Description:FIELD OF THE INVENTION

The present disclosure relates to the field of food processing and, more specifically, pertains to a high-moisture extrusion process and a system for producing high-moisture texturized protein (HMTP) food products. The invention addresses the challenges associated with the limited thickness of extrudates in the context of plant-based meat analogs, offering a novel solution that enhances the versatility, structural integrity, and textural attributes of the final products.

BACKGROUND OF THE INVENTION

High-moisture extrusion technology has emerged as a pivotal advancement in the production of textured protein food products, particularly within the rapidly growing plant-based meat industry. This innovative extrusion process involves the use of high-moisture texturized protein (HMTP) to create meat analogs that closely mimic the texture and mouthfeel of traditional meat products. However, one persistent limitation in existing high-moisture extrusion processes is the inherent constraint on the thickness of the resulting extrudate.

As consumer preferences continue to evolve, there is an increasing demand for plant-based meat alternatives that not only replicate the taste of meat but also offer diverse textures and forms. The challenge of achieving thicker constructs with enhanced structural integrity has prompted the exploration of effective binding solutions to layer multiple sheets of extrudate, creating a cohesive and robust final product.

Conventional binding agents have often fallen short in providing the necessary adhesion and durability for these extruded products, leading to limitations in achieving thicker structures. In this context, the present invention addresses the shortcomings of existing methods by introducing a specialized application of wheat gluten as a robust binder. Unlike traditional binders, this innovative approach ensures superior adhesion, allowing for the creation of thicker, multi-layered structures that withstand various cooking conditions.

In one prior art solution (US20230255234A1), a Bacon analogue product is disclosed. The invention talks about gluing together different layers of protein, fat-based and/or protein-based emulsion by optionally applying a binding agent. The layers are applied on top of each other, and a heating step is incorporated later in the process to activate the binding process.

In another prior art solution (WO2012075489A1) and (WO2013184916A1) uses gluten to form a structure around a porousfibre mix to form boards.

Yet, in another prior art solution (NL1003133C2) and (CN114686162A) modifies gluten to make it easier to handle by reducing viscosity and to be used in plywood type applications.

In another prior art solution (EP1940240B1), produces a food grade adhesive slurry with gluten but makes a solution and incorporates use of other ingredients such as humectants and modifying the gluten with reducing acid to reduce viscosity.

In summary, the background of the invention establishes the context within the evolving landscape of plant-based meat alternatives, highlighting the need for advancements in high-moisture extrusion processes to meet the growing consumer demand for diverse, meat-like textures and forms. Generally heat and pressure are applied after aligning the layers to be glued togetherbutdon't deal with rolled products, where binding is required to happen soon after the layers to be glued together come together, so that the rolled shape is maintained without opening up. Limited work of gluing of high moisture extruded textured protein sheets has been done.

Generally, Wood or paper-based gluing methods modify gluten through chemical means to reduce viscosity and make gluten easier to handle. In current invention,the gluten is not modified, instead vital wheat gluten in its native form is used without modification. Existing prior arts involve creation of a slurry or a liquid mix of gluten with some other liquid and ingredients to ease handling of gluten-adhesive. The reliance on additional ingredients other than gluten is unnecessary in the current invention, and to address viscosity issues, application in dry powder form is preferred. Since moisture is still required by gluten to form cross-links, this is derived from the product on which the gluten adhesive is applied.

In view of the foregoing discussion, it is portrayed that there is a need to have a high-moisture extrusion process and a system for producing high-moisture texturized protein (HMTP) food products. The present invention addresses these challenges head-on, offering a novel and effective solution that contributes to the ongoing evolution of the plant-based food industry.

