Description:TECHNICAL FIELD
[0001] The present disclosure relates to the field of food production. Moreover, the present disclosure relates to a food product and a method of manuacturing the food product.
BACKGROUND
[0002] The food industry is changing according to consumer needs while focusing on protein-rich food products that are good for the health of the consumer. The existing protein-rich food products, such as meat, chicken, beef, pork and the like have been a part of everyone's daily life because of the taste, texture, and nutritional value, and the like as the protein-rich food helps the consumers to improve their metabolism. Thus, there is an increase in demand for food products that can meet the rising global demand for protein. Traditional methods of manufacturing meat involve breeding of animals to obtain meat product, which contribute to global challenges, such as environmental degradation due to imbalance in food chain as well as animal welfare or ethical concerns. As global protein demands grow, the traditional methods for manufacturing meat products at large scale while maintaining consistent quality of the meat products faces many difficulties due to many reasons, such as limited availability of natural resources, less time availability for the animals to grow completely due to which under nourished animals are slaughtered for meeting the demand of meat product, and the like.
[0003] Certain attempts have been made to fufil the demand of the meat product, such as by manufacturing an artificial meat (e.g., by using plant-based products or by cultivating animal cells in controlled environments), which has similar fibrous texture, taste, and nutritional profile as that of the traditional meat products which are obtained from animals. Moreover, plant-based meat products are used to fulfil the demand of the consumers. Additionally, such plant-based meat products are environmentally friendly but lacks in the fibrous texture as well as nutritional profile of the original meat and may also adversely affects the overall experience of the consumers while consuming such plant-based meat products. Thus, there exists a technical problem of how to manufacture a food product that can meet the rising global demand for protein without compromising the characteristics of the meat product which is obtained from animals.
[0004] Therefore, in light of the foregoing discussion, there exists a need to overcome the aforementioned drawbacks associated with the existing food products and a method of manufacturing the food products.
SUMMARY
[0005] The present disclosure provides a food product and a method of manufacturing the food product, which resembles with the characteristics, such as texture, taste, nutritional value, and the like of the meat product which is obtained from animals. The present disclosure provides a solution to the existing problem of how to manufacture a food product that can meet the rising global demand for protein without compromising the characteristics of the meat product which is obtained from animals. An objective of the present disclosure is to provide a solution that overcomes at least partially the problems encountered in the prior art and provide the food product and the method of manufacturing the food product.
[0006] One or more objectives of the present disclosure that are achieved by the solutions provided in the enclosed independent claims. Advantageous implementations of the present disclosure are further defined in the dependent claims.
[0007] In one aspect, the present disclosure provides the food product that includes cultured chicken cells selected from one cell type or a plurality of cell types, including a chicken fibroblast cell, a chicken myoblast cell, or a chicken adipocyte cell. Furthermore, the food product includes a biopolymer composition that supports the structure and texture of the cultured chicken cells. The biopolymer composition comprises a blend of an animal-based biopolymer, an algal-based biopolymer, and a plant-based biopolymer in the form of a biopolymer matrix. Moreover, the food product is a bio-printed structure of the biopolymer matrix and the cultured chicken cells.
[0008] Advantageously, the food product of the present disclosure resembled with the characteristics including texture, flavour, appearance, nutritional profile, and the like of the traditional meat, which is obtained from animals by combining the cultured chicken cells with the biopolymer matrix. Moreover, the biopolymer matrix incorporates a specific ratio of animal-based, algal-based, and plant-based polymers that is used to provide an enhanced texture, moisture retention, and structural stability of the food product with an enhanced tactile and organoleptic properties of the food product. Additionally, the microporous structure of the food product enhances the nutritional composition by supporting a balanced distribution of proteins, carbohydrates, and lipids while maintaining the structural integrity of the food product under various conditions, such as cooking, storage and transportation and the like. Additionally, the food product exhibits an extended shelf life due to the biopolymer composition, which helps to preserve the nutritional and sensory characterstics of the food product over time.
[0009] In another aspect, the present disclosure provides a method of manufacturing the food product. The method includes culturing chicken cells selected from one cell type or the plurality of cell types comprising the chicken fibroblast cell, the chicken myoblast cell, or the chicken adipocyte cell in a bioreactor until the predefined density is reached in the bioreactor. Furthermore, the method of manufacturing the food product includes blending the animal-based biopolymer, the algal-based biopolymer, and the plant-based biopolymer sequentially to form the biopolymer matrix, mixing the chicken cells harvested from the cultured chicken cells with the biopolymer matrix in a jacketed-stirred tank reactor to form a first mixture. Additionally, the method of manufacturing the food product includes automatically bio-printing the first mixture through a screw extruder to obtain the food product as a bio-printed structure.
[00010] The method achieves all the advantages and technical effects of the food product of the present disclosure.
[00011] It is to be appreciated that all the aforementioned implementation forms can be combined. All steps which are performed by the various entities described in the present application as well as the functionalities described to be performed by the various entities are intended to mean that the respective entity is adapted to or configured to perform the respective steps and functionalities. It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
[00012] Additional aspects, advantages, features, and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative implementations construed in conjunction with the appended claims that follow.

