DESC:TECHNICAL FIELD
[0001] The present disclosure relates, in general, to edible products, food technology or food engineering and more specifically, relates to an apparatus and method for preparing a ready to eat vegan protein powder.

BACKGROUND
[0002] The technology to prepare expanded edible products for consumption as breakfast cereals, and other products has long been established. Many Indians being vegetarians are having protein deficiency. To address this issue, many companies are offering more affordable, sustainable vegan protein supplements than the expensive whey and egg protein-based ones, which help the general population overcome their protein deficiency. This is a growing segment with many more companies offering similar products.
[0003] Extruders are very versatile machines that can be used to produce finished products, such as breakfast cereals and snacks, as well as intermediate products that can be used as ingredients in other finished products, such as ready to serve, ready to bake and ready to cook products as well as various functional foods. There are several existing technologies of extrusion process used extensively for making several types of food products mainly snacks. Further, the mixtures with high protein are very difficult to extrude, so attempts are being made to continuously push for a higher protein level, particularly where the focus is to make vegan meat analogues. A few research publications also describe different aspects of extrusion technology, different compositions of blends that are extruded, the temperatures of extrusion barrels, high moisture extrusion and so on. However, the existing process focuses on texturizing the finished product to get better homogeneity, digestibility, dispersibility in water and great taste. The aim is to achieve the extrusion with minimum water and get crispy nuggets that are high on protein, which then can be crushed to fine water dispersible powder.
[0004] As one varies the composition of the blend of vegan protein isolates and carbohydrates, there can be a need to fine-tune the conditions of the extrusion. Depending on the composition of the blend the resulting product can be very sensitive to developing an unpleasant base odor thus requiring strict control of the extrusion parameters. The drying process of the nuggets before pulverizing is also very critical. The drying rate and temperature of the continuous drying oven may have to be adjusted based on the moisture content of the extruded nuggets. Too slow or too fast drying will result in an unpleasant base odor.
[0005] Most of these vegan protein supplements are made by blending the native proteins and protein isolates from various plant sources like wheat, rice, pea, peanut, soybean, various pulses, and millets, combining them with other herbal ingredients, dietary fibres, flavours, sugar, or sugar substitutes, vitamin premixes etc. These products are offered in powder form and consumers consume them as a drink by combining a scoop of this product with water or non-diary milk such as almond, coconut or rice, mixing it thoroughly and drinking it. However, all these existing products have poor dispersibility in water, uncooked taste and grainy mouth feel that most consumers find not palatable. They take them more as medicines as they need to fight their protein deficiency. They all have a very raw taste and feel uncooked. Their hard grainy texture makes them not easily dispersible in water thus giving the drink a very unpleasant grainy mouth feel.
[0006] Most of the native proteins and protein isolates used in preparing the protein supplements and not cooked (denatured) making them more difficult to digest.
[0007] Further, most of these plant proteins do have their own characteristic odor often described as the beany odor which is not very pleasant when consumed as a drink. It is often impossible to mask this odor and deliver good flavours that are enjoyable. These negative factors are limiting the growth of this segment.
[0008] Therefore, it is desired to overcome the drawbacks, shortcomings, and limitations associated with existing solutions, and develop a unique process that provides vegan protein supplements having a pleasant odor, taste, flavour, and texture and which are easy to digest.

OBJECTS OF THE PRESENT DISCLOSURE
[0009] An object of the present disclosure relates, in general, to edible products, and more specifically, relates to an apparatus and method for preparing a vegan protein powder
[0010] Another object of the present disclosure is to provide a method that provides vegan protein supplements having a pleasant odor, taste, flavor, and texture and easy to digest.
[0011] Another object of the present disclosure is to provide a method that denatures the proteins and gelatinizes the starch to give a better taste, the gelatinized starch gives thickness and prevents the settling of the water-insoluble proteins giving a stable smoothie-like consistency to the drink.
[0012] Another object of the present disclosure is to provide a method that reduces the base odour of the protein mixture.
[0013] Another object of the present disclosure is to provide a method that prepares proteins, starch and fibres that gives a very homogenous mixture to give a better mouth feel.
[0014] Another object of the present disclosure is to provide a method that ensures the homogeneity of the flour, and smooth dispersion of the flour as all the components are cooked, precooked, or gelatinized starch giving a thickness to prepare a truly ready-to-serve protein shake.
[0015] Another object of the present disclosure is to provide an extrusion process followed by grinding gives homogenous mass, soft particles that easily get hydrated and become very soft.
[0016] Yet another object of the present disclosure is to provide a method that produces a fine powder easily dispersible in water and gives a creamy taste.