SUMMARY OF THE INVENTION

The present disclosure seeks to provide a high-moisture extrusion process and a system for producing high-moisture texturized protein (HMTP) food products with improved thickness and structural integrity. The process involves a unique binding technique suitable for creating food products resembling soya chaap, roulades, and similar items. The invention further introduces a comprehensive methodology encompassing the entire process, from the formation of HMTP sheets to the rolling and binding stages. The disclosed process involves the use of a specialized binding mix, including wheat gluten and other proteins, to create cohesive and thicker structures through a temperature-controlled, innovative extrusion and rolling methodology. The invention significantly contributes to the advancement of high-moisture extrusion technology, particularly in the plant-based meat industry, meeting the evolving demands for diverse textures and forms in modern culinary applications.The temperature-controlled process, innovative binding mix, and enhanced structural integrity achieved through cross-linking contribute to a significant improvement over existing methods. The method simplifies the extrusion process by applying the binding mix in a dry powder form, eliminating the need for additional liquid adhesives or slurries and seamlessly integrating into the continuous extrusion process. The advantages of this high-moisture extrusion process include not only structural integrity but also versatility in producing a broader range of textures and forms in plant-based meat analogs. Additionally, the method is cost-effective and scalable, primarily relying on wheat gluten, a widely available and economical ingredient. As with any technological innovation, the invention recognizes certain limitations such as sensitivity to surface moisture, temperature requirements, and potential allergenicity associated with wheat gluten. However, the disclosure provides solutions and strategies to mitigate these challenges, ensuring a comprehensive and practical approach to the high-moisture extrusion process for texturized protein food products.

In an embodiment, a high-moisture extrusion process for producing high-moisture texturized protein (HMTP) food products is disclosed. The process includes collecting a plurality of HMTP sheets, the plurality of HMTP sheets having a temperature in a range of 40 degrees Celsius to 95 degrees Celsius.
The process further includes applying a binding mix to at least one surface of the plurality of HMTP sheets for creating cross-linking between the surfaces of the HMTP sheets and the binding mix.
However, the process further includes rolling and pressing individual HMTP sheets simultaneously for preparing thick rolls of the HMTP sheets, such that the cross-linking of proteins between surfaces of the same sheet happens due to pressure application along with rolling; and the rolled structure doesn't open up after removal of the pressure application and the rolled structure remains intact even upon immersion in boiling water.

In another embodiment, the rolling and pressing the HMTP sheets are done using an automated process.

In a further embodiment, the plurality of HMTP sheets are collected from an extruder at a temperature in the range of 40 degrees Celsius to 95 degrees Celsius and maintained in the similar temperatures during rolling and pressing.

Yet, in another embodiment, the rolled sheet is pressed for 2-20 seconds to facilitate cross-links between folds in the rolled product.

In one embodiment, the binding mix comprising at least one of wheat protein or enzyme

In another embodiment, the wheat protein is selected from at least one of wheat gluten powder, wheat protein isolate or wheat protein concentrate.

In a further embodiment, the enzyme is transglutaminase.

In another embodiment, the binding mix is applied in a dry powder form.

In another embodiment, a system for producing high moisture texturized protein (HMTP) food products is disclosed. The system comprises: an extruder unit configured to extrude high moisture texturized protein (HMTP) sheets; a conveyor system connected to the extruder unit, the conveyor system configured to maintain a temperature range of 40°C to 95°C of HMTP sheets along the conveyor path to preserve the desired moisture content and softness of the HMTP sheets during transportation and rolling; a cutting mechanism positioned downstream of the conveyor system, the cutting mechanism designed to slice the HMTP sheets into individual segments; a hopper (or spray machine) positioned downstream of the conveyor system, the hopper equipped to uniformly distribute a binding mix onto at least one surface of the HMTP sheets to facilitate cross-linking between the HMTP sheets and the binding mix; and a rolling and pressing unit positioned downstream of the cutting mechanism, the rolling and pressing unit configured to roll and press the individual HMTP segments, thereby creating thick rolls of the HMTP sheets and cross-linking of proteins between adjacent surfaces of the HMTP segments.

In one embodiment, the rolling and pressing unit configured to roll the individual HMTP segments from their edges, applying pressure while the roll is being formed and applying pressure to the edge along the length of cylindrical shape after the roll is formed for a minimum of 2 seconds and preferably longer than 5 seconds, to cause cross-linking of proteins between adjacent surfaces of the HMTP segments while forming thick rolls of the HMTP sheets.