[00013] BRIEF DESCRIPTION OF THE DRAWINGS
[00014] The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those skilled in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
[00015] Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 is a diagram that illustrates a method of manufacturing a food product, in accordance with an embodiment of the present disclosure;
FIG. 2 is another diagram that illustrates a method of manufacturing the food product, in accordance with an embodiment of the present disclosure;
FIG. 3 is a diagram that illustrates a three-dimensional (3D) printing of the food product through a 3D printer, in accordance with an embodiment of the present disclosure;
FIG. 4 is a diagram that illustrates the food product, in accordance with an embodiment of the present disclosure;
FIGs 5A and 5B depict a Field-Emission Scanning Electron Microscope (FESEM) image of the food product, in accordance with an embodiment of the present disclosure;
FIG. 6 is a chromatography graph of the biopolymer matrix present in the food product, in accordance with an embodiment of the present disclosure; and
FIG. 7 is a flowchart that illustrates a method of manufacturing the food product, in accordance with an embodiment of the present disclosure.
[00016] In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION OF EMBODIMENTS
[00017] The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practicing the present disclosure are also possible.
[00018] FIG. 1 is a diagram that illustrates a method of manufacturing a food product, in accordance with an embodiment of the present disclosure. With reference to FIG. 1, there is shown a diagram 100 that depicts manufacturing a food product, such as meat.
[00019] The conventional methods used for chicken meat production rely on traditional farming practices that require substantial resources, including 6-7 weeks of animal raising time, extensive land usage, significant water consumption, and feed resources. Moreover, such conventional methods face challenges related to animal welfare concerns and environmental impact. The traditional methods and systems for manufacturing meat involve multiple manual steps, including slaughtering, de-feathering, and butchering, which often result in inconsistent quality outputs and variable processing times. Furthermore, the conventional methods are limited by biological constraints and environmental factors due to which it is difficult to standardize the production process or customize the final product characteristics. Additionally, the conventional methods often struggle to address growing concerns about scalable production.
[00020] In contrast to the conventional methods, the disclosed food product and the method for manufacturing the food product provide a controlled and efficient approach to meat manufacturing. Unlike conventional methods that depend on traditional animal agriculture, the present disclosure utilizes the automated 3D bioprinting techniques to produce meat products in a sterile environment, such as by combining the harvested cultured cells with a precisely formulated biopolymer matrix, creating a bioink that can be processed through automated 3D printing units. Thereafter, the printed structures through specific post-processing steps, including cross-linking treatment, PBS washing, and controlled cold storage, are used to ensure product stability, thereby enabling customization of nutritional profiles and consistent quality metrics. As a result, the food product has a microporous network structure, specific nutritional composition, and extended shelf life while ensuring efficient resource utilization and reduced environmental impact.
[00021] In an implementation, cells are selected from a working cell bank that stores the cells under controlled conditions (e.g., temperature, pH, Oxygen level, and the like), such as at operation 102, while ensuring the quality and viability of the cells. In contrast, traditional meat production starts with raising farm animals, which requires land, water, and time to grow the animals to produce food. The cell selection from the working cell bank eliminates the need for animal breeding. Thereafter, at operation 104, the selected cells from the working cell bank are placed into a small container called a seed flask in order to allow them to multiply under controlled conditions, such as optimal temperature, pH levels and the like and reach the required population density. After that, the expanded cells from the seed flask are transferred to a cell bioreactor to allow the cells to multiply under controlled conditions in a large-scale environment, such as at operation 106, in order to allow large-scale cell production, reaching densities of hundreds of millions of cultured cells per millilitre. At operation 108, the cell bioreactor is stirred to prepare a biopolymer mixture by combining animal-based, algal-based, and plant-based biopolymers in a specific ratio of 1:2:25 to create the structural matrix. Furthermore, at operation 110, a mixing vessel combines the harvested cultured cells from the cell bioreactor with the prepared biopolymer matrix and a binding substance at a predetermined concentration, resulting in a paste-like bioink formulation with a cell-to-biopolymer ratio of 1:12. Thereafter, at operation 112A to operation 112F multiple automated 3D bioprinting units are used to utilize the bioink, which is delivered through a screw-pusher system to create multi-layered structures resembling chicken breast with specific dimensions of 110-130 mm in length, 70-90 mm in breadth, and 5-9 mm in thickness. The final stages involve post-processing steps, including a 20-40 minute cross-linking treatment, PBS washing to remove excess salts (e.g., at operation 114), cold storage at 2-8°C for 10-24 hours (e.g., operation 116), final packaging (eg., at operation 118) and shipping (e.g., at operation 120). As a result, the method is used for obtaining a food product having a microporous network structure with 100-150 μm pore size, specific nutritional composition, and a shelf life of 7 days under refrigeration.
[00022] FIG. 2 is a diagram that illustrates a method of manufacturing a food product, in accordance with an embodiment of the present disclosure. With reference to FIG. 2, there is shown a diagram 200 that depicts manufacturing of the food product, such as meat.
[00023] In an implementation, at operation 202, a master cell bank maintains the primary cell lines under controlled conditions and at operation 204, the cells are transferred to a working cell bank for routine production use. At operation 206, the cell culture expansion branches into three parallel pathways (e.g., at operation 208A, at operation 208B, and at operation 208C) for cultivating different cell types, such as chicken fibroblasts, chicken myoblasts, chicken adipocytes, and the like. Furthermore, the cultured cells are converged for co-culture integration, such as at operation 210. Furthermore, at operation 212, the bioink is prepared by combining specific biopolymers (e.g., at operation 214). At operation 216, the 3D bioprinting process takes place, utilizing the cell-bioink (or the bioink) combination to create structured meat products, which involves crosslinking treatment to stabilize the printed structure, such as at operation 218. Furthermore, at operation 220 and 222, post-processing procedures are performed under controlled conditions that includes washing and quality control measures of the food product. Finally, at operation 226, the food product is prepared for commercial use after passing quality checks at operation 224. As a result, the food product is used for utilizing controlled cell culture conditions, implementing precise bioink formulation, and employing the automated 3D bioprinting while ensuring consistent quality through standardized procedures.
[00024] FIG. 3 is a diagram that illustrates a three-dimensional (3D) printing of the food product through a 3D printer, in accordance with an embodiment of the present disclosure. With reference to FIG. 3, there is shown a diagram 300 that depicts the 3D printing of the food product, such as meat, through the 3D printer 302.
[00025] The 3D printer 302 includes a precision printing head with a screw extruder mechanism and a needle for depositing the bioink. In an implementation, the 3D printer 302 includes a 15-gauge needle to form precise layers of the bioink. In another implementation, the 3D printer 302 includes a 16-gauge needle to form precise layers of the bioink. Moreover, the bioink is forced through the screw extruder mechanism, which controls the flow rate and pressure of the bioink. The printing head moves in multiple directions (i.e., X, Y, and Z axis) to form exact patterns and build up layers of the bio-printed structure through the bioink. The 3D printer 302 deposits the bioink in a loop-like texture, fiber-like texture, thread-like texture, or meaty texture for forming a multi-layered bio-printed structure that provides the similar texture as the real meat. The final bio-printed structure is in the shape of a chicken breast with length ranging from (110-130) mm, breadth ranging from (70-90) mm, and thickness ranging from (5-9) mm. The 3D printer 302 controls all aspects of the 3D printing process, including the movement of the printing head, the air-pressure controlled flow rate of the bioink, and the precise patterns of the bio-printed structure and ensures consistent quality and exact imitation of the desired meat structure. Additionally, the bio-printed structure forms a microporous network with pore sizes ranging from 100 to 150 micrometres. The microstructure network of the bio-printed structure maintains proper cell distribution and forms the right texture in the final food product. The printing process ensures that each layer is precisely deposited to form the specific internal structure of the meat. In an implementation, the printing parameters for the 3D printer 302 used for 3D printing of the food product are provided in Table 1 and Table 2 given below: -
Parameter Category Value Unit
Speed settings
Default Printing Speed 900.0 mm/min
XY Axis Movement Speed 1800.0 mm/min
Z Axis Movement Speed 600.0 mm/min
Layer settings
Primary Layer Height 0.5000 mm
First Layer Height 100 %
First Layer Width 100 %
First Layer speed 100 %
Outline/Perimeter Shells 2 -
Extruder Settings
Nozzle Diameter 1.37 mm
Extrusion Multiplier 3.50 -
Table 1
Parameter Category Value Unit
Retraction Settings
Retraction Distance 15.00 mm
Extra Restart Distance 1.00 mm
Retraction Vertical Lift 2.00 mm
Retraction Speed 6000.0 mm/min