SUMMARY
[0017] Within the scope of this application, it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments, unless such features are incompatible.
[0018] In an aspect, the apparatus designed for preparing vegan protein powder integrates several essential components to efficiently and effectively transform raw ingredients into high-quality protein powder. This innovative apparatus offers a comprehensive solution for optimizing the production process and enhancing the nutritional, sensory, and functional attributes of the final product. The core components of the apparatus include a first sigma blender extruder, an oven, a first pulverizer, a second sigma blender, and a second pulverizer. This assembly is meticulously designed to ensure a step-by-step process that yields consistent and desirable outcomes.
[0019] In an aspect, the process begins with the first sigma blender, where various vegan protein sources, flavorings, and other ingredients are meticulously mixed and the mixture is transmitted to the extruder. The extruder then plays a pivotal role in shaping and texturizing the mixture through controlled temperature, pressure, and shear. The mixture proceeds to the oven, where precise heat treatment is applied. This process enhances the denaturation of proteins and improves the nutritional and functional qualities of the protein powder. The first pulverizer follows the oven stage, ensuring that the extruded mixture is ground into consistent and manageable particle sizes, setting the stage for further processing. The second pulverizer fine-tunes the particle size of the mixture, providing the flexibility to create a protein powder with the desired texture and dispersibility for various applications. The second sigma blender takes the protein powder and incorporates additional functional ingredients such as vitamins, minerals, and antioxidants. This step enhances the nutritional content and sensory aspects of the final protein powder.
[0020] In an aspect, the apparatus concludes by producing vegan protein powder of superior quality. This protein powder showcases improved texture, nutritional content, and functional properties. Its versatility enables usage across different product formulations, including beverages, baked goods, and dietary supplements. By skilfully combining the first sigma blender extruder, oven, first and second pulverizers, and second sigma blender, this apparatus presents an integrated and advanced solution for the preparation of vegan protein powder. The precise control over processing conditions and the incorporation of functional ingredients results in a product that not only aligns with consumer preferences but also fulfils the demands of a rapidly growing market for plant-based alternatives.
[0021] Various objects, features, aspects, and advantages of the inventive subject matter will become apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The following drawings form part of the present specification and are included to further illustrate aspects of the present disclosure. The disclosure may be better understood by reference to the drawings in combination with the detailed description of the specific embodiments presented herein.
[0023] FIG. 1 illustrates an exemplary apparatus for preparing a vegan protein powder, in accordance with an embodiment of the present disclosure.
[0024] FIG. 2 illustrates an exemplary method for preparing a vegan protein powder, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0025] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.
[0026] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0027] The present disclosure relates, in general, to edible products, food technology or food engineering and more specifically, relates to an apparatus and method for preparing a ready to eat vegan protein powder. The proposed method disclosed in the present disclosure overcomes the drawbacks, shortcomings, and limitations associated with the conventional method by providing a method for preparing a vegan protein powder. The process can make protein blends under high temperature and pressure in combination with fibers and starches from different cereals, pulses, and nuts. This denatures the proteins and gelatinizes the starch to give a better taste.
[0028] The process utilises an extruder capable of mixing proteins, fiber and carbohydrates without fat followed by grinding that results in powder to give a homogenous paste when mixed with water. The extrusion process is performed to denature the proteins and gelatinise the carbohydrates resulting in an easily dispersible mixture in room temperature water. The extrusion mixture is a mixture of plant-based proteins and uses a multi-grain starch base. The extrusion is done between 80 to 100 C high temperature to ensure denaturation of all plant protein and gelatinisation of mixed starches.
[0029] The advantages achieved by the process of the present disclosure can be clear from the embodiments provided herein. The process gives thickness and prevents the settling of the water-insoluble proteins giving a stable smoothie-like consistency to the drink. This unique feature of the extrusion technology is used to reduce the base odour of the protein mixture. The preparation of the proteins, starch and fibers gives a very homogenous mixture to give a better mouth feel.
[0030] Most snacks available in the market are made by the extrusion process, where the flour of cereals and millets are extruded to prepare a crunchy puffed product. So, the conditions of the extrusion and set for getting maximum puffing result in a better crunch. In the proposed method, the extruded product is pulverized to get a homogenous flour. Using the extrusion process for making flour of desired quality. This process ensures the homogeneity of the flour, and smooth dispersion of the flour as all the components are cooked, precooked, or gelatinized starch giving a thickness to the constituted drink, and lower base odor as a base odor is removed in the extrusion process. Using such flour enables one to prepare a truly ready-to-serve protein shake.