Yet another embodiment, the hopper is adjustable to control the quantity of the binding mix applied onto the HMTP sheets.

In one embodiment, the cutting mechanism comprises a blade assembly with adjustable cutting parameters configured to provide variations in HMTP sheet thickness, dimensions, and texture.

In one embodiment, the rolling and pressing unit comprises the cut HMTP segment moving on a bottom conveyor, rolling and initial pressing action performed with top counter-rotating roller or a static belt creating backward drag on the top surface of the segment with respect to the bottom surface to create the rolling action, and a final pressing performed by maintaining the HMTP roll between a pair of co-rotating belts or rollers with controllable pressure settings to ensure uniform pressing and rolling of the HMTP segments.

An object of the present disclosure is to facilitate the creation of textured protein food products with increased thickness and enhanced texture through a specialized rolled product formation. The invention focuses on engineering High-Moisture Texturized Protein (HMTP) sheets to be seamlessly rolled upon themselves, resulting in products such as Soya Chaap and Roulades with superior thickness and texture.

Another object of the present disclosure is to implement a temperature-controlled process that ensures optimal activation of the binding mix. By maintaining the HMTP sheet at a temperature exceeding 40°C prior to rolling, the invention aims to activate the binding mix during and immediately after the rolling process. This temperature control is crucial for maintaining the integrity of the rolled shape and preventing unrolling, contributing to the overall success of the extrusion process.

Another object of the present disclosure is to introduce an innovative binding mix that encourages cross-linking between the layers of HMTP sheets, as well as with the binding agent itself.

Another object of the present disclosure is to enhance the structural integrity of rolled products. By creating cross-links between the layers of HMTP sheets through the innovative binding mix, the method aims to produce rolled products that maintain their durability and shape throughout various cooking processes and manual handling. This objective contributes to the development of plant-based meat analogs with improved quality and consumer appeal.

Yet another object of the present invention is to deliver an expeditious and cost-effective high-moisture extrusion process modified by eliminating the need for a separate adhesive slurry or liquid mix. The utilization of the binding mix in a dry powder form for bonding purposes is a key element in this process simplification. Additionally, the objective is to design a continuous process seamlessly integrated with the extrusion process, reducing the need for additional handling and enhancing overall production efficiency.

To further clarify the advantages and features of the present disclosure, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which are illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail in the accompanying drawings.

BRIEF DESCRIPTION OF FIGURES

These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read concerning the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1 illustrates a flow chart of a high-moisture extrusion process for producing high moisture texturized protein (HMTP) food products, in accordance with an embodiment of the present disclosure;
Figure 2 illustrates a texturized vegetable protein rolled product, in accordance with an embodiment of the present disclosure;
Figure 3 illustrates a strong interaction between the texturized protein surface, in accordance with an embodiment of the present disclosure;
Figure 4illustrates a gluten cross-linking between the texturized protein surface, in accordance with an embodiment of the present disclosure;
Figure 5 illustrates Table 1 depicts different combinations of gluing agents tried to form the rolled products and their assessment by performing cooking test, in accordance with an embodiment of the present disclosure;
Figure 6 illustrates a block diagram of a system for producing high moisture texturized protein (HMTP) food products, in accordance with an embodiment of the present disclosure; and
Figure 7 illustrates an exemplary profile of a system for producing high moisture texturized protein (HMTP) food products, in accordance with an embodiment of the present disclosure.

Further, skilled artisans will appreciate those elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present disclosure. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present disclosure so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein.

DETAILED DESCRIPTION:

To promote an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates.

It will be understood by those skilled in the art that the foregoing general description and the following detailed description are exemplary and explanatory of the invention and are not intended to be restrictive thereof.