Infill Settings
Infill Percentage 100 %

Internal Fill Angle 45 deg
Outline Overlap 90 %
Minimum Infill Length 5.00 mm
Combine Infill Every 1 Layers
Solid Diaphragm Every 20 Layers
Table 2
[00026] In the above-mentioned tables (i.e., The Table 1 and the Table 2), the printing parameters are used to control the speed of movement in different axis, layer settings that define the bio-printed structure build-up, extruder settings for the bioink flow through a nozzle, retraction settings to prevent the bioink leaking, and infill settings that ensure a solid product structure. However, the printing parameters provide a high-quality bio-printed structure.
[00027] FIG. 4 is a diagram that illustrates the food product, in accordance with an embodiment of the present disclosure. FIG. 4 is described in conjunction with FIGs. 1 to 3. With reference to FIG. 4, there is shown a diagram 400, which includes a food product 402.
[00028] The food product 402 refers to a cultivated chicken breast analogue that is fabricated through a combination of cultured chicken cells and a biopolymer matrix (or composition). In an implementation, the food product 402 refers to a meat product, a substitute of the existing meat product (e.g., chicken, meat, and the like) and an analogue of the meat product and the like. The food product 402 is shaped into a three-dimensional, multi-layered structure resembling a chicken breast, with dimensions such as a length ranging from 110 millimetres (mm) to 130 mm, a breadth ranging from 70 mm to 90 mm, and a thickness ranging from 5 mm to 9 mm. For example, the dimensions of the food product 402 may include the length of 110 mm, the breadth of 70 mm, and the thickness of 5 mm. In another example, the dimensions of the food product 402 may include the length of 130 mm, the breadth of 90 mm, and the thickness of 9 mm. In yet another example, the dimensions of the food product 402 may include the length of 120 mm, the breadth of 80 mm, and the thickness of 7 mm.
[00029] There is provided the food product 402, which includes cultured chicken cells selected from one cell type or a plurality of cell types comprising a chicken fibroblast cell, a chicken myoblast cell, or a chicken adipocyte cell. The inclusion of the cultured chicken cells in the food product 402 provides the nutritional profile, protein content, and amino acid composition of traditional chicken meat to the food product 402. In an example, the cultured chicken cells are selected from the chicken fibroblast cells. The chicken fibroblast cells provide structural proteins to the cultured chicken cells. In another example, the cultured chicken cells are selected from the chicken myoblast cells. The chicken myoblast cells provide a muscle-like texture to the cultured chicken cells. In yet another example, the cultured chicken cells are selected from the chicken adipocyte cells. The chicken adipocyte cells enhance flavour and mouthfeel by contributing lipids to the cultured chicken cells. Thus, the inclusion of the cultured chicken cells in the food product 402 provides a scalable alternative to conventional meat production. Moreover, the ability to select specific cell types from the cultured chicken cells allows for customization of the product's texture, flavour, and nutritional content to closely resemble or even surpass that of traditional chicken meat (or breast).
[00030] In accordance with an embodiment, the cultured chicken cells are cultured in a serum-free or a serum-alternative medium or in a combination of animal-derived serum and serum-free or serum-alternative medium. The process of culturing chicken cells in such mediums provides the biological conditions required for cell growth. Such mediums provide the appropriate pH, osmotic pressure, and nutrient composition to ensure optimal cell viability and proliferation. In cases where a combination of serum and serum-free mediums is used, the process emphasizes on gradually reducing the reliance on animal-derived components while maintaining high cell yield and quality. Such a hybrid approach allows for a smoother transition towards completely serum-free cultivation processes. The use of serum-free or serum-alternative mediums provides a substitute for the traditional serums, such as Fetal bovine serum (FBS), which is not ethical for large-scale production.
[00031] Furthermore, the food product 402 includes a biopolymer composition that supports the structure and texture of the cultured chicken cells. The biopolymer composition in the food product 402 replicates the structural, textural, and sensory attributes of the traditional chicken breast. In an implementation, the biopolymer composition comprises a blend of an animal-based biopolymer, an algal-based biopolymer, and a plant-based biopolymer in the form of a biopolymer matrix. The animal-based biopolymers provide gelation and a meat-like chewiness. The algal-based biopolymers contribute to moisture retention and structural stability. The plant-based biopolymers act as binders, ensuring the mixture remains cohesive during processing and cooking. Moreover, the biopolymer composition is mixed with the cultured chicken cells to create a bioink, which is used in 3D bioprinting to fabricate a multi-layered structure that resembles a natural chicken breast. Cultured chicken cells alone lack the structural and mechanical properties needed to replicate the texture and firmness of the traditional (or real) chicken breast. Thus, the inclusion of biopolymer composition ensures that the food product 402 closely resembles the texture, moisture content, and structural integrity of the traditional chicken breast. In an implementation, the food product 402 is a bio-printed structure of the biopolymer matrix and the cultured chicken cells. The food product 402 is created using the 3D bioprinting technology, allowing precise arrangement of the components to replicate the texture, structure, and appearance of the traditional chicken breast. In operation, the cultured chicken cells and biopolymer matrix are combined to form the bioink with specific viscosity and consistency suitable for the 3D bioprinting. The bioink is loaded into the screw-based extruder and deposited layer by layer on the printer bed under controlled parameters. The 3D printing process precisely replicates the muscle fiber alignment and layering found in the traditional chicken breast. The method of 3D bioprinting the food product 402 provides customization of texture, thickness, and other essential properties of the food product 402.
[00032] In accordance with an embodiment, the cultured chicken cells and the biopolymer composition are present in a ratio of 1:12. In other words, for every part of the cultured chicken cells, there are twelve parts of the biopolymer composition in the food product 402. The specific ratio ensures the right balance between the nutritional content contributed by the cells and the structural and textural support provided by the biopolymer matrix. The 1:12 ratio of the cultured chicken cells and the biopolymer composition ensures that the cultured cells are adequately supported by the biopolymer matrix while retaining their nutritional and sensory properties. Moreover, the cultured cells is in the range between 2%-5%w/v and the total biopolymers includes in the range between 40%-60%, as a result the ratio turns out to be 1:12. However, the ratio of the cultured chicken cells and the biopolymer composition can be varied depending on the desired texture, taste, and nutritional profile of the food product 402. For example, increasing the proportion of cultured chicken cells may enhance the flavour and nutritional content while reducing the biopolymer composition can modify the structure of the food product 402. Conversely, increasing the biopolymer composition can strengthen the texture and stability, allowing the food product 402 to retain its form during processing and consumption.
[00033] In accordance with an embodiment, the ratio of the animal-based biopolymer, the algal-based biopolymer, and the plant-based biopolymer is 1:2:25. In other words, for every one part of an animal-based biopolymer, the biopolymer composition includes two parts of the algal-based biopolymer and twenty-five parts of plant-based biopolymer. The specific ratio of the animal-based biopolymer, algal-based biopolymer, and the plant-based biopolymer has been carefully determined to achieve the desired texture, moisture retention, and binding characteristics that imitate the traditional chicken breast. The predominance of plant-based biopolymers (i.e., the 25 parts of the plant-based biopolymers) helps in reduce costs,while the smaller proportions of the animal-based biopolymer and the algal-based biopolymers provide essential functional properties that cannot be achieved with plant-based components alone. Moreover, the food product 402 includes the animal-based biopolymer, such as a gelatin and the like ranging between 0.5-2.5% (w/v) , the algal-based biopolymer, such as a sodium alginate and the like ranging between 2-5 % (w/v), and the plant-based biopolymer, such as a dialdehyde starch + wheat gluten and the like ranging between 55-65% (w/v). However, the ratios of the animal-based biopolymer, the algal-based biopolymer, and the plant-based biopolymer are adjusted to meet specific requirements of the food product 402, such as altering the texture, taste, or nutritional profile. For instance, increasing the proportion of the animal-based biopolymers can enhance the flavour profile of the food product 402, providing a richer, more authentic taste reminiscent of traditional meat products. Similarly, adjusting the algal-based biopolymer content could influence the moisture retention and mouthfeel of the food product 402.