[0031] Further, mixing plant proteins, protein isolates, grains, and nuts and directly grinding them typically gives particles that can be fine but remain gritty in nature and not get hydrated easily thus giving an unpleasant mouth feel where one can feel the gritty particles. The presently disclosed method of extrusion followed by grinding gives homogenous mass, soft particles that easily get hydrated and become very soft. The easy hydration of particles is mainly because of the gelatinization of starch and denaturing of the proteins. This results in a taste that is close to a milkshake in terms of smoothness. The description of terms and features related to the present disclosure shall be clear from the embodiments that are illustrated and described; however, the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents of the embodiments are possible within the scope of the present disclosure. Additionally, the invention can include other embodiments that are within the scope of the claims but are not described in detail with respect to the following description.
[0032] FIG. 1 illustrates an exemplary apparatus for preparing a vegan protein powder, in accordance with an embodiment of the present disclosure.
[0033] Referring to FIG. 1, an apparatus 100 is configured for preparing a vegan protein powder. The apparatus 100 can include a first sigma blender 102, an extruder 104, a continuous drying oven 106, a first pulverizer 108, a second pulverizer 110 and a second sigma blender 112. The apparatus 100 is configured to perform a unique process that provides vegan protein supplements having a pleasant odor, taste, and texture, which easily disperses in water or milk and gives the best creamy taste.
[0034] In an embodiment, the first sigma blender 102 is adapted to receive weight flour, protein isolates, salt, acid regulator, and other food additives and an appropriate quantity of water and mix for a few minutes e.g., 15 to 25 minutes to ensure homogeneity of protein and carbohydrate blend. The weight flour can be selected from rice, corn, wheat, jowar, oats and the likes and the protein isolates selected from pea, peanut, rice, wheat, pulses, soy, and the likes. The protein content of this blend will be around 49 to 50%.
[0035] The mixture is slowly fed along with the controlled quantity of water to the extruder 104. The operating parameters of the extruder 104 are set to produce the irregular-shaped nuggets. The extruder 104 according to the present disclosure can include a barrel with an inlet and an outlet. The barrel can include an opening for feeding the mixture. The barrel can include a water input receiving connection, where these connections are connected to sources of water and controlled by controlling mechanisms.
[0036] The temperature of the barrel can be set at 160 to 180 C, depending on the composition of the blend. The extrusion process is performed to denature the proteins and gelatinise the carbohydrates resulting in an easily dispersible mixture in room temperature water. The mixture is pushed or pulled through the unique dye of the desired cross-section to produce irregular nuggets with around 5-6 mm diameter, where the nuggets are in semi-dry form. The water flow and feed rate of the mixture should be adjusted such that the resulting nuggets produced have a bulk density between 100 to 140 g/L. These conditions may vary depending upon the composition of the mixture. The shape of the nuggets also plays an important role in deciding the grindability in the next step. Further, the nuggets produced at this stage may still have around 10 to 15 % moisture in them.
[0037] Subsequently, the extruded mixture is subjected to a sudden drop in pressure by the extruder after the extrusion process resulting in an expansion of the mixture before it enters the oven. This is a process known as "rapid depressurization" or "rapid expansion." Rapid depressurization can lead to the expansion of the extruded mixture, resulting in a unique texture. The expansion creates a lighter texture, enhancing the consumer's sensory experience. When the extruded mixture exits the extruder and encounters the sudden drop in pressure, any trapped gases within the mixture, such as water vapor or air, rapidly expand. This causes the material to form a porous structure, resulting in a light and airy texture. The rapid expansion introduced by depressurization increases the volume of the product without adding additional ingredients. This process is used to create products with a lower density, which can be desirable for protein powders as powders that undergo rapid expansion tend to have a more appealing texture and mouthfeel. By adjusting the pressure drop and the timing of the expansion, users can control the final volume and of the extruded protein powder and rapid expansion can lead to more uniform expansion across the product, resulting in consistent texture and visual appearance.
[0038] The semi-dried nuggets are then passed through a continuous drying oven 106 maintained at around 100 to 110 C to form dry nuggets. The temperature and speed of the continuous oven 106 may also have to be set based on the composition of the mixture. The resultant nuggets from oven 106 should have less than 1% moisture. Moisture is a critical factor for microbial growth, including mold and bacteria. By reducing the moisture content of protein powder, the oven 106 creates an environment where microbial proliferation is inhibited, thus extending the shelf life of the protein powder and ensuring its safety for consumption. Moisture in protein powder can also cause it to agglomerate or form lumps during storage. This reduces the stability of the powder, making it less convenient to use and leading to a non-uniform distribution of nutrients when added to liquids increasing the importance of the drying oven 106.
