Progress 09/01/04 to 08/31/06
Outputs
The product (commercialized as HPTS [TM], High Protein Textured Soy) is a dry, shelf stable textured soy chunk ideal for use as a meat analog when rehydrated and flavored. Other uses are being explored. The key benefits are improved texture and better flavor delivery that allow creation of excellent all-natural meat mimics. Material selection: A range of high protein all-natural soy flours (54-61% DB Protein) has been validated to work in the process. High protein is key to achieving the desired firm "meat-like" structure that is important when delivering a vegetarian meat analog that is familiar in the western diet. Residual oil (5-8%) and oleo-compounds, including the tocopherols and natural emulsifiers inherent to the flour by virtue of our expeller-press processing and air swept flour-milling process, have been identified as critical to the development of superior flavor and texture profiles of the HPTS. Structure/Flavoring: The dried, shelf stable product has an
open cell, fibrous structure that facilitates easy rehydration. A low flavor profile allows for ease of topical flavoring. Flavoring of the product is best achieved in the rehydration step, as the flavor can easily penetrate through the entire matrix of the HPTS structure. Less flavor addition is required when added at rehydration, and the added flavor is subjected to very little heat. By contrast adding flavors in extrusion results in heat exposure and flashing of desirable volatiles. We also succeeded in coating of dry HPTS with liquid flavors as an alternate delivery form. Keeping Quality: Commercial interest in HPTS as a meat analog in frozen entrees led to keeping quality studies. We have passed the 15-month mark in an 18-month study and to date the meat analog and the entire entree have held up well with very little flavor or texture deterioration. The product meets and exceeds frozen food channel shelf life expectations. HPTS can be shaped and sized for a range of applications
from flour/meal and granules to chunks as large as 2+ inch-long strips. Our focus has been on developing the larger pieces, as the market opportunity for larger pieces is largely unmet. Chunks are now used as beef and chicken flavored analogs in Heartland Field entrees sold at retail in California and the Midwest. Midsize pieces have also found commercial application as flavored pizza Vegan topping (e.g. Crumbled Italian sausage analog). This is in keeping with the ultimate goal of the USDA-SBIR program - the establishment of enterprises that benefit agriculture. The product is patent pending. The prior art has not shown any product to have the unique naturally inherent combinations of nutrients in a shelf stable product and we anticipate a late 2006 patent issue. In preparation for increased commercial demand we have validated the scaled up of the process to achieve rates of up to 1500lbs/hr. The process scaled well and product consistency appears to be improved with higher
throughput. Some refinements of the extrusion die and forming assembly will be required to optimize specific product shape/size/texture attributes in preparation of commercial operation, driven by market needs.
Impacts
A simply better meat analog by virtue of its texture and flavor, the high protein textured soy will be a preferred meat analog for vegetarian foods, particularly when larger whole-muscle-like pieces are desired. The process used is all-natural (water, heat, and pressure only) and avoids any chemical solvents thus offering improved food safety for consumers and an environmentally better option to processors. The result is no special EPA or state environmental permitting is required in for production; and fewer allergenicity concerns for consumers with chemical sensitivities. Broad appeal of the high protein textured soy can increase the consumption of vegetable proteins.
Publications
- No publications reported this period
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Progress 10/01/03 to 09/30/04
Outputs
The project is advancing well. The product (commercialized as HPTS [TM], High Protein Textured Soy) is a dry, shelf stable textured soy chunk ideal for use as a meat analog when rehydrated and flavored. Other uses are being explored. The key benefits are improved texture and better flavor delivery that allow creation of excellent meat mimics. We have completed most of the material trials and a number of the process and scale-up trials scoped in the Phase II solicitation. Heartland Fields, LLC has been fortunate to achieve some commercial business resulting in some added focus on application trials and support of commercialization, a directional change we have taken in keeping with the ultimate goal of the USDA-SBIR program, the establishment of enterprises that benefit agriculture. Material selection: A range of high protein soy varieties (48-52% DB in whole Soybeans, 56-61% in low fat flour from same) has been validated to work in the process. The high protein is key
to achieving the desired firm meat-like structure that is important when delivering a vegetarian meat analog that is familiar in the western diet. Residual oil and oleo-compounds, including the tocopherols and natural emulsifiers inherent to the flour by virtue of our expeller-press processing and air swept flour-milling process, have been identified as critical to the development of flavor and texture profiles of the HPTS. Structure/Flavoring: The dried, shelf stable HPTS product has an open cell, fibrous structure that facilitates easy rehydration. Also, its low flavor profile allows for ease of topical flavoring. Its been determined that flavoring of the product is best achieved in the rehydration step, because the flavor can easily penetrate through the entire matrix of the HPTS structure. Less flavor addition is required when added at rehydration, and the added flavor is subjected to very little heat. By contrast adding flavors in extrusion results in heat exposure and flashing
of desirable volatiles. Keeping Quality: Commercial interest in HPTS as a meat analog (chicken strips, beef tips) component in frozen rice-bowl and pasta-bowl entrees led us to initiate keeping quality studies. We have passed the halfway mark in this 18-month study and to date the meat analog and the entire entree have held up well with very little flavor or texture deterioration. We expect the products to have a shelf life equal to or greater than a meat-containing entree. HPTS can be shaped and sized for a range of applications from small meal and granules to chunks as large as 2+ inch long strips. Our focus has been on developing the larger pieces, as the market opportunity for larger pieces is largely unmet. Midsize pieces have also found commercial application as flavored pizza Vegan topping (e.g. Crumbled Italian sausage analog). The product is patent pending. The prior art has not shown any product to have the unique naturally inherent combinations of nutrients in a shelf
stable product and we anticipate a 2006 patent issue. The progress to date and the planned year 2 refinements of the scaled up process will combine to enhance the product for wider commercialization.
Impacts
A simply better meat analog by virtue of its texture and flavor, the high protein textured soy will be a preferred meat analog for vegetarian foods, particularly when larger whole-muscle-like pieces are desired. The process used is all-natural (water, heat, and pressure only) and avoids any chemical solvents thus offering an environmentally better option to processors. The result is no special EPA or state environmental permitting is required in for production; and fewer allergenicity concerns for consumers with chemical sensitivities. Broad appeal of the high protein textured soy can increase the consumption of vegetable proteins.
Publications
- No publications reported this period
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