[00034] In accordance with an embodiment, the food product 402 comprises a binding substance at a set concentration to form a paste-like final bioink formulation. In an example, the binding substance includes additional components, such as yeast extract (1.0%-3.5% w/v), fat (0.5%-0.9 w/v), wheat gluten (43.5%-45.5% w/v), and salts (1.0%-2.5% w/v) that provide the desired consistency and functionality. In another example, the binding substance is wheat gluten at 45% (w/v) concentration as a plant-based biopolymer operation, the binding substance is added at a specific concentration during the blending stage in the jacketed-stirred tank reactor, where the binding substance reacts with the biopolymer matrix to create the bioink with a uniform and printable consistency. Thus, the inclusion of the binding substance ensures precise control over the rheological properties of the bioink, thereby ensuring consistent printability. Moreover, the binding substance supports the formation of stable, well-defined layers in the 3D printed structure of the food product 402.
[00035] In accordance with an embodiment, the food product 402 comprises a microporous network structure having an average pore size ranging from 100 micrometres (μm) to 150 μm. The microporous network structure is an integral part of the food product 402 that contains cultured chicken cells (i.e., the fibroblasts, the myoblasts, or the adipocytes) supported within the biopolymer matrix composed of animal, algal, and plant-based polymers in specific ratios. In an example, the microporous network structure exhibits an average pore size of 100 μm. In another example, the microporous network structure exhibits an average pore size of 100 μm. In yet another example, the microporous network structure exhibits an average pore size of 125 μm. Thus, the microporous network structure enables the food product 402 to achieve a target nutritional profile with (23-26) g/100g protein, (23.5-26.5) g/100g carbohydrates, (2.5-3.0g)/100g fat while maintaining structural integrity.
[00036] In accordance with an embodiment, the bio-printed structure is a three-dimensional (3D) multi-layered structure with a loop-like texture, fiber like texture, thread-like texture or meaty texture formed using a 3D printing operation. The three-dimensional multi-layered structure with a loop-like texture, fiber like texture, thread-like texture or meaty texture is achieved through an automated bioprinting process using a screw extruder system. The paste-like bioink formulation, containing the precise 1:12 ratio of cells to biopolymer matrix, is extruded through 15 or 16-gauge needles to extrude bioink, allowing to form fine, controlled strands that closely resembles the muscle fiber structure that found in traditional chicken meat. The needles produce strands of a consistent diameter, facilitating precise layering and alignment to replicate the natural muscle fiber structure. The food product 402 includes a textured, fibrous composition that gives the cultivated chicken its characteristic "stretchy" look and feel. The controlled extrusion and layering technique enables to produce meat that not only resembles the texture of traditional chicken but also maintains structural integrity during cooking and handling. The ability of 3D bioprinting operation to replicate the fine strands and layered structures is differentiating the food product 402 from from simpler, non-textured meat alternatives. The process creates a structure with specific dimensions 110-130 mm length, 70-90 mm breadth, and 5-9 mm thickness through careful layer-by-layer deposition. The structure is then stabilized through a 20-40 minute crosslinking treatment followed by a phosphate-buffered saline wash. Thus, the multi-layered structure with a loop-like texture, fiber like texture, thread-like texture or meaty texture of the food product 402 enables optimal mechanical properties that allow the food product 402 to withstand various cooking methods while maintaining structural integrity.
[00037] In accordance with an embodiment, the bio-printed structure is in the shape of a chicken breast with length ranging from 110-130 mm, breadth ranging from 70-90 mm, and thickness ranging from 5-9 mm. In an example, the bio-printed structure is in the shape of the chicken breast with a length of 110 mm, a breadth of 70 mm, and a thickness of 5 mm. In another example, the bio-printed structure is in the shape of the chicken breast with the length of 130 mm, the breadth of 90 mm, and the thickness of 9 mm. In yet another example, the bio-printed structure is in the shape of the chicken breast with the length of 120 mm, the breadth of 80 mm, and the thickness of 7 mm.
[00038] In accordance with an embodiment, the food product 402 comprises carbohydrate ranging from 23.5-26.5g/100g, protein ranging from (23-26)grams (g)/100g, fat ranging from (2.5-3.0)g/100g, moisture ranging from (42-45)g/100g, phosphorous ranging from (0.028–0.029)g/100g, sodium ranging from (0.34–0.35)g/100g, calcium ranging from (0.18–0.19)g/100g, potassium ranging from (0.03–0.04)g/100g and copper less than 0.00005 g/100g. In an example, the food product 402 comprises the carbohydrate 23.5g/100g, the protein 23g/100g, the fat 2.5g/100g, the moisture 42g/100g, the phosphorus 0.028g/100g, the sodium 0.34g/100g, the calcium 0.18/100g, the potassium 0.03g/100g, and the copper 0g/100g. In another example, the food product 402 comprises the carbohydrate 26.5g/100g, the protein 26g/100g, the fat 3.0g/100g, the moisture 45g/100g, the phosphorus 0.029g/100g, the sodium 0.35g/100g, the calcium 0.19/100g, the potassium 0.04g/100g, and the copper 0.0005g/100g. In yet another example, the food product 402 comprises the carbohydrate 25g/100g, the protein 24.5g/100g, the fat 2.8g/100g, the moisture 44g/100g, the phosphorus 0.029g/100g, the sodium 0.35g/100g, the calcium 0.19/100g, the potassium 0.04g/100g, and the copper 0.0003g/100g.
[00039] Advantageously, the food product 402 of the present disclosure resembled with the characteristics including texture, flavour, appearance, nutritional profile, and the like of the traditional meat, which is obtained from animals by combining the cultured chicken cells with the biopolymer matrix. Moreover, the biopolymer matrix incorporates a specific ratio of animal-based, algal-based, and plant-based polymers that is used to provide an enhanced texture, moisture retention, and structural stability of the food product 402 with an enhanced tactile and organoleptic properties of the food product 402. Additionally, the microporous structure of the food product 402 enhances the nutritional composition by supporting a balanced distribution of proteins, carbohydrates, and lipids while maintaining the structural integrity of the food product 402 under various conditions, such as cooking, storage and transportation and the like. Additionally, the food product 402 exhibits an extended shelf life due to the biopolymer composition, which helps to preserve the nutritional and sensory characterstics of the food product 402 over time.
[00040] FIGs 5A and 5B depict a Field-Emission Scanning Electron Microscope (FESEM) image of the food product, in accordance with an embodiment of the present disclosure. FIGs. 5A and 5B are described in conjunction with FIGs. 1 to 4. With reference to FIG. 5A and 5B there are shown a diagram 500A and 500B that represent the Field-Emission Scanning Electron Microscope (FESEM) images of the food product 402.
[00041] In an exemplary scenario, the diagram 500A depicts a consistent microporous network structure throughout the food product 402 through the FESM image, which is captured using a Carl Zeiss Ultra 55 FESEM at 500x magnification that specifically focuses on the microporous network structure of the food product 402. The food product 402 is initially placed in an -80°C freezer, followed by a 48-hour freeze-drying process under vacuum-sealed conditions, which is dried and chopped into small pieces and mounted on an SEM platforming order to enhance the imaging quality of the food product 402. Moreover, the chopped pieces of the food product 402 underwent gold sputtering treatment before microscopic examination, which depicts that the average pore size of the food product 402 falls within the range of 100 μm to 150 μm. Moreover, the average pore size of the food product 402 is given in the below-mentioned Table 3, that depict measurements across multiple areas, with mean values consistently falling within this range (i.e., as shown by entries ranging from 102.237μm to 151.092μm):-
S.No Area S. Dev. Min Max major Minor Angle Circ. % Area AR Round Solidity
1 711680 119.222 33.849
73 254 784.224 0 0.757 0 1.473 0.679 1
2 713728
151.004 39.467 79 255 786.48 0 0.757 0 1.469 0.681 1
3 713728
151.092 39.333 85 255 786.48 0 0.757 0 1.469 0.681 1
4 713728
151.092 39.333 79 255 786.48 0 0.757 0 1.469 0.681 1
5 713728
151.046 39.415 75 255 786.48 0 0.757 0 1.469 0.681 1
6 710656
102.237 38.333 50 254 783.095 0 0.756 0 1.476 0.678