Reference throughout this specification to “an aspect”, “another aspect” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrase “in an embodiment”, “in another embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

The terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a process or method that comprises a list of steps does not include only those steps but may include other steps not expressly listed or inherent to such process or method. Similarly, one or more devices or sub-systems or elements or structures or components proceeded by "comprises...a" does not, without more constraints, preclude the existence of other devices or other sub-systems or other elements or other structures or other components or additional devices or additional sub-systems or additional elements or additional structures or additional components.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

Embodiments of the present disclosure will be described below in detail concerning the accompanying drawings.

Referring to Figure 1, a flow chart of a high-moisture extrusion process for producing high moisture texturized protein (HMTP) food products is illustrated in accordance with an embodiment of the present disclosure. At step 102, process 100 includes collecting a plurality of HMTP sheets, the plurality of HMTP sheets having a temperature in a range of 40 degrees Celsius to 95 degrees Celsius.

At step 104, process 100 includes applying a binding mix to at least one surface of the plurality of HMTP sheets for creating cross-linking between the surfaces of the HMTP sheets and the binding mix.

At step 106, process 100 includes rolling and pressing individual HMTP sheets simultaneously for preparing thick rolls of the HMTP sheets, such that the cross-linking of proteins between surfaces of the same sheet happens due to pressure application along with rolling; and the rolled structure doesn't open up after removal of the pressure application and the rolled structure remains intact even upon immersion in boiling water.

In another embodiment, the rolling and pressing the HMTP sheets are done using an automated process.

In a further embodiment, the plurality of HMTP sheets are collected from an extruder at a temperature in the range of 40 degrees Celsius to 95 degrees Celsius and maintained in the similar temperatures during rolling and pressing.

Yet, in another embodiment, the rolled sheet is pressed for 2-20 seconds to facilitate cross-links between folds in the rolled product.

In one embodiment, the binding mix comprising at least one of wheat protein or enzyme

In another embodiment, the wheat protein is selected from at least one of wheat gluten powder, wheat protein isolate or wheat protein concentrate.

In a further embodiment, embodiment, the enzyme is transglutaminase.

In another embodiment, the binding mix is applied in a dry powder form.

In another embodiment, an uniform finger-like cuts textures are fabricated on the surface preventing easy separation of surfaces.

In one embodiment, a binding mix comprises: 50-99 wt.% of wheat gluten powder; 0-1 wt.% of soya proteins; and 0.2-1 wt.% of transglutaminase.

In another embodiment, the weight percentage of the wheat gluten powder, soya proteins, and transglutaminase, is 99%, 0.5%, and 0.5%, respectively.

High-moisture extrusion technology has revolutionized the field of textured protein applications, particularly in the plant-based meat industry. However, one inherent limitation is the restricted thickness of the resulting extrudate. As consumer demands for diverse textures and form factors grow, there is a pressing need for effective solutions that can overcome this limitation.

This challenge underlines the critical role of binders in layering multiple sheets of extrudate to produce a cohesive, thicker structure. Unlike conventional binders, which often fail to create a robust and unified product, the present invention employs a specialized application of wheat gluten to achieve superior adhesion. Crucially, this robust binder not only facilitates the creation of thicker constructs but also ensures durability under various cooking conditions. This enhances the versatility and utility of high-moisture extruded products, fulfilling an unmet need in the industry.

Methodology
Rolled Product Formation: The HMTP sheets are designed to be rolled upon themselves. This rolling process increases the thickness and texture of the final product, making it suitable for a variety of culinary applications.

Temperature-Controlled Process: Prior to the rolling, the HMTP sheets are heated to a temperature exceeding 40°C. This temperature is critical for activating the binding mix, ensuring that the bonding begins as soon as the product is rolled and slightly pressed. This step is vital for maintaining the rolled shape and preventing the product from unraveling.

Innovative Binding Mix: The binding agent, applied to the HMTP sheets, is a mixture of wheat gluten, other proteins like soya proteins, and potentially an enzyme such as transglutaminase. This mix is specifically formulated to encourage cross-linking between the protein layers of the HMTP sheets and the binding mix itself, thereby enhancing the overall structural integrity of the rolled product.