[0039] The dry nuggets are then fed to the first pulverizer 108 to grind the dry nuggets into a powder with a particle size between 200 to 250 microns. This powder is passed to the second pulverizer 110 to further grind the powder to get particle size between 50 to 80 microns. The powder obtained is a multi-protein blend that is then transferred to a second sigma blender 112. The finished product is blended in the second sigma mixer 112 with a substance for 15 to 20 minutes to a get a homogeneous powder blend, thereby providing multi-vegan protein powder with a pleasant odor, texture, taste, and flavour of a smoothie. The substance is selected from a group including natural sweeteners, hydrocolloids, base odor modifiers, acid regulators, fat powders, soluble plant fibers, flavor, probiotics, and prebiotics. The flavours are selected from chocolate, coffee, berry, mango, and the like. Any natural stabilizers, binders or other additives can also be added in this stage. Finally, the powder mixture is immediately packed into containers, sealed with induction sealing and capped.
[0040] For example, in the extrusion process, the proteins and carbohydrates are cooked, denatured, deodorized, and homogenized as the extrusion happened under high shear, temperature, and pressure. Shear refers to the force or stress that causes one layer of the protein powder to slide or move in relation to an adjacent layer. The process can denature the protein and break down any kind of structure so that the final product can be pulverized easily to get particles in the range of 50 to 60 microns. This pre-cooked vegan protein mixture when blended with fat powder, hydrocolloids, sweeteners, and flavours resulted in a vegan protein that tasted like a milkshake. The preparation of the protein, starch and fiber mixture is performed under high pressure and temperature using the extrusion process. When the mass cooked under high pressure and temperatures comes out of the extrusion, it puffs up and releases a lot of steam. The beany odor components being steam volatile are released along with the steam thus reducing the base odour of the protein mixture. The low base odour allows delivering better flavours. This unique feature of the extrusion technology reduces the base odour of the protein mixture. The cooking of the proteins, starch and fibers gives a very homogenous mixture to give a better mouth feel.
[0041] In an embodiment, the crucial factors that must be optimized and controlled are as follows:
• composition of the mixture to deliver the desired level of protein and fiber, the combination of proteins, protein isolates, and cereals.
• temperature and pressure of the extrusion process.
• the bulk density of the extruded granules.
• Drying temperature and the rate of drying of the extruded granules.
Various pulverization techniques had to be tried to arrive at the right pulverization technology to get soft particles of the desired size. This resulting base flour is then mixed with hydrocolloids, natural sweeteners, base odor modifiers, soluble plant fibres, flavour, probiotics, vitamin and mineral premixes and digestive enzymes to get the finished vegan protein supplement.
[0042] In an embodiment, the second pulverizer 110 is equipped with a set of interchangeable screens with different hole sizes. These screens determine the size of the particles that can pass through them. Screens with larger holes allow larger particles to pass through, while screens with smaller holes result in finer particles. By selecting the appropriate screen based on the desired particle size, the user can achieve the specific texture and characteristics needed in the final product. For example, a finer screen might be used for creating a smoother protein powder suitable for mixing into beverages, while a coarser screen could produce a protein powder with a slightly grainy texture for baking applications. The use of interchangeable screens provides flexibility and control over the particle size distribution, ensuring consistency and meeting product specifications. By adjusting the screen size in the second pulverizer, manufacturers can tailor the particle size distribution to meet the requirements of different applications and consumer preferences. This flexibility in particle size control is valuable in producing vegan protein powders with varying textures and functionalities.
[0043] Thus, the present invention overcomes the drawbacks, shortcomings, and limitations associated with existing solutions, and provides vegan protein supplements having a pleasant odor, taste, flavor, and texture. The process that ensures the homogeneity of the flour, smooth dispersion of the flour as all the components are cooked, pre-cooked, or gelatinized starch giving a thickness to the constituted drink, and lower base odor in the extrusion process. Using such flour enables one to prepare a truly ready-to-serve protein shake.
[0044] FIG. 2 illustrates an exemplary method for preparing a vegan protein powder, in accordance with an embodiment of the present disclosure.
[0045] Referring to FIG. 2, method 200 can include block 202, the weight flour, protein isolates, salt, acid regulator, and other food additives and appropriate quantity of water are fed into the first sigma blender 102 and mixed for a few minutes e.g., 15 to 25 minutes to ensure homogeneity.
[0046] At block 204, the mixture obtained from the first sigma blender 102 is slowly fed along with the controlled quantity of water to the extruder 104. The operating parameters of the temperature of the barrel can be set at 160 to 180 C.
[0047] At block 206, the mixture is pushed or pulled through the unique dye of the desired cross-section to produce irregular nuggets of around 5-6 mm in diameter. The water flow and feed rate of the mixture should be adjusted such that the resulting nuggets produced have a bulk density between 100 to 140 g/L. These conditions may vary depending upon the composition of the mixture. The shape of the nuggets also plays an important role in deciding grindability. Further, the nuggets produced at this stage may still have around 10 to 15 % moisture in them.
[0048] At block 208, the semi-dry nuggets are then passed through a continuous drying oven 106 maintained at around 100 to 110 C to form dry nuggets. The temperature and speed of the continuous oven 106 may also have to be set based on the composition of the mixture. The resultant nuggets coming out of the oven should have less than 1% moisture.