1
7 710656 103.997 36.731 57 254 783.095 0 0.756 0 1.476 0.678 1
Table 3
[00042] In another exemplary scenario, the diagram 500B, presents another view of the consistent microporous network structure throughout the food product 402. The food product 402 is initially placed in an -80°C freezer, followed by a 48-hour freeze-drying process under vacuum-sealed conditions to enhance imaging quality, the chopped pieces of the food product 402 underwent gold sputtering treatment before microscopic examination. The quantitative analysis for the microporous network structure of the food product 402 shown in the second diagram 500B utilizes ImageJ software, confirming that the average pore size of the food product 402 consistently falls within the crucial range of 100 μm to 150 μm. The small pore size distribution visible in the second diagram 500B indicates a dense surface network with higher mechanical properties, demonstrating consistency across scaffolds. The image reveals the effectiveness of the precise 1:12 ratio of cultured cells to biopolymer composition and 1:2:25 ratio of animal biopolymers, algal biopolymers and plant biopolymers in creating this optimal microporous structure. The structural characteristics visible in the second diagram 500B further validate the findings from 500A, showing the uniform distribution of pores and the dense network structure that is crucial for maintaining the mechanical properties, cell distribution, and moisture retention capabilities of the food product 402. As a result, the FESEM analysis of the food product 402, as demonstrated through the diagram 500A and 500B, provides a consistent and well-controlled microporous network structure of the food product 402.
[00043] FIG.6 is a chromatography graph of the biopolymer matrix present in the food product, in accordance with an embodiment of the present disclosure. FIG. 6 is described in conjunction with FIGs. 1 to 5B. With reference to FIG. 6, there is shown the chromatography graph 600 of the biopolymer matrix present in the food product 402.
[00044] There is provided the chromatography graph 600 that includes an X-axis 602 and a Y-axis 604. The X-axis 602 corresponds to the retention time, which is the time required for each component of the biopolymer matrix to pass through the chromatography column and reach the detector while the Y-axis 604 represents the signal intensity, which is typically related to the detector's response, such as absorbance, fluorescence, or ion count. The chromatography graph 600 displays various peaks, each corresponding to distinct components or molecular structures within the biopolymer matrix. For example, the first peak at a retention time of 1.032 minutes and a signal height of 150.93 represents one component of the biopolymer matrix. Similarly, the second peak at 1.609 minutes, with a significantly higher signal height of 1282.33, indicates another component, likely present in a larger quantity due to its greater signal intensity. Other peaks on the graph provide additional information about the different components, highlighting the composition and relative abundance of the biopolymer constituents. Thus, the chromatography graph 600 provides a detailed representation of the biopolymer matrix composition within the food product 402. The distinct peaks identified on the chromatography graph 600 provide valuable insights into the molecular structures and the relative concentrations of different components of the food product 402, which is essential for analyzing the functional and structural attributes of the biopolymer matrix.
[00045] FIG. 7 is a flowchart depicting a method for manufacturing the food product, in accordance with an embodiment of the present disclosure. With reference to FIG. 7, there is shown a flowchart of a method 700 for manufacturing the food product, such as a chicken breast. The method 700 includes steps 702 to 714.
[00046] At step 702, the method 700 includes culturing chicken cells selected from one cell type or a plurality of cell types comprising a chicken fibroblast cell, a chicken myoblast cell, or a chicken adipocyte cell in a bioreactor until a predefined density is reached in the cell bioreactor. Furthermore, at step 704, the method 700 includes blending an animal-based biopolymer, an algal-based biopolymer, and a plant-based biopolymer sequentially to form a biopolymer matrix and mixing chicken cells harvested from the cultured chicken cells with the biopolymer matrix in a jacketed-stirred tank reactor to form a first mixture, such as at step 706. At step 708, the method 700 includes automatically bio-printing the first mixture through a screw extruder to obtain the food product 402 as a bio-printed structure.
[00047] In accordance with an embodiment, the method 700 includes transferring the food product 402 bio-printed through the screw extruder in a crosslinked medium for a time-period ranging from 20-40 minutes transferring the food product 402 bio-printed through the screw extruder in a crosslinked medium for a time period ranging from 20-40 minutes, such as at step 710. Thereafter, at step 712, the method 700 includes performing phosphate buffered saline wash on the food product 402 to remove extra salts and at step 714, the method 700 includes transferring the food product 402 for storage for 10-24 hours at a temperature ranging between 2°C to 8°C and packaging the food product 402 for end-use.
[00048] Advantageously, the food product 402 of the present disclosure resembled with the characteristics including texture, flavour, appearance, nutritional profile, and the like of the traditional meat, which is obtained from animals by combining the cultured chicken cells with the biopolymer matrix. Moreover, the biopolymer matrix incorporates a specific ratio of animal-based, algal-based, and plant-based polymers that is used to provide an enhanced texture, moisture retention, and structural stability of the food product 402 with an enhanced tactile and organoleptic properties of the food product 402. Additionally, the microporous structure of the food product 402 enhances the nutritional composition by supporting a balanced distribution of proteins, carbohydrates, and lipids while maintaining the structural integrity of the food product 402 under various conditions, such as cooking, storage and transportation and the like. Additionally, the food product 402 exhibits an extended shelf life due to the biopolymer composition, which helps to preserve the nutritional and sensory characterstics of the food product 402 over time.
[00049] The steps 702 to 714 are only illustrative, and other alternatives can also be provided where one or more steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
[00050] Examples
[00051] Example 1: Method for Preparing the Food Product
Materials Used: Cultured chicken cells (fibroblasts), Animal-based biopolymer, Algal-based biopolymer, Plant-based biopolymer, Phosphate buffered saline (PBS), Binding substance and Growth medium, 3D printing Machine (3D Printer).
Steps for preparing the Food product
1. Cell Cultivation Process
i) The cell cultivation process starts with the selection of high-quality cells from a working cell bank. The cells are chosen for the ability to grow and multiply efficiently.
ii) The working cell bank maintains the cells under controlled conditions, such as optimal temperature, pH levels, oxygen supply, and a nutrient-rich growth medium, ensuring the quality and viability of the cells.
2. Cell Expansion in Seed Flask
i) The selected cells are placed into a seed flask, where the cells begin to multiply under controlled conditions such as optimal temperature, pH levels, and oxygen levels.
ii) The seed flask environment provides optimized cell growth, allowing the cells to rapidly reach the required population cell density for further production.
3. Large-Scale Cell Production
i) The expanded cells from the seed flask are transferred to a cell bioreactor, where thecells continue to multiply in a large-scale environment under controlled conditions.
ii) The cell bioreactor maintains optimal conditions, including temperature, pH, oxygen levels, and nutrient supply, ensuring consistent and efficient large-scale cell production.
iii) The cell bioreactor provides cell densities of hundreds of millions of cultured cells per millilitre, enabling a scalable and efficient production of the cultured cells.
4. Cell Harvesting and Processing
i) Once the optimal cell density is reached, the cultured cells are harvested from the cell bioreactor.
ii) The harvested cells undergo centrifugation at set parameters to collect the cell pellet.
iii) The supernatant is removed, and the cell pellet undergoes two PBS wash cycles to remove any traces of growth medium.
iv) The harvested cells are collected and stored in deep refrigeration for subsequent use.
5. Bioink Formulation
i) The different biopolymers, such as an animal-based, an algal-based, and a plant-based polymer and the like are added sequentially in a ratio of 1:2:25 and mixed until completely dissolved.
ii) The harvested cells are incorporated into a biopolymer mixture at a cell-to-biopolymer ratio of 1:12 and stirred for complete distribution of the cells with the biopolymer mixture.
iii) The harvested cells and biopolymer mixture are transferred to a blender where binding substance, such as yeast extract 1.0%-3.5% w/v, fat 0.5%-0.9% w/v, wheat gluten 43.5%-45.5% w/v, and salts 1.0-2.5% w/v and the like is added to provide a paste-like consistency and forming the bioink.
6. 3D Bioprinting Process
i) Using controlled parameters, such as the pressure and the like, the bioink is extruded through a precision printing head equipped with a 15- and 16-gauge needle. The printing head, including a screw extruder mechanism, moves along the X, Y, and Z axis to deposit the bioink in precise loop-like, fiber like texture, thread-like texture or meaty texture patterns.
ii) The final bio-printed structure forms in a of the chicken breast with length ranging from 110-130 mm, breadth ranging from 70-90 mm and thickness ranging from 5-9 mm.
7. Post-printing process
i) The bio-printed structures are removed from the printing bed and immersed ina crosslinker medium for approximately 30 minutes.
ii) Following cross-linking, the bio-printed structures undergo a PBS wash to remove excess salts.
iii) The bio-printed structures are vacuum packed to ensure preservation.
iv) The vacuum packed bio-printed structure are stored at 2-8 degrees Celsius for cold storage and prepared for commercial distribution.

