Such a material largely has the texture of meat , which promotes acceptance of the use of the formed material as a meat substitute .

Although the invention is not limited thereto , it is preferred that the protein starting material is a plant based material . The depletion of raw materials is thus greatly reduced, while the consumer has a similar experience as when eating meat . It is also noted that the composition that is subj ected to the method according to the present invention, may comprise other materials and substances than a single protein . For example , the starting material or starting composition may comprise carbohydrates , fats , colorants , flavors and other additives . Among others , water may be added in surplus amounts relative to the protein in the starting composition .

Instead of plant based proteins , the present invention may apply proteins from other sources , for example proteins of animal origin, proteins based on fungi/mycelium and proteins based on microorganisms or on fermentation processes . Examples thereof comprise but are not limited to mammals , poultry, insects , aquatic animals , et cetera . However , fully synthesized proteins may be subj ected to the method and apparatus of the present invention as well .

It is preferred in the method according to the invention, that it comprises the step of heating at least one wall , for example at least one of the outer wall and the inner wall , for inducing heat exchange between any of the said walls and at least one of the starting material and the textured material . The lid or bottom may be heated as well , alone or in combination with one of the above mentioned walls . Heating to a predetermined temperature , wherein the actual temperature depends on the specific material processed in the method and commonly at least 100 ° C, and maximally 140 ° C or even more , induces a required state of denaturation of the protein starting material , providing it with right properties such that the material can be structured by the shear, induced by scrapers or the like . The combination of temperature and shear therefore provides the material with the required or intended structure . Cooling is essential as well , since this sets of fixates the created structure , resulting in the preferred or preferable texture of the product .

Furthermore , the invention relates to a preferred method, wherein the protein starting material is chosen from any one or a combination of two or more of Gluten, Soy, Mycoprotein, Cultured Animal Protein, Precision fermentation protein, Pea , Lentils . These provide an advantageous result in that a highly structured product is obtained with a fibrous structure .

Preferably, the method comprises the step of increasing the pressure to at least 5 atm, more preferably at least 10 atm, still more preferably at least 15 atm . Such increased pressure allows a higher processing temperature , successfully evoking the boiling of water contained in the processing materials .

The invention also relates to an apparatus for manufacturing a textured material based on protein starting material , for instance a plant based protein starting material , to be used in the method according to the invention, comprising a container with an internal cylindrical space with an outer wall defining the cylindrical space at the outer circumference , the device comprising a stirring element placed in said space . The method according to the invention can be suitably carried out with this apparatus . Of course , the apparatus will have additional elements that have a necessary cause , such as an inlet for starting materials and an outlet for the converted or formed material . There are also facilities for energy supply, heat supply and removal , and the like . The space in which the material is reacted is a closed cylindrical space that is also closed at the ends to keep the material in the space for as long as desired .

In this connection, the invention also relates to a device as mentioned above , wherein in said space an inner cylindrical body is placed concentrically with respect to the outer wall . The advantages obtained hereby correspond to what has been mentioned in connection with the method using such a device .

It is especially preferred that the inner body is positioned stationary relative to the outer wall defining an outer periphery during manufacture of the textured material . Because the inner wall and the outer wall are stationary relative to each other , an accurate definition of the forces on the material in the space is obtained, so that only the movement of the stirring element needs to be taken into account as a variable .

It is particularly preferred that the stirring element is a scraping stirring element which moves along the outer wall defining the outer wall or circumference , so that the wall remains free of encrusted material and an optimum heat exchange is obtained .

It is therefore preferred that the stirring element is moved against the outer wall defining the outer circumference .

Similarly and for the same reason, it is preferred that the stirring element is a scraping stirring element which moves along the inner wall of the inner cylindrical body .

Here too it is preferred that the stirring element is moved against the inner wall of the inner cylindrical body .

In addition, so as to easily and predictably obtain a preferred texture of the protein material , it is preferred that the apparatus comprises a heater for heating at least one of the outer wall and the inner wall .

According to a further aspect , the invention relates to a protein product , obtained by a method according to the invention, having a textured structure . The invention also relates to such a protein product , obtained by an apparatus according to the invention, having a textured structure .

The invention further relates to a protein product according to the invention, with an anisotropic textured structure , preferably with a fibrous and/or layered structure .