[0049] At block 210, the dry nuggets are then fed to the first pulverizer 108 to grind the dry nuggets into a powder with a particle size between 200 to 250 microns. At block 212, the powder obtained from the first pulverizer 108 is passed to the second pulverizer 110 to further grind the powder to get particle size between 50 to 80 microns.
[0050] At block 214, the powder is a multi-protein blend obtained from the second pulverizer 110 and is then transferred to the second sigma mixer 112. The finished product is blended in the second sigma mixer 112 with a substance for 15 to 20 minutes to a homogeneous powder blend. The substance is selected from a group including sweeteners, hydrocolloids, acid regulators, fat powders, powder flavours, probiotics, and prebiotics. The flavors are selected from chocolate, coffee, berry, mango, and the like. Finally, the powder mixture is immediately packed into containers, sealed with induction sealing and capped.
[0051] The method 200 can make protein blends under high temperature and pressure in combination with fibers and starches from different cereals, pulses, and nuts. This denatures the proteins and gelatinizes the starch to give a better taste. The gelatinized starch gives thickness and prevents the settling of the water-insoluble proteins giving a stable smoothie-like consistency to the drink. The cooking of the protein, starch and fiber mixture is performed under high pressure and temperature using an extrusion process. When the mass cooked under high pressure and temperatures comes out of the extrusion, it puffs up and releases a lot of steam. The beany odor components being steam volatile are released along with the steam thus reducing the base odour of the protein mixture. The low base odour allows delivering better flavors. This unique feature of the extrusion technology reduces the base odour of the protein mixture. The cooking of the proteins, starch and fibers gives a very homogenous mixture to give a better mouth feel.
[0052] In an embodiment, the process of extrusion enables the combination of different plant-based protein sources to create a balanced amino acid profile in the final powder. For example, blending pea protein with rice protein can help address amino acid deficiencies present in each protein source individually. The extrusion process allows for precise control over the texturization and structuring of the protein mixture. This means that one can adjust the texture and mouthfeel of the protein powder to mimic the characteristics of animal-based proteins or to meet the desired sensory preferences of consumers. Beyond protein sources, extrusion makes it possible to incorporate additional functional ingredients into the formulation. This could include dietary fibers, vitamins, minerals, antioxidants, and flavor enhancers to improve the nutritional profile and overall product quality.
[0053] In the proposed method, the extruded product is pulverized to get a homogenous powder. Using the extrusion process for making powder of desired quality is a unique concept. This process ensures the homogeneity of the powder, and smooth dispersion of the powder as all the components are cooked, precooked, or gelatinized starch giving a thickness to the constituted drink, and lower base odor in the extrusion process. Using such powder enables the user to prepare a truly ready-to-serve protein shake.
[0054] Mixing plant proteins, protein isolates, grains, and nuts and directly grinding them typically gives fine particles but can remain gritty and not get hydrated easily thus giving an unpleasant mouth feel where one can feel the gritty particles. The presently disclosed method of extrusion followed by grinding gives homogenous mass, soft particles that easily get hydrated and become soft. The easy hydration of particles is mainly because of the gelatinization of starch and denaturing of the proteins. This results in a taste that is close to a milkshake in terms of smoothness.
[0055] In various embodiments, different applications require different properties from vegan protein powders. For example, a protein powder meant for baking might need different functional properties than one intended for use in beverages. Extrusion allows the user to tailor the formulation to meet these specific requirements. While extrusion can lead to improved binding and stability properties on its own, the process also accommodates the addition of natural stabilizers and binders to enhance the cohesion and structure of the final product. The extrusion process can impact the flavor and aroma profile of the protein powder. By carefully selecting processing conditions and flavoring agents, you can achieve a desirable taste and aroma that appeals to consumers. Extrusion followed by milling allows for control over the particle size distribution of the protein powder. This is crucial for achieving the desired solubility, dispersibility, and mouthfeel in different applications. If there are concerns about allergens in the final product, extrusion can help manage these concerns by processing ingredients at high temperatures that can reduce the allergenic potential. This extrusion process can improve the bioavailability of nutrients by breaking down anti-nutritional factors and enhancing digestibility contributing to a more nutritionally valuable end product. Extrusion can often achieve the desired functional properties without need for additives, aligning with consumer preferences.
[0056] It will be apparent to those skilled in the art that method 200 of the disclosure may be provided using some or all the mentioned features and components without departing from the scope of the present disclosure. While various embodiments of the present disclosure have been illustrated and described herein, it will be clear that the disclosure is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the disclosure, as described in the claims.