Enhanced Structural Integrity: The cross-linking facilitated by the binding mix ensures that the rolled products retain their shape and structural integrity through various cooking processes and manual handling. This robustness is a significant improvement over existing methods that struggle to maintain cohesion in rolled or multi-layered plant-based products.

Process Simplification: The binding mix is applied in a dry powder form, eliminating the need for a separate adhesive slurry or liquid mix. Furthermore, this process is designed to be continuous and seamlessly integrated with the extrusion process, further streamlining production and reducing the need for additional handling.

The invention ensures immediate activation of the binding agents at temperatures above 40°C, leading to a strong, cohesive structure crucial for maintaining the rolled shape soon after the product is rolled. The ability to produce thicker, rolled products expands the range of textures and forms achievable in plant-based meat analogs. The texture and mouthfeel are greatly improved, mimicking traditional meat products. Relying primarily on wheat gluten, the method is more cost-effective and scalable compared to other binding techniques that require more complex or expensive ingredients. Integrating the adhesive application in-line with the continuous extrusion process reduces additional handling or processing steps.

The technique's sensitivity to surface moisture can be mitigated through precise monitoring and regulation of process parameters. Maintaining the extrudate sheet temperature above 40°C is crucial for immediate protein cross-linking. This is managed through controlled heating during the extrusion and pre-rolling phases. While wheat gluten is a known allergen, alternatives like soya proteins or enzymes like transglutaminase can be used to address this concern. The current method is optimized for rolled products, which may limit its application to other forms. However, ongoing research and development may extend its applicability.

Figure 2 illustrates a texturized vegetable protein rolled product, in accordance with an embodiment of the present disclosure.

Figure 3 illustrates a strong interaction between the texturized protein surface, in accordance with an embodiment of the present disclosure.

Figure 4 illustrates a gluten cross-linking between the texturized protein surface, in accordance with an embodiment of the present disclosure.

Figure 5 illustrates Table 1 depicts different combinations of gluing agents tried to form the rolled products and their assessment by performing a cooking test, in accordance with an embodiment of the present disclosure. Trials (1-15) showing the different combinations of gluing agents including methylcellulose, pregel starches, proteins, and enzymes like transglutaminase showed the gluing effect while rolling the product and maintaining intact structure while freezing and thawing (Table 1).
The gluing agent is screened through a cooking process that can withstand the heating and vigorous cooking process to keep the product in its rolled form. All the gluing combinations (trials 1-15) which showed the freeze-thaw stability are carried forward to the boiling water test with vigorous stirring and marination test. Gluing combinations that didn’t show a promising effect on keeping the structure intact throughout the cooking process, are not selected for the final product.
Gluten powder (Trial 16) is applied on the texturized vegetable protein sheet having a minimum temperature of 40°C. The sheet is rolled and pressed for 5-10 seconds to form the cross-links between the folds in the rolled product. The present invention discloses the simplified process to form the novel-shaped product using a high moisture texturized protein substrate. The innovative gluing agent and process showed a significant effect on maintaining the rolled structure while exposing it to the vigorous cooking process. Gluten powder hydrates by absorbing the water content present on the surface of the texturized protein sheet and when the high moisture sheet comes into contact while rolling then hydrated gluten forms the cross-links between the surfaces. The strong cross-links help maintain the structural integrity of rolled products during the cooking process.
Transglutaminase (TG) also formed strong cross-links between the texturized protein sheets which helped in retaining the rolled form in cooking tests. Different concentrations of TG are tried as 0.2%, 0.3%, 0.5%, 0.7%, and 1% w/w on the texturized protein sheet. 0.5% and 0.7% w/w concentration showed positive results on gluing the sheets and maintaining the structure in the cooking test. In the case of TG, the post-application optimum temperature needs to be maintained at 45-50°C with some pressure to make the closer contact between the surfaces. TG can be combined with proteins that can act synergistically with TG to form strong cross-links. TG combinations with starches didn’t work as they impart the hindrance in cross-linking formation.
Texturized vegetable protein sheets should have enough moisture content that they retain their flexible structure avoiding brittleness to get the optimum results in gluing and rolling. High moisture texturized vegetable protein-based rolled products as shown in Figure 2 have uniform finger-like cuts on the surface which are strongly glued and the surfaces cannot be easily separated as shown in Figure 3. The strong gluten crosslinks (Figure 4) help in maintaining the rolled structure intact throughout the vigorous cooking processes.
The inventive process focuses on the engineered formation of High-Moisture Texturized Protein (HMTP) sheets that seamlessly roll upon themselves, resulting in textured protein products with amplified thickness and enhanced texture. This method caters to the demand for diverse culinary applications, particularly in the plant-based meat industry.