The invention will be explained in more detail below with reference to a drawing . The drawing shows in :

Fig . 1 a sectional side view of a reactor according to the invention,

Fig . 2 a sectional top view of a reactor according to the invention,

Fig . 3 a sectional side view of a stirrer according to Fig .

2 .

In the figures , the same parts are designated by the same reference numerals . However , not all parts necessary for a practical implementation of the invention are shown, for simplicity of presentation .

Fig . 1 shows a sectional side view of a reactor 1 according to the invention . The reactor 1 is a shear reactor 1 , comprising an outer wall 2 and an inner wall 3 . A reactor compartment 4 is formed in between the walls 2 , 3 . Inside the reactor compartment 4 scraping elements 5 , 6 are provided that are guided along wall surfaces 7 , 8 and that thus exert a shear stress on the wall surfaces 7 , 8 of the reactor 1 . The scraping elements 5 , 6 are connected to carrying arms 10 , 11 . Scraping elements 5 exert a shear stress on the wall surface 7 , whereas scraping elements 6 exert a shear stress on the wall surface 8 .

A protein starting material to be processed in the reactor 1 is added to the reactor compartment 4 through a material inlet 9 .

In the Fig . 1 two sets of scraping elements 5 , 6 ( that also act as stirring elements ) are shown, at the left side and at the right side of Fig . 1 . These sets are placed opposite each other in the reactor 1 .

The top view according to Fig . 2 clearly shows that a total of four sets of scraping elements 5 , 6 are provided in the reactor 1 . Each set is connected to a carrying arm 10 , 11 , 12 , 13 . The carrying arms 10 , 11 each comprise two scraping elements 5 whereas carrying arms 12 , 13 each comprise two scraping elements 6 . The complete wall surface 7 , 8 is treated by scraping elements 5 and 6 , respectively . For example , the position of elements 5 on carrying arms 10 , 12 may be such that there is some overlap of wall surface 8 treated by these elements 5 . This applies mutatis mutandis for elements 5 on carrying arms 11 , 13 and elements 6 on carrying elements 10 , 11 , 12 , 13 . As a result , the complete wall surface area is scraped by elements 5 , 6 ensuring an even treatment of all material to be processed in reactor compartment 4 .

The walls 2 , 3 are provided with a temperature controlling element 20 . This temperature controlling element 20 may be a cooling element or a heating element provided in temperature exchanging contact with the outer wall 2 or inner wall 3 . The temperature controlling element may be embodied as a heating element to add heat to the material to be processed for denaturation of the protein starting material . When a sufficient denaturation has been obtained, the temperature can be cooled by the temperature controlling element , limiting the rate of denaturation and setting the product obtained to a preferred state or condition . Nonlimiting examples of a heating element are an electric heater and a pipe comprising a hot fluid ( for example a liquid or gas ) in energy exchanging contact with any of the walls 2 , 3 and the lid 21 and bottom 22 . The advantage of a pipe comprising a hot fluid ( for example a liquid or gas ) is that it can be used both for heating and for cooling , depending on the temperature of the fluid flowing there through .

In Fig . 3 a side view of a stirring element 14 shows two carrying arms 13 , 11 each connected to a central coupling element 15 .

As shown in Fig . 2 , all carrying arms 10 , 11 , 12 , 13 run clockwise and are coupled to the coupling element 15 through connectors 16 , 17 , 18 , 19 , respectively . The coupling element 15 is connected to a rotation axis 20 , as shown in Fig . 1 . This axis 20 is connected to a drive unit ( not shown ) , for example an electromotor , for rotating the axis and the carrying elements for exerting a shear stress on the wall surfaces 7 , 8 and thus to the material adhered to these wall surfaces . In combination with the heat transferred to the protein starting material close to the wall surfaces , the material undergoes a denaturation . The shear stress ensures a desired texture and structure to the denatured protein material .

