A method of manufacturing a textured food product and a textured food product

Abstract

A method of manufacturing a textured food product comprising the steps of preparing a slurry comprising dry matter and water, wherein the dry matter comprises 1. at least 35% by weight legume protein, 2. 10% to 45% by weight oat bran, whole grain oat flour or a mixture thereof, and 3. 2% t 35% by weight of the dry matter of oat protein, of which 2. and 3. must always add up to no more than 65% by weight. The slurry further comprises water 20%-80% by weight of the weight of the dry matter. The method further includes cooking the slurry in an extruder cooker and extruding the cooked slurry to form the textured food product.

1 . A method of manufacturing a textured food product, comprising the steps of:
 preparing a slurry comprising dry matter and water,
 i) wherein the dry matter comprises:
 1. at least 35% by weight legume protein, 
 2. 10% to 45% by weight oat bran, whole grain oat flour or a mixture thereof, and 
 3. 2% to 35% by weight of the dry matter of oat protein, 
 of which 2. and 3. must always add up to no more than 65% by weight; 
 and 
 
 ii) wherein the slurry further comprises water 20%-80% by weight of the weight of the dry matter; and 
   cooking the slurry in an extruder cooker; and   extruding the cooked slurry to form said textured food product.   
     
     
         2 . The method according to according to  claim 1 , wherein: the step of cooking is performed at a temperature between 130° to 191° C. 
     
     
         3 . The method according  claim 1 , wherein: the share of oat bran and of oat protein is 40% to 60% by weight of the dry matter weight of the slurry and is preferably selected to produce a textured food product having a consistency for which a resistance force exhibited by 9.0 to 10.5 mm high sample of said textured food product during a compression test with a knife blade required to cut the sample textured food product is between 16 N and 28 N with a penetration distance between 5.5 and 8.5 mm. 
     
     
         4 . The method according to  claim 1 , wherein: after the step of extruding the cooked slurry to form said textured food product, the textured food product is further processed with water, salt, oil and spices and brewed, hydrated, wetted or soaked before performing an additional baking, cooking or high pressure cooking step on said further processed textured food product. Preferably, water, oil and spices are sprayed at the textured food product and salt is sprinkled. 
     
     
         5 . The method according to  claim 4 , wherein: during the brewing, hydration, wetting or soaking step, the ratio of water to the textured food product is between 1:1.0 to 1:3 by weight, preferably between 1:1.0 to 1:1.5 by weight, or essentially about 1:3 by weight. 
     
     
         6 . The method according to  claim 4 , wherein: amylase is added to the textured food product after the extruder cooking step but before the additional high pressure cooking step. 
     
     
         7 . The method according to  claim 4 , wherein: the additional high pressure cooking step is performed in an autoclave or in a pressurized cooking device, preferably at a pressure of at least 1.9 bar, most preferably at 2 bar, and preferably for between 20 to 60 minutes, or for between 30 to 60 minutes. 
     
     
         8 . The method according to  claim 4 , wherein: the step of brewing, hydrating, wetting or soaking is carried out for at least 10 minutes, preferably between 2 to 12 h. 
     
     
         9 . The method according to  claim 1 , wherein: the dry matter of oat protein is as at least one oat protein fraction, or a plurality of oat protein fractions. 
     
     
         10 . The method according to  claim 1 , wherein: the legume protein introduced into the slurry is selected from at least one of the following: pea protein concentrate, pea protein isolate,  vicia faba  protein concentrate,  vicia faba  protein isolate, peanut protein concentrate, peanut protein isolate. 
     
     
         11 . The method according to  claim 1 , wherein: the step of extruding is carried out as a protein texturation extrusion. 
     
     
         12 . The method according to  claim 10 , wherein: a water feed rate during the step of extruding and other extruding step parameters are selected such that the textured food product will result co-aligned fibres that are bunched together and that are relatively thick, preferably having a thickness of between 15 and 20 μm. 
     
     
         13 . The method according to  claim 1 , wherein: the percentage of oat protein is chosen to compensate for effects leading to a dough-like texturation of the textured food product due to the percentage of oat bran, whole grain oat flour or the mixture thereof in the dry matter. 
     
     
         14 . The method according to  claim 1 , wherein: said water in said slurry comprises between 28% and 40%, preferably between 30% and 40%, by weight of the dry matter. The percentage of water preferably includes water/humidity in the flour. 
     
     
         15 . The method according to  claim 1 , wherein: said water in said slurry comprises between 35% and 40% by weight of the dry matter. The percentage of water preferably includes water/humidity in the flour. 
     
     
         16 . The method according to  claim 1 , wherein: the step of cooking is performed at a temperature in the range of between 170° C. to 191° C. 
     
     
         17 . The method according to  claim 1 , wherein: the step of cooking is performed essentially at a temperature of about 175° C. 
     
     
         18 . The method according to  claim 1 , wherein: the step of cooking is performed at a temperature between 130° C. to 180° C. 
     
     
         19 . The method according to  claim 3 , wherein: said penetration distance is between 7.5 and 8.5 mm. 
     