ADVANTAGES OF THE PRESENT INVENTION
[0057] The present disclosure provides a method that provides vegan protein supplements having a pleasant odor, taste, flavour, and texture.
[0058] The present disclosure is to provide a method that denatures the proteins and gelatinizes the starch to give a better taste, the gelatinized starch gives thickness and prevents the settling of the water-insoluble proteins giving a stable smoothie-like consistency to the drink.
[0059] The present disclosure provides a method that reduces the base odour of the protein mixture and prepares proteins, starch and fibres that gives a very homogenous mixture to give a better mouth feel.
[0060] The present disclosure provides a method that ensures the homogeneity of the flour, and smooth dispersion of the flour as all the components are cooked, precooked, or gelatinized starch giving a thickness to prepare a truly ready-to-serve protein shake.
[0061] The present disclosure provides an extrusion followed by grinding gives homogenous mass, soft particles that easily get hydrated and become very soft with real-time quality assessment, ensuring that the final product meets desired specifications.
[0062] The present disclosure provides a method that produces a fine powder easily dispersible in water and gives a creamy taste and ensures that processing parameters are within regulatory guidelines, contributing to product safety and compliance.
[0063] The present disclosure contributes to cost savings in terms of production time, energy usage, and ingredient utilization and leads to the development of unique protein powder formulations that stand out in the market.
[0064] The present disclosure can facilitate the creation of clean label products by enabling the production of protein powders with a minimal and understandable list of ingredients.
,CLAIMS:1. An apparatus to prepare a protein powder, the apparatus comprising:
a first sigma blender (102) designed to prepare a mixture of a plurality of raw vegan protein sources or any other protein ingredients under one or more controlled conditions of temperature, pressure, and shear;
an extruder (104) to carry out an extrusion process to process the mixture by subjecting said mixture to a high temperature and pressure to denature the plurality of raw vegan protein sources and improve a texture of the mixture;
an oven (106) for drying the extruded mixture by subjecting said extruded mixture to a controlled heating process to reduce a moisture content and enhance one or more nutritional and functional properties of said extruded mixture;
a first pulverizer (108) designed to coarsely grind the dried mixture into a plurality of smaller particles of a particular particle size to achieve a consistent texture with a consistent particle size distribution;
a second pulverizer (110) designed to further refine the coarsely grinded mixture to further reduce the particular particle size and produce a finer powder of said grinded mixture; and
a second sigma blender (112) to homogenize the refined mixture and incorporate one or more additional functional ingredients, flavorings, or additives into said refined mixture to produce a vegan protein powder.