[00052] Example 2: Amino Acid Profile Analysis of the Food Product
1. Primary Amino Acids
Amino Acids Concentration (>3000pmol/mg) Functional Role
Glutamic Acid 13889.7 Flavor enhancer, neurotransmitter
Glycine 4044.6 Collagen formation
Serine 3631.8 Protein structure
Leucine 3340.1 Muscle protein synthesis
Table 4
The above-mentioned table (i.e., The Table 4) shows the most abundant amino acids found in the food product that are present in concentrations above 3,000 pmol/mg. The primary amino acids are the most abundant amino acids present in the food product, providing the food product meat-like flavour. The primary amino acids are essential components found in natural chicken meat, and the presence of the amino acids in the food product in similar proportions indicates that the food product is replicated in the nutritional aspects of conventional chicken meat.
2. Intermediate Amino Acids
Amino Acids Concentration (1000-3000pmol/mg)
Category
Alanine 2305.3 Non -Essential
Valine 2259.9 Essential
Phenylalanine 1865.2 Essential
Isoleucine 1837.2
Essential
Aspartic acid 1412.3 Non-essential
Table 5
The Table 5 represents the amino acids that are found in moderate concentrations between 1,000-3,000 pmol/mg in the present food product. The food product includes both essential amino acids, such as valine, phenylalanine, and isoleucine and the like, which our body cannot make on its own. It must be from the food we eat and non-essential amino acids, such as alanine and aspartic acid and the like, which our body can produce naturally. The presence of the amino acids in the food product in the concentrations mentioned above demonstrates that the food product maintains a balanced amino acid profile similar to conventional chicken meat, contributing to the nutritional value of the food product.
3. Supporting Amino Acids
Amino Acids Concentration (300-1000 pmol/mg) Category
Arginine 978.4
Conditional
Histidine
795.3 Essential
Lysine 713.3 Essential

