Low shear meat analog
Methods for producing meat analog as well as formulations are disclosed. The novel production method uses a device designed to texturize the product while providing superior heat transfer for cooking. The device includes a helical compression conveyer with internal and external heating sources that delivers a high ratio of surface area for heat transfer to product volume. This results in the device being capable of heating of the emulsion volume as it is moved from the inlet to the outlet of the device to form a meat analog within the device in which the meat analog is formed in multiple segments to result in the meat analog having a defined surface texture.
1. A process for making a meat analog comprising the steps of:
a) forming an emulsion comprising one or more ingredients supplying 10-28% protein and 0.5-20% fat
b) introducing the emulsion into a helical conveyor device having an inlet and an outlet with a screw compression ratio from the inlet to the outlet of 1:1 to 1:6, the device having at least a heated screw and a heated barrel, each having heated surface areas providing for a uniform heat transfer surface area;
c) conveying the emulsion through the conveyor device by means of an external pump which provides a feeding pressure of 10 PSI to 100 PSI;
d) transferring heat from the surface areas of the heated screw and barrel to the emulsion as it is conveyed through the helical conveyor device wherein a predetermined screw compression ratio results in an emulsion flow of layers of material at different velocities and different residence times as it passes through the device;
e) wherein coagulation of the emulsion occurs against the heat transfer surface area of the heated screw and barrel resulting in the layers being cooked at different rates thereby forming a textured meat analog.
2. The process of claim 1 , wherein the textured meat analog comprises a) 10-28% protein, b) 0.5-20% fat, c) 50-75% moisture, and wherein 80% or more of the protein is derived from animal sources.
3. The process of claims 1 , wherein the heat from the surface area of the heated screw and barrel transferred to the emulsion results in an emulsion temperature of from about 60° C. to about 100° C.
4. The process of claim 1 , wherein the emulsion is formed under a vacuum of about −10 inches Hg to about −30 inched Hg.
5. The process of claim 1 , wherein the protein is from animal sources.
6. The process of claim 1 , wherein the emulsion has a protein to fat ratio of about 3 to 2.
7. The process of claim 1 , wherein the textured meat analog is formed in multiple individual segments.
8. The process of claim 1 , wherein the formation of the meat analog further comprises a processing step in an initial feed section, a processing step in a compression section and a processing step in a metering section.
9. The process of claim 8 , wherein the processing in the metering section provides a low shear egress that allows the meat emulsion to emerge with a texture and structure similar to real muscle tissue.
10. The process of claim 1 , wherein as the heat is transferred from the screw and the barrel to the emulsion, the heat from the barrel and rotation of the heated screw continuously renews the heat transfer area exposed to the emulsion.
11. The process of claim 1 , wherein the outlet provides little back pressure within the conveyor device or compressive shear forces on the meat analog as it exits the conveyor device.