High soy protein nuggets and applications in food products

Abstract

The present invention relates to food materials containing a high concentration of vegetable protein and processes for their manufacture. More particularly, the present invention relates to vegetable protein extrudates containing high concentrations of protein and low concentrations of carbohydrates, processes for manufacturing such protein extrudates, and the use of such protein extrudates as functional food ingredients.

1 . A protein extrudate comprising at least about 70% by weight vegetable protein on a moisture-free basis and having a density of from about 0.10 g/cm 3  to about 0.40 g/cm 3 .  
   
   
       2 . A protein extrudate as set forth in  claim 1  comprising at least about 70% by weight soy protein on a moisture-free basis.  
   
   
       3 . A protein extrudate as set forth in  claim 2  wherein said extrudate comprises less than about 10% by weight carbohydrate on a moisture-free basis.  
   
   
       4 . A protein extrudate as set forth in  claim 3  wherein said extrudate comprises from about 2% to about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       5 . A protein extrudate as set forth in  claim 3  wherein said extrudate comprises from about 2% to about 5.5% by weight water on a total weight basis.  
   
   
       6 . A protein extrudate as set forth in  claim 2  wherein said extrudate has a density of from about 0.15 g/cm 3  to about 0.35 g/cm 3 .  
   
   
       7 . A protein extrudate as set forth in  claim 6  wherein said extrudate has a density of from about 0.20 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       8 . A protein extrudate as set forth in  claim 7  wherein said extrudate has a density of from about 0.24 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       9 . A protein extrudate as set forth in  claim 6  wherein said extrudate has a density of from about 0.27 g/cm 3  to about 0.32 g/cm 3 .  
   
   
       10 . A protein extrudate as set forth in  claim 2  comprising from about 2 to about 8 parts by weight hydrolyzed soy protein per part by weight unhydrolyzed soy protein.  
   
   
       11 . A protein extrudate as set forth in  claim 10  wherein said hyrolyzed soy protein exhibits a degree of hydrolysis of less than about 15%.  
   
   
       12 . A protein extrudate as set forth in  claim 11  wherein said hydrolyzed soy protein exhibits a degree of hydrolysis of less than about 10%.  
   
   
       13 . A protein extrudate as set forth in  claim 12  wherein said hydrolyzed soy protein exhibits a degree of hydrolysis of from about 1% to about 5%.  
   
   
       14 . A protein extrudate as set forth in  claim 10  wherein said hydrolyzed soy protein exhibits a TNBS value of from about 30 to about 70.  
   
   
       15 . A protein extrudate as set forth in  claim 2  comprising at least about 80% by weight soy protein on a moisture-free basis.  
   
   
       16 . A protein extrudate as set forth in  claim 15  wherein said extrudate comprises less than about 10% by weight carbohydrate on a moisture-free basis.  
   
   
       17 . A protein extrudate as set forth in  claim 16  wherein said extrudate comprises from about 2% to about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       18 . A protein extrudate as set forth in  claim 16  wherein said extrudate comprises from about 2% to about 5.5% by weight water on a total weight basis.  
   
   
       19 . A protein extrudate as set forth in  claim 15  wherein said extrudate has a density of from about 0.15 g/cm 3  to about 0.35 g/cm 3 .  
   
   
       20 . A protein extrudate as set forth in  claim 19  wherein said extrudate has a density of from about 0.20 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       21 . A protein extrudate as set forth in  claim 20  wherein said extrudate has a density of from about 0.24 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       22 . A protein extrudate as set forth in  claim 19  wherein said extrudate has a density of from about 0.27 g/cm 3  to about 0.32 g/cm 3 .  
   
   
       23 . A protein extrudate as set forth in  claim 22  comprising from about 2 to about 8 parts by weight hydrolyzed soy protein per part by weight unhydrolyzed soy protein.  
   
   
       24 . A protein extrudate as set forth in  claim 23  wherein said hyrolyzed soy protein exhibits a degree of hydrolysis of less than about 15%.  
   
   
       25 . A protein extrudate as set forth in  claim 24  wherein said hydrolyzed soy protein exhibits a degree of hydrolysis of less than about 10%.  
   