Prior to the rolling phase, meticulous temperature control is applied to the HMTP sheets, ensuring maintenance at a temperature exceeding 40°C. This critical step activates the binding mix promptly during and immediately after rolling. By preventing unrolling and maintaining the rolled shape, the process achieves superior control over the structural characteristics of the final product.

The binding mix employed on HMTP sheets plays a pivotal role in encouraging cross-linking between layers and potentially with the binding agent itself. For instance, in a specific embodiment involving wheat gluten as the primary binder for HMPT sheets made of soya and wheat gluten proteins, cross-links form between the wheat gluten binder and both sides of the HMTP sheets. The versatile binding mix, comprising proteins such as wheat gluten, soya proteins, or other proteins, may also incorporate transglutanimase, an enzyme known for effectively gluing different protein sheets. The preferred embodiment emphasizes wheat gluten as a dominant component, constituting more than 50% of the binding mix.

The method is intricately designed to address the specific requirements for creating thicker, rolled products like Soya Chaap and Roulades. The binding mix facilitates the formation of cross-links between layers, ensuring a robust and durable structure that withstands various cooking processes and manual handling. This enhancement in structural integrity positions the invention as a significant advancement over existing methods in the plant-based meat industry.

The inventive approach aims to streamline the high-moisture extrusion process by eliminating the need for a separate adhesive slurry or liquid mix. The binding mix, applied in a dry powder form, serves as an efficient bonding agent. Furthermore, the process is seamlessly integrated with the extrusion process, promoting continuity and reducing the requirement for additional handling. This process simplification enhances overall production efficiency, meeting the demand for scalable and streamlined manufacturing processes in the plant-based food industry.

Enhanced Structural Integrity: By using a binding mix at temperatures above 40°C, our method ensures immediate activation of the binding agents, leading to a strong, cohesive structure. This is crucial for maintaining the rolled shape soon after the product is rolled, so that further pressure can be applied. Existing methods apply pressure and heat after layers have been placed flat on each other, but in a case of rolled product with elastic tendency, the roll will tend to open up before pressure and heat can be applied.

The ability to create rolled products that are thicker than standard extruded sheets allows for a greater variety of product types, catering to diverse culinary needs and preferences. It expands the range of textures and forms achievable in plant-based meat analogs. The combination of binding mix that provides cross-linking between layer not only enhances binding strength but also contributes to a desirable texture. This mimics the mouthfeelof traditional meat products, making it appealing for consumers seeking plant-based alternatives. The method, especially when highly reliant on wheat gluten, is more cost-effective and scalable compared to other binding techniques that might require more complex or expensive ingredients and processes. While our method is particularly beneficial for products like soya chaap and roulades, its versatility could extend to a wide range of plant-based food products, offering significant commercial potential. Integrates the adhesive application in-line with the continuous extrusion process, reducing additional handling or processing steps.

The technique may be sensitive to variations in moisture content on top of the surface of the product, which could affect the binding quality. However, this can be controlled through precise monitoring and regulation of process parameters. The temperature of the extrudate sheet has to be fairly warm, above 40oC, so that cross-linking with proteins or enzymes can immediately start to happen to maintain the rolled structure. Wheat gluten is a known allergen, which might limit the product’s consumer base. Soya proteins, other proteins or enzymes like Transglutanimase might solve this problem. Rolled product shape and inflexibility in generating other irregular thicker shapes.

