System and method for producing an extruded protein product
The present disclosure relates to systems and methods for producing an extruded protein product. In particular, a system for making an extruded protein product using a system that includes a die including channel having a transverse cross section that is a continuous loop along at least a portion of the length of the die is disclosed.
1. A method for producing an extruded protein product having a thickness and fibers that are oriented in a generally parallel orientation throughout the thickness of the extruded protein product, the method comprising:
producing a stream comprising a proteinaceous composition having a protein component that can form oriented fibers, the proteinaceous composition having a protein content of about 15% to about 90% based on dry weight of the proteinaceous composition, the stream having a moisture content of at least 27%;
directing the stream through an elongated channel of a die to form oriented fibers from the protein component in a generally parallel orientation to form the extruded protein product, the die including an inner portion and an outer portion forming the elongated channel, and a support supporting the inner portion within the outer portion at one or more points along a length of the die, the elongated channel having a length, an outer diameter, an inner surface, and a cooling apparatus configured to cool the inner surface, the elongated channel having a gap thickness between the inner surface and the outer diameter, and having a generally constant transverse cross-section that is a continuous loop along substantially the entire length of the die, the die having a ratio of the length of the elongated channel to a gap thickness of the elongated channel between about 30:1 and about 1000:1, the outer diameter being between about 200 mm and about 750 mm, and the gap thickness being between 5 mm and about 30 mm, and
cooling the stream at a rate sufficient to provide the oriented fibers throughout the thickness of the extruded protein product,
such that the extruded protein product exits the die having a transverse cross-section that is a continuous loop.
2. The method of claim 1 , wherein the ratio of the length of the elongated channel to the gap thickness of the elongated channel is between about 40:1 and about 240:1.
3. The method of claim 1 , wherein the ratio of the length of the elongated channel to the gap thickness of the elongated channel is between about 50:1 and about 160:1.
4. The method of claim 1 , wherein the ratio of the length of the elongated channel to the gap thickness of the elongated channel is between about 60:1 to about 140:1.
5. The method of claim 1 , wherein a temperature of the extruded protein product upon exiting the elongated channel is between about 40° C. to about 110° C.
6. The method of claim 1 , wherein a temperature of the extruded protein product upon exiting the elongated channel is between about 55° C. to about 90° C.
7. The method of claim 1 , wherein a temperature of the extruded protein product upon exiting the elongated channel is between about 70° C. to about 85° C.
8. The method of claim 1 , wherein a temperature of the stream upon entering the elongated channel is between about 90° C. to about 180° C.
9. The method of claim 1 , wherein a temperature of the stream upon entering the elongated channel is between about 100° C. to about 155° C.
10. The method of claim 1 , wherein a temperature of the stream upon entering the elongated channel is between about 115° C. to about 120° C.
11. The method of claim 1 , wherein the extruded protein product is made at a rate of at least 400 kg/hr.
12. The method of claim 1 , wherein the protein comprises a non-animal derived protein.
13. The method of claim 1 , further comprising at least partially mixing an additive into the stream.
14. The method of claim 13 , wherein additive is incompletely mixed into the stream.
15. The method of claim 13 , wherein additive comprises one or more of a lipid, a coloring agent, a hydrocolloid, a carbohydrate, a softener or polyol, an enzyme, a pH adjusting agent, a salt, a macronutrient, or a micronutrient.
16. The method of claim 15 , wherein additive provides a predetermined appearance or function in the extruded protein product.
17. The method of claim 1 , further comprising directing the stream through a transition apparatus wherein the stream is substantially evenly distributed by the transition apparatus into the continuous loop of the elongated channel.
18. The method of claim 17 , wherein the transition apparatus pre-aligns portions of the stream to facilitate texturization.
19. The method of claim 17 , wherein the transition apparatus splits the stream into two or more substreams in order to distribute stream.
20. The method of claim 1 , further comprising directing the stream through a transition apparatus wherein the transition apparatus pre-aligns portions of the stream to facilitate texturization.
21. The method of claim 1 , wherein the support comprises at least one leg.
22. The method of claim 1 , wherein the support comprises an attachment plate.