Extruded protein product and methods of making

Abstract

The present disclosure relates to extruded protein products and methods for producing an extruded protein product. In particular, an extruded piece is disclosed having a high protein content and having a desirable texture and flavor. Methods for making an extruded piece include processing, under extrusion conditions, a combination of a powdered protein ingredient, a protein matrix disruptive ingredient, water, and an oil.

What is claimed is: 
     
         1 . A composition comprising extruded pieces, the extruded pieces comprising:
 a. protein in an amount of about 30% to about 90% by weight,   b. a protein matrix disruptive ingredient in an amount of from about 5% to about 50% by weight,   c. oil in an amount of from about 2% to about 20% by weight,   d. water in an amount of from about 1.5% to about 8% by weight, and   e. inclusions in an amount of from 0% to about 50% by weight.   
     
     
         2 . The composition of  claim 1 , wherein the extruded pieces comprise a substantially non-linearly oriented protein matrix. 
     
     
         3 . The composition of  claim 1 , wherein the extruded pieces have a texture analysis measurement of from about 1000 g to about 7400 g force. 
     
     
         4 . The composition of  claim 1 , wherein the oil is substantially uniformly distributed throughout the extruded pieces. 
     
     
         5 . The composition of  claim 1 , wherein the extruded pieces have a density of from about 0.5 g/cc to about 1.0 g/cc. 
     
     
         6 . The composition of  claim 1 , wherein the extruded pieces comprise inclusions substantially uniformly distributed throughout the extruded pieces. 
     
     
         7 . The composition of  claim 1 , wherein the extruded pieces comprise a rough and/or uneven surface. 
     
     
         8 . The composition of claiml, wherein the protein comprises soy protein. 
     
     
         9 . The composition of  claim 1 , wherein the protein comprises whey protein, bean protein, pea protein, wheat protein, canola protein, or algae protein. 
     
     
         10 . The composition of  claim 1 , wherein the protein matrix disruptive ingredient comprises a flour or a syrup. 
     
     
         11 . The composition of  claim 1 , wherein the protein matrix disruptive ingredient comprises a starch, a sugar, or a fiber. 
     
     
         12 . The composition of  claim 1 , wherein the inclusions comprise nuts, seeds, fruit, grains, or coconut. 
     
     
         13 . The composition of  claim 1 , wherein the extruded pieces comprise a sugar-based coating, a fat-based coating, or a protein-based coating. 
     
     
         14 . The composition of  claim 1  wherein an extruded piece is adhered with one or more edible component to form a cluster. 
     
     
         15 . The composition of  claim 14 , wherein the one or more edible component is one or more additional extruded piece. 
     
     
         16 . A food product comprising the composition of  claim 1  and food product pieces. 
     
     
         17 . A composition comprising particulates derived from extruded pieces, the extruded pieces comprising:
 a. protein in an amount of about 30% to about 90% by weight,   b. a protein matrix disruptive ingredient in an amount of from about 5% to about 50% by weight,   c. oil in an amount of from about 2% to about 20% by weight,   d. water in an amount of from about 1.5% to about 8% by weight, and   e. inclusions in an amount of from 0% to about 50% by weight.   
     
     
         18 . The composition of  claim 17 , wherein the particulates are coated on a food product. 
     
     
         19 . The composition of  claim 17 , wherein the particulates are formed into a food product. 
     
     
         20 . A food product or kit comprising the composition of  claim 1  as a first food component, the food product or kit further comprising a second food component. 
     
     
         21 . A method of making a protein product, comprising:
 processing, under extrusion conditions, a powdered protein ingredient comprising at least 45% protein by weight of the powdered protein ingredient and a protein matrix disruptive ingredient combined with water and an oil to form a protein matrix composition having a protein content of from about 10% to about 65% by weight, a moisture content of from about 25% to about 55% by weight and an oil content of from about 1% to about 15% by weight, and forming the protein matrix composition into pieces to form the protein product.   
     
     
         22 . The method of  claim 21 , wherein the extrusion conditions comprise a specific mechanical energy (SME) of from about 8 Wh/kg to about 100 Wh/kg, a die pressure of from about 150 PSI to about 1000 PSI, and/or a die temperature of from about 200° F. to about 350° F. 
     
     
         23 . The method of  claim 21 , wherein the powdered protein ingredient comprises at least a portion of the protein matrix disruptive ingredient. 
     
     
         24 . The method of  claim 21 , wherein the protein matrix disruptive ingredient comprises a flour or a syrup. 
     
     
         25 . The method of  claim 21 , wherein the protein matrix disruptive ingredient comprises a starch, a sugar, or a fiber. 
     
     
         26 . The method of  claim 21 , wherein the pieces comprise a substantially non-linearly oriented protein matrix. 
     
     
         27 . The method of  claim 21 , further comprising drying the protein matrix composition pieces to a moisture content of from about 1.5% to about 8% by weight to form extruded pieces. 
     
     
         28 . The method of  claim 27 , wherein the extruded pieces have a texture analysis measurement of from about 1000 g to about 7400 g force. 
     
     
         29 . The method of  claim 27 , wherein the extruded pieces have a density of from about 0.5 g/cc to about 1.0 g/cc. 
     
     
         30 . The method of  claim 27 , further comprising applying a sugar-based or protein-based coating to the extruded pieces to form coated pieces and drying the coated pieces. 
     
     
         31 . The method of  claim 27 , further comprising applying a fat-based coating to the extruded pieces to form coated pieces and cooling the coated pieces. 
     
     
         32 . The method of  claim 27 , further comprising comminuting the extruded pieces to form particulates. 
     
     
         33 . The method of  claim 32 , further comprising producing a food product comprising the particulates. 
     
     
         34 . The method of  claim 32 , further comprising coating a food product with the particulates. 
     
     
         35 . The method of  claim 21 , wherein the oil is substantially uniformly distributed throughout the pieces. 
     
     
         36 . The method of  claim 21 , further comprising processing inclusions with the powdered protein ingredient, protein matrix disruptive ingredient, water, and oil. 
     
     
         37 . The method of  claim 36 , wherein the inclusions comprise nuts, seeds, fruit, grains, or coconut.