Tyrosine 392.8 Conditional
Methionine 331.6 Essential
Table 6
The Table 6 shows the amino acids that are present in lower amounts, between 300-1,000 pmol/mg, in the present food product. The Food Product includes three essential amino acids, such as histidine, lysine, and methionine and the like, that we must get from the food we eat and two conditional amino acids, such as arginine and tyrosine and the like, that our body sometimes needs more during illness or stress, even though these amino acids are present in smaller quantities but making the present food product nutritionally similar to regular chicken meat.
4. Trace Amino acids
Amino Acids
Concentration (<300 pmol/mg) Category
Hydroxyproline 174.5 Non-essential

Table 7
The Table 7 shows the trace amino acid i.e., hydroxyproline, which is present in a very small amountless than 300 pmol/mg in the present food product. The hydroxyproline is a non-essential amino acid, meaning the body can naturally produce the hydroxyproline, and the low presence of the hydroxyproline is normal in meat products.
In an implementation, the above-mentioned tables, i.e., The Table 4 to The Table 7, represents the amino acid profile analysis that depicts the concentration levels of the amino acids present in the food product. Furthermore, the Table 4 represents the primary amino acids, such as the glutamic acid, the glycine, and the leucine and the like, that are found in high concentrations in the food product and enhance the flavour of the food product. Moreover, The Table 5 represents the intermediate amino acids, such as alanine, valine, phenylalanine and the like, which are present in moderate amounts and help in the formation of the structure of the protein present in the food product. Furthermore, the Table 6 represents the supporting amino acids that include amino acids, such as arginine and lysine and the like, that are found in smaller amounts in the food product and help in maintaining the functioning of the immune system of the body. Additionally, the Table 7 represents the trace amino acids, such as hydroxyproline, found in very low concentrations in the food product and help in the formation of collagen.
[00053] Example 3 Optimization of Bioink Composition and 3D Printing Parameters
Sample of the Food Product Bioink Composition Printing Parameters Observations
01 Wheat Gluten 40% Pressure: 0.30 mPa, Speed: 15 mm/s, Needle: 18-gauge Printable, suitable for characterization