Figure 6 illustrates a block diagram of a system for producing high moisture texturized protein (HMTP) food products, in accordance with an embodiment of the present disclosure. The system 200 comprises an extruder unit (202) configured to extrude high moisture texturized protein (HMTP) sheets.

In an embodiment, a conveyor system (204) is connected to the extruder unit (202), the conveyor system configured to maintain a temperature range of 40°C to 95°C of HMTP sheets along the conveyor path to preserve the desired moisture content and softness of the HMTP sheets during transportation and rolling.

In an embodiment, a cutting mechanism (206) is positioned downstream of the conveyor system (204), the cutting mechanism designed to slice the HMTP sheets into individual segments.

In an embodiment, a hopper (or spray machine) (208) is positioned downstream of the conveyor system (204), the hopper equipped to uniformly distribute a binding mix onto at least one surface of the HMTP sheets to facilitate cross-linking between the HMTP sheets and the binding mix.

In an embodiment, a rolling and pressing unit (210) is positioned downstream of the cutting mechanism (206), the rolling and pressing unit configured to roll and press the individual HMTP segments, thereby creating thick rolls of the HMTP sheets and cross-linking of proteins between adjacent surfaces of the HMTP segments.

In one embodiment, the rolling and pressing unit configured to roll the individual HMTP segments from their edges, applying pressure while the roll is being formed and applying pressure to the edge along the length of cylindrical shape after the roll is formed for a minimum of 2 seconds and preferably longer than 5 seconds, to cause cross-linking of proteins between adjacent surfaces of the HMTP segments while forming thick rolls of the HMTP sheets.

Yet another embodiment, the hopper is adjustable to control the quantity of the binding mix applied onto the HMTP sheets.

In one embodiment, the cutting mechanism comprises a blade assembly (212) with adjustable cutting parameters configured to provide variations in HMTP sheet thickness, dimensions, and texture.

In one embodiment, the rolling and pressing unit comprises the cut HMTP segment moving on a bottom conveyor, rolling and initial pressing action performed with top counter-rotating roller or a static belt creating backward drag on the top surface of the segment with respect to the bottom surface to create the rolling action, and a final pressing performed by maintaining the HMTP roll between a pair of co-rotating belts or rollers with controllable pressure settings to ensure uniform pressing and rolling of the HMTP segments.

Figure 7 illustrates an exemplary profile of a system for producing high moisture texturized protein (HMTP) food products, in accordance with an embodiment of the present disclosure. The system includes an extruder unit for creating HMTP sheets, a conveyor system to maintain sheet temperature and softness, a cutting mechanism to slice sheets into segments, a hopper for applying a binding mix, and a rolling and pressing unit to form thick rolls and cross-link proteins.
The conveyor system is designed to transport HMTP sheets while preserving their moisture content and softness. It maintains a temperature range of 40°C to 95°C along the conveyor path. This temperature control is crucial for preventing drying and hardening of the HMTP sheets during handling.
Downstream of the conveyor, a cutting mechanism slices the HMTP sheets into individual segments. These segments are then passed through a hopper where a binding mix is uniformly applied to at least one surface. The binding mix is intended to facilitate cross-linking between the HMTP sheets during the subsequent rolling and pressing process.
The core of the system is the rolling and pressing unit. It processes the individual HMTP segments by rolling them into thick rolls. This process involves applying pressure while the roll is being formed and continuing to apply pressure to the edge of the roll for at least 2 seconds. This mechanical action promotes cross-linking of proteins between the adjacent surfaces of the HMTP segments, resulting in a cohesive and structured product.
The system is designed to be adaptable. The hopper can be adjusted to control the amount of binding mix applied to the HMTP sheets. The cutting mechanism features adjustable cutting parameters to allow for variations in sheet thickness, dimensions, and texture. The rolling and pressing unit utilizes a combination of conveyors and rollers to achieve the desired rolling and pressing effects. Pressure settings on the final pressing stage can be controlled to ensure uniform product consistency.