The device according to the present invention can be embodied easily such to withstand very high internal pressure required for texturization of the material to be processed . The reactor should be able to operate at normal pressure ( 1 atm; 101 , 3 kPa ) , and preferably is able to withstand an internal pressure of at least 5 bar, more preferably at least 10 atm, still more preferably at least 15 atm . Resistance to higher pressures is even more preferred . The cylindrical shape of the container can withstand high internal pressure whereas the lid 21 can be easily connected strongly to the outer wall . By applying well-known and proven methods and constructions known in the art , the rotation axis can be connected in a leak-free manner to the device . Such high internal pressure is essential to keep the material from boiling , i . e . to prevent water from evaporating inside the device while it is heated to above 100 ° C . This is a highly preferred effect .

Table 1 gives examples of recipes (w/w ) that can be processed in accordance with the present invention .

Table 1 :

Protein

Polysaccharides

Additives

Although salt is added to the recipes above , the invention equally applies to the same recipes without any salt added or with a limited or even higher amount of salt .

The invention also extends to any combination of features described above independently of each other . The invention is not limited to the embodiments described above and shown in the figures and the table . For example , a dif- ferent number of scraping arms may be provided, for example more scraping arms , like five , six , seven, eight or even more , or optionally less scraping arms than depicted in the figures , for example three , two or only one scraping arm . The scraper arms may run anti-clockwise opposed to the embodiment shown in Figure 2 , in which case the scrapers are directed in the opposite direction .

The invention is limited only by the appended claims .

Claims

C L A I M S

1 . A method for manufacturing a textured material based on a protein starting material , for instance a plant based protein starting material , comprising the use of a device comprising a container with an inner cylindrical space with an outer wall defining the cylindrical space on the outer circumference , characterized in that the device comprises a scraping stirring element placed in said space , the scraping stirring element moving along the outer wall for inducing shear forces on the protein starting material and for forming the textured material .

2 . A method according to claim 1 , comprising the use of a device wherein in the cylindrical space a cylindrical inner body is placed concentrically with respect to the outer wall , wherein a surface of the inner body that is positioned inside the said space forms an inner wall of the space and wherein both the inner wall and outer wall are held mutually stationary .

3 . A method according to claim 2 , comprising the step of moving the stirring element along the inner wall to induce shear forces on the protein starting material and to form the textured material .

4 . A method according to any one of claims 1 to 3 , comprising the step of forming an anisotropic textured material during the method, preferably with a fibrous and/or layered structure .

5 . A method according to any one of claims 1 to 4 , wherein the protein starting material is a plant based material .

6 . A method according to any of claims 1 to 5 , comprising the step of heating at least one of the outer wall and the inner wall for inducing heat exchange between any of the said walls and at least one of the starting material and the textured material .

7 . A method according to any of the preceding claims , wherein the protein starting material is chosen from any one or a combination of two or more of Gluten, Soy, Mycoprotein, Cultured Animal Protein, Precision fermentation protein, Pea, Lentils .

8 . A method according to any of the preceding claims , comprising the step of increasing the pressure to at least 5 atm, more preferably at least 10 atm, still more preferably at least 15 atm .

9 . An apparatus for manufacturing a textured material based on protein starting material , for instance a plant based protein starting material , for use in the method according to any of claims 1 to 5 , comprising a container with an internal cylindrical space with an outer wall defining the cylindrical space at the outer circumference , the device comprising a stirring element placed in said space .

10 . An apparatus according to claim 9 , wherein in said space an inner cylindrical body is placed concentrically with respect to the outer wall .

11 . An apparatus according to claim 9 or 10 , wherein the inner body is positioned stationary relative to the outer wall defining an outer periphery during manufacture of the textured material .

12 . An apparatus according to claim 9 , 10 or 11 , wherein the stirring element is a scraping stirring element which moves along the outer wall defining the outer circumference .

13 . An apparatus according to claim 12 , wherein the stirring element is moved against the outer wall defining the outer circumference .

14 . An apparatus according to any one of claims 10 to 13 , wherein the stirring element is a scraping stirring element which moves along the inner wall of the inner cylindrical body .

15. An apparatus according to claim 14, wherein the stirring element is moved against the inner wall of the inner cylindrical body.

16. An apparatus according to any of claims 7 to 15, comprising a heater for heating at least one of the outer wall and the inner wall .

17. A protein product, obtained by a method according to any one of claims 1 to 6, having a textured structure.

18. A protein product according to claim 17, with an anisotropic textured structure, preferably with a fibrous and/or layered structure .