02 Wheat Gluten 45% + Fat 3.6% Pressure: 0.32 mPa, Speed: 15 mm/s, Needle: 18-gauge Printable, desired texture, sticky
03 Wheat Gluten 45% + Fat 0.4% Pressure: 0.37 mPa, Speed: 15 mm/s, Needle: 18-gauge Best suitable fat range (0.5-1)%
04 Wheat Gluten 45% + Fat 0.7% + Yeast Extract 5% Pressure: 0.26 mPa, Speed: 15 mm/s, Needle: 16-gauge Printable, sticky
05 Wheat Gluten 45% + Fat 0.7% + Yeast Extract 3% + Garlic 0.1% + Broth 0.1% Pressure: 0.47 mPa, Speed: 15 mm/s, Needle: 16-gauge
Improved printing with square plate
06 Wheat Gluten 45% + Fat 0.7% + Yeast Extract 3% + Garlic 0.4% + Onion 0.4% Pressure: 0.37 mPa, Speed: 15 mm/s, Needle: 16-gauge Printable, variable pressure operation
Table 8
The Table 8 represents the experimental data, a systematic optimization of the samples of the food product that contain the optimal concentration of the components present in the bioink composition and 3D printing parameters for the food product. The optimal formulation was identified as 45% wheat gluten with 0.7% fat and 3% yeast extract, supplemented with flavour enhancers of 0.2-0.4% each of garlic and onion powder. The printing parameters were standardized at room temperature conditions with a consistent printing speed of 15 mm/s. The experimental data shows that utilizing 15–16-gauge needles at pressure ranges of 0.30-0.40 mPa provides the optimal printability of the food product. The experimental data also represents the correlation between formulation complexity and printing parameters, where higher wheat gluten concentrations exhibited poor printability, while the optimized bioink composition represents consistent extrusion and structural integrity of the bio-printed structure.
[00054] Modifications to embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as "including", "comprising", "incorporating", "have", "is" used to describe, and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. The word "exemplary" is used herein to mean "serving as an example, instance or illustration". Any embodiment described as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments and/or to exclude the incorporation of features from other embodiments. The word "optionally" is used herein to mean "is provided in some embodiments and not provided in other embodiments". It is appreciated that certain features of the present disclosure, which are, for clarity, described in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features of the present disclosure, which are, for brevity, described in the context of a single embodiment, may also be provided separately or in any suitable combination or as suitable in any other described embodiment of the disclosure.
, C , Claims:CLAIMS

1. A food product (402), comprising:
cultured chicken cells selected from one cell type or a plurality of cell types comprising a chicken fibroblast cell, a chicken myoblast cell, or a chicken adipocyte cell; and
a biopolymer composition that supports structure and texture of the cultured chicken cells, wherein the biopolymer composition comprises a blend of an animal-based biopolymer, an algal-based biopolymer, and a plant-based biopolymer in form of a biopolymer matrix,
and wherein the food product (402) is a bio-printed structure of the biopolymer matrix and the cultured chicken cells.

2. The food product (402) as claimed in claim 1, wherein the cultured chicken cells and the biopolymer composition is present in ratio of 1:12.

3. The food product (402) as claimed in claim 1, wherein a ratio of the animal-based biopolymer, the algal-based biopolymer, and the plant-based biopolymer is 1:2:25.

4. The food product (402) as claimed in claim 1, wherein the food product (402) comprises a binding substance at a set concentration to form a paste-like final bioink formulation.

5. The food product (402) as claimed in claim 1, wherein the food product (402) comprises a microporous network structure having an average pore size ranging from 100 micrometre (μm) to 150 μm.

6. The food product (402) as claimed in claim 1, wherein the bio-printed structure is a three-dimensional (3D) multi-layered structure with a loop-like texture, fiber-like texture, thread-like texture or meaty texture formed using a 3D printing operation.

7. The food product (402) as claimed in claim 1, wherein the cultured chicken cells are cultured in a serum-free or a serum-alternative medium or in a combination of animal-derived serum and serum-free or serum-alternative medium.

8. The food product (402) as claimed in claim 1, wherein the bio-printed structure is in the shape of a chicken breast with length ranging from 110-130 mm, breadth ranging from 70-90 mm, and thickness ranging from 5-9 mm.

9. The food product (402) as claimed in claim 1, wherein the food product comprises carbohydrates ranging from 23.5-26.5g/100g, protein ranging from 23-26 g/100g, fat ranging from 2.5-3.0g/100g, moisture ranging from 42-45 g/100g, phosphorous ranging from0.028–0.029g/100g, sodium ranging from 0.34–0.35 g/100g, calcium ranging from 0.18–0.19 g/100g, potassium ranging from 0.03–0.04 g/100g and copper less than 0.00005 g/100g.

10. A method (700) of manufacturing a food product (402), the method comprising:
culturing chicken cells selected from one cell type or a plurality of cell typescomprising a chicken fibroblast cell, a chicken myoblast cell, or a chicken adipocyte cell, in a bioreactor until a predefined density is reached in the bioreactor;
blending an animal-based biopolymer, an algal-based biopolymer, and a plant-based biopolymer sequentially to form a biopolymer matrix;
mixing chicken cells harvested from the cultured chicken cells with the biopolymer matrix in a jacketed-stirred tank reactor to form a first mixture; and
automatically bio-printing the first mixture through a screw extruder to obtain the food product (402) as a bio-printed structure.
11. The method (700) as claimed in claim 9, wherein the method (700) comprises blending the first mixture with a binding substance at a set concentration to form a paste-like final bioink formulation which in turn is fed in the screw extruder to obtain the food product (402), wherein the bio-printed structure is shaped in the form of a chicken breast with length ranging from 110-130 mm, breadth ranging from 70-90 mm, and thickness ranging from 5-9 mm.

12. The method (700) as claimed in claim 9, wherein the method (700) comprises:
transferring the food product (402) bio-printed through the screw extruder in a crosslinked medium for a time period ranging from 20-40 minutes;
performing phosphate buffered saline wash on the food product (402) to remove extra salts; and
transferring the food product (402) for storage for 10-24 hours at a temperature ranging between 2°C to 8°C and packaging the food product (402) for end-use.