2. The apparatus of claim 1, wherein the extruder (104) is equipped with an adjustable temperature and one or more pressure controls to optimize the extrusion process for the plurality of vegan protein sources.

3. The apparatus of claim 1, wherein the oven (106) is programmable to execute a plurality of heating profiles tailored to the plurality of vegan protein sources and any desired functional attributes of the vegan protein powder.

4. The apparatus of claim 1, wherein the second pulverizer (110) is equipped with a set of interchangeable screens with a plurality of hole sizes that the user chooses to achieve a specific texture and any characteristics desired in the vegan protein powder.

5. The apparatus of claim 1, wherein the second sigma blender (112) incorporates a plurality of flavorings, sweeteners, vitamins, minerals, or other functional ingredients to enhance a taste and a nutritional value of the vegan protein powder.

6. The system as claimed in claim 1, wherein a temperature, a pressure, or one or more processing times of the extrusion process and the controlled heating process are regulated based on any specific vegan protein sources being processed.

7. The apparatus as claimed in claim 1, wherein the apparatus is configured to produce the vegan protein powder with an improved texture, a solubility, and a nutritional profile.

8. A method for preparing a vegan protein powder, the method comprising:
feeding a weight flour, one or more protein isolates, an acid regulator, and salt or any other food additives and an appropriate quantity of water into a first sigma blender (102) and mixing for a short duration to obtain a homogeneous mixture;
feeding the obtained mixture from the first sigma blender (102) along with a controlled quantity of water into an extruder (104);
passing the mixture from the extruder (104) through a unique dye of a desired cross-section to produce one or more irregular nuggets with a diameter of around 5-6 mm, wherein all nuggets are in a semi-dry form;
passing the semi-dry nuggets through a continuous drying oven (106) maintained at a temperature of around 100 to 110 degrees Celsius to obtain dried nuggets;
feeding the dried nuggets to a first pulverizer (108) to obtain a powder with a particle size between 200 to 250 microns and feeding the obtained powder from the first pulverizer (108) to a second pulverizer (110) to further grind the powder to obtain a particle size between 50 to 80 microns; and
blending the powder obtained from the second pulverizer (110) into a second sigma blender (112) with a substance for 15 to 20 minutes to obtain a final homogenous powder blend.

9. The method as claimed in claim 8, wherein the method accommodates an addition of one or more natural stabilizers or binders in the second sigma blender (112) to enhance cohesion and structure of the final homogenous powder blend.

10. The method as claimed in claim 8, wherein the extruded mixture is subjected to a sudden drop in pressure by the extruder (104) after the extrusion process resulting in an expansion of the mixture before it enters the oven (106).