   
       26 . A protein extrudate as set forth in  claim 25  wherein said hydrolyzed soy protein exhibits a degree of hydrolysis of from about 1% to about 5%.  
   
   
       27 . A protein extrudate as set forth in  claim 23  wherein said hydrolyzed soy protein exhibits a TNBS value of from about 30 to about 70.  
   
   
       28 . A protein extrudate as set forth in  claim 2 , wherein said extrudate comprises from about 80% to about 95% by weight soy protein on a moisture-free basis.  
   
   
       29 . A protein extrudate as set forth in  claim 28  wherein said extrudate comprises less than about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       30 . A protein extrudate as set forth in  claim 29  wherein said extrudate comprises from about 2% to about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       31 . A protein extrudate as set forth in  claim 28  wherein said extrudate comprises from about 2% to about 5% by weight water on a total weight basis.  
   
   
       32 . A protein extrudate as set forth in  claim 28  wherein said extrudate has a density of from about 0.15 g/cm 3  to about 0.35 g/cm 3 .  
   
   
       33 . A protein extrudate as set forth in  claim 32  wherein said extrudate has a density of from about 0.20 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       34 . A protein extrudate as set forth in  claim 33  wherein said extrudate has a density of from about 0.24 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       35 . A protein extrudate as set forth in  claim 32  wherein said extrudate has a density of from about 0.27 g/cm 3  to about 0.32 g/cm 3 .  
   
   
       36 . A protein extrudate as set forth in  claim 28  comprising from about 2 to about 8 parts by weight hydrolyzed soy protein per part by weight unhydrolyzed soy protein.  
   
   
       37 . A protein extrudate as set forth in  claim 2  wherein said extrudate has a hardness of at least about 10,000 grams, as measured by a texture analyzer having a 25 kg load cell.  
   
   
       38 . A protein extrudate as set forth in  claim 37  wherein said extrudate has a hardness of from about 1000 grams to about 50,000 grams, as measured by a texture analyzer having a 25 kg load cell.  
   
   
       39 . A protein extrudate as set forth in  claim 38  wherein said extrudate has a hardness of from about 30,000 grams to about 45,000 grams, as measured by a texture analyzer having a 25 kg load cell.  
   
   
       40 . A protein extrudate as set forth in  claim 2  wherein said extrudate is in the form of a powder having an average particle size of less than about 10 microns.  
   
   
       41 . A protein extrudate as set forth in  claim 40  wherein said powder has an average particle size of less than about 5 microns.  
   
   
       42 . A protein extrudate as set forth in  claim 41  wherein said extrudate comprises from about 0.001% to about 5% fiber on a moisture free basis.  
   
   
       43 . A protein extrudate as set forth in  claim 42  wherein said extrudate comprises from about 1% to about 3% by weight fiber on a moisture free basis.  
   
   
       44 . A protein extrudate comprising unhydrolyzed vegetable protein and at least about 2 parts by weight hydrolyzed protein per part by weight unhydrolyzed protein.  
   
   
       45 . A protein extrudate as set forth in  claim 44  comprising unhydrolyzed soy protein and at least about 2 parts by weight hydrolyzed soy protein per part by weight unhydrolyzed soy protein.  
   
   
       46 . A protein extrudate as set forth in  claim 45  comprising from about 2 to about 8 parts by weight hydrolyzed soy protein per part by weight unhydrolyzed soy protein.  
   
   
       47 . A protein extrudate as set forth in  claim 46  comprising from about 4 to about 6 parts by weight hydrolyzed soy protein per part by weight unhydrolyzed soy protein.  
   
   
       48 . A protein extrudate as set forth in  claim 46  herein said hyrolyzed soy protein exhibits a degree of hydrolysis of less than about 15%.  
   
   
       49 . A protein extrudate as set forth in  claim 48  wherein said hydrolyzed soy protein exhibits a degree of hydrolysis of less than about 10%.  
   
   
       50 . A protein extrudate as set forth in  claim 49  wherein said hydrolyzed soy protein exhibits a degree of hydrolysis of from about 1% to about 5%.  
   
   
       51 . A protein extrudate as set forth in  claim 49  wherein said hydrolyzed soy protein exhibits a TNBS value of from about 30 to about 70.  
   
   
       52 . A protein extrudate as set forth in  claim 49  wherein said extrudate comprises at least about 70% by weight soy protein.  
   
   
       53 . A protein extrudate as set forth in  claim 52  wherein said extrudate comprises less than about 10% by weight carbohydrate on a moisture-free basis.  
   
   
       54 . A protein extrudate as set forth in  claim 53  wherein said extrudate comprises from about 2% to about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       55 . A protein extrudate as set forth in  claim 53  wherein said extrudate comprises from about 2% to about 5.5% by weight water on a total weight basis.  
   
   
       56 . A protein extrudate as set forth in  claim 46  wherein said extrudate has a density of from about 0.10 g/cm 3  to about 0.40 g/cm 3 .  
   
   
       57 . A protein extrudate as set forth in  claim 56  wherein said extrudate has a density of from about 0.15 g/cm 3  to about 0.35 g/cm 3 .  
   
   
       58 . A protein extrudate as set forth in  claim 57  wherein said extrudate has a density of from about 0.24 g/cm 3  to about 0.29 g/cm 3 .  
   
   
       59 . A protein extrudate as set forth in any  claim 56  wherein said extrudate has a density of from about 0.20 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       60 . A protein extrudate as set forth in  claim 46  wherein said extrudate comprises at least about 80% by weight soy protein.  
   
   
       61 . A protein extrudate as set forth in  claim 60  wherein said extrudate comprises less than about 10% by weight carbohydrate on a moisture-free basis.  
   
   
       62 . A protein extrudate as set forth in  claim 61  wherein said extrudate comprises from about 2% to about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       63 . A protein extrudate as set forth in  claim 61  wherein said extrudate comprises from about 2% to about 5.5% by weight water on a total weight basis.  
   
   
       64 . A protein extrudate as set forth in  claim 60  wherein said extrudate has a density of from about 0.10 g/cm 3  to about 0.40 g/cm 3 .  
   
   
       65 . A protein extrudate as set forth in  claim 64  wherein said extrudate has a density of from about 0.15 g/cm 3  to about 0.35 g/cm 3 .  
   
   
       66 . A protein extrudate as set forth in  claim 65  wherein said extrudate has a density of from about 0.20 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       67 . A protein extrudate as set forth in  claim 60  wherein said extrudate has a density of from about 0.24 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       68 . A protein extrudate as set forth in  claim 46  wherein said extrudate comprises from about 80% to about 95% by weight soy protein.  
   
   
       69 . A protein extrudate as set forth in  claim 68  wherein said extrudate comprises less than about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       70 . A protein extrudate as set forth in  claim 69  wherein said extrudate comprises from about 2% to about 5% by weight carbohydrate on a moisture-free basis.  
   
   
       71 . A protein extrudate as set forth in  claim 46  wherein said extrudate has a density of from about 0.10 g/cm 3  to about 0.40 g/cm 3 .  
   
   
       72 . A protein extrudate as set forth in  claim 71  wherein said extrudate has a density of from about 0.15 g/cm 3  to about 0.35 g/cm 3 .  
   
   
       73 . A protein extrudate as set forth in  claim 72  wherein said extrudate has a density of from about 0.20 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       74 . A protein extrudate as set forth in  claim 73  wherein said extrudate has a density of from about 0.24 g/cm 3  to about 0.27 g/cm 3 .  
   
   
       75 . A protein extrudate as set forth in  claim 46  wherein said extrudate has a hardness of from about 1000 grams to about 50,000 grams, as measured by a texture analyzer having a 25 kg load cell.  
   
   
       76 . A protein extrudate as set forth in  claim 75  wherein said extrudate has a hardness of from about 30,000 grams to about 45,000 grams, as measured by a texture analyzer having a 25 kg load cell.  
   
   
       77 . A protein extrudate as set forth in  claim 46  wherein said extrudate is in the form of a powder having an average particle size of less than about 10 microns.  
   
   
       78 . A protein extrudate