     
         20 . The method according to  claim 4 , wherein: said water, oil and spices are sprayed at the textured food product and said salt is sprinkled on said textured food product. 
     
     
         21 . The method according to  claim 10 , wherein: at least 35% of legume protein is computed from the protein fraction of the respective legume protein or legume proteins introduced into the slurry. 
     
     
         22 . The method according to  claim 1 , wherein: the dry matter comprises 5% to 35% by weight of the dry matter of oat protein. 
     
     
         23 . The method according to  claim 1 , wherein: said oat bran, said whole grain oat flour or said mixture thereof is replaced with barley bran and/or whole grain barley flour or a mixture thereof. 
     
     
         24 . The method according to  claim 1 , wherein: said oat bran and/or said whole grain oat flour or said mixture thereof is replaced with rye bran and/or whole grain rye flour or a mixture thereof. 
     
     
         25 . The method according to  claim 1 , wherein: the dry matter comprises: 10% to 45% by weight of: i) oat bran, whole grain oat flour, or a mixture of oat bran and whole grain oat flour, ii) barley bran, whole grain barley flour, or a mixture of barley bran and whole grain barley flour, iii) rye bran, whole grain rye flour, or a mixture of rye bran and whole grain rye flour, or iv) a mixture of at least two or three of the ingredients listed under i) to iii) 
     
     
         26 . The method according to  claim 1 , wherein: the oat protein is at least partly replaced with rye protein and/or barley protein. 
     
     
         27 . The method according to  claim 1 , wherein: the percentage of oat protein in the dry matter is taken as a percentage of oat protein fraction or fractions in the dry matter. 
     
     
         28 . The method according  claim 1 , wherein: the percentage of oat protein in the dry matter is taken as the sum of a percentage of the matter under nr. 2. and of the percentage of oat protein fraction or fractions in the dry matter. 
     
     
         29 . A textured food product, manufactured according to the method according to  claim 1 . 
     
     
         30 . The textured food product according to  claim 29 , wherein: the percentage of oat protein is chosen to produce a textured food product having an apparent viscosity between 10 and 20 mPas at 10 1/s. 
     
     
         31 . The method according to  claim 1 , wherein: the percentage of oat protein is chosen to produce a textured food product having water absorption rate of less than 70% water level in 120 minutes. 
     
     
         32 . A method of manufacturing a textured food product, comprising the steps of:
 preparing a slurry comprising dry matter and water,
 i) wherein the dry matter comprises:
 1. at least 35% by weight legume protein, 
 2. 10% to 45% by weight oat bran, whole grain oat flour or a mixture thereof, and 
 3. 2% to 35% by weight of the dry matter of oat protein, 
 of which 2. and 3. must always add up to no more than 65% by weight, and wherein the percentage of oat protein is chosen to produce a textured food product having an apparent viscosity less than 20 mPas at 10 1/s; 
 and 
 
 ii) wherein the slurry further comprises water 20%-80% by weight of the weight of the dry matter; and 
   cooking the slurry in an extruder cooker; and   extruding the cooked slurry to form said textured food product.   
     
     
         33 . A method according to  claim 32 , wherein: the percentage of oat protein is chosen to produce a textured food product having an apparent viscosity between 10 and 20 mPas at 10 1/s. 
     
     
         34 . A method of manufacturing a textured food product, comprising the steps of:
 preparing a slurry comprising dry matter and water,
 i) wherein the dry matter comprises:
 1. at least 35% by weight legume protein, 
 2. 10% to 45% by weight oat bran, whole grain oat flour or a mixture thereof, and 
 3. 2% to 35% by weight of the dry matter of oat protein, 
 of which 2. and 3. must always add up to no more than 65% by weight, wherein the percentage of oat protein is chosen to produce a textured food product having water absorption rate of less than 70% water level in 120 minutes; 
 and 
 
 ii) wherein the slurry further comprises water 20%-80% by weight of the weight of the dry matter; and 
   cooking the slurry in an extruder cooker; and   extruding the cooked slurry to form said textured food product.   
     
     
         35 . The method of improving the structure of a textured food product, wherein: an amount of legume protein in a slurry comprising water and dry matter of oat bran, rye bran, barley bran, whole grain oat flour, whole grain rye flour, whole grain barley flour, or a mixture thereof, and of legume protein is replaced with oat protein, rye protein, barley protein or mixture thereof before cooking the slurry in an extruder cooker and extruding the cooked slurry to form said textured food product. 
     
     
         36 . The method of  claim 35 , wherein: the dry matter used to prepare the slurry comprises at least 10 weight-% of oat protein, rye protein, barley protein or mixture thereof. 
     
     
         37 . The method according to  claim 36 , wherein: in the dry matter, the oat/rye/barley bran or whole grain flour with the replacement protein must always add up to no more than 65% by weight. 
     
     
         38 . The method according to  claim 35 , wherein: the percentage of oat protein is chosen to produce a textured food product having an apparent viscosity less than 20 mPas at 10 l/s.