The drawings and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible. The scope of embodiments is at least as broad as given by the following claims.

Benefits, other advantages, and solutions to problems have been described above about specific embodiments. However, the benefits, advantages, solutions to problems, and any component(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature or component of any or all the claims.

, Claims:1. A high-moisture extrusion process for producing high moisture texturized protein (HMTP) food products, the process comprising:
collecting a plurality of HMTP sheets, said plurality of HMTP sheets having a temperature in a range of 40 degrees Celsius to 95 degrees Celsius;
applying a binding mix to at least one surface of the plurality of HMTP sheets for creating cross-linking between the surfaces of the HMTP sheets and the binding mix; and
rolling and pressing individual HMTP sheets simultaneously for preparing thick rolls of the HMTP sheets, such that the cross-linking of proteins between surfaces of the same sheet happens due to pressure application along with rolling; and the rolled structure doesn't open up after removal of the pressure application and the rolled structure remains intact even upon immersion in boiling water.

2. The process as claimed in claim 1, wherein rolling and pressing the HMTP sheets are done using an automated process.
3. The process as claimed in claim 1, wherein said plurality of HMTP sheets are collected from an extruder at a temperature in the range of 40 degrees Celsius to 95 degrees Celsius and maintained in the similar temperatures during rolling and pressing.
4. The process as claimed in claim 1, wherein the rolled sheet is pressed for 2-20 seconds to facilitate cross-links between folds in the rolled product.
5. The process as claimed in claim 1, wherein said binding mix comprising at least one of wheat protein or enzyme.
6. The process as claimed in claim 5, wherein the wheat protein is selected from at least one of wheat gluten powder, wheat protein isolate or wheat protein concentrate.
7. The process as claimed in claim 5, wherein the enzyme is transglutaminase.
8. The process as claimed in claim 1, wherein the binding mix is applied in a dry powder form.
9. A system for producing high moisture texturized protein (HMTP) food products, comprising:
an extruder unit configured to extrude high moisture texturized protein (HMTP) sheets;
a conveyor system connected to said extruder unit, said conveyor system configured to maintain a temperature range of 40°C to 95°C of HMTP sheets along the conveyor path to preserve the desired moisture content and softness of the HMTP sheets during transportation and rolling;
a cutting mechanism positioned downstream of said conveyor system, said cutting mechanism designed to slice the HMTP sheets into individual segments;
a hopper (or spray machine) positioned downstream of said conveyor system, said hopper equipped to uniformly distribute a binding mix onto at least one surface of the HMTP sheets to facilitate cross-linking between the HMTP sheets and the binding mix; and
a rolling and pressing unit positioned downstream of said cutting mechanism, said rolling and pressing unit configured to roll and press the individual HMTP segments, thereby creating thick rolls of the HMTP sheets and cross-linking of proteins between adjacent surfaces of the HMTP segments.

10. The system as claimed in claim 9, wherein said rolling and pressing unit configured to roll the individual HMTP segments from their edges, applying pressure while the roll is being formed and applying pressure to the edge along the length of cylindrical shape after the roll is formed for a minimum of 2 seconds and preferably longer than 5 seconds, to cause cross-linking of proteins between adjacent surfaces of the HMTP segments while forming thick rolls of the HMTP sheets.
11. The system as claimed in claim 9, wherein said hopper is adjustable to control the quantity of the binding mix applied onto the HMTP sheets.
12. The system as claimed in claim 9, wherein the cutting mechanism comprises a blade assembly with adjustable cutting parameters configured to provide variations in HMTP sheet thickness, dimensions, and texture.
13. The system as claimed in claim 9, wherein the rolling and pressing unit comprises the cut HMTP segment moving on a bottom conveyor, rolling and initial pressing action performed with top counter-rotating roller or a static belt creating backward drag on the top surface of the segment with respect to the bottom surface to create the rolling action, and a final pressing performed by maintaining the HMTP roll between a pair of co-rotating belts or rollers with controllable pressure settings to ensure uniform pressing and rolling of the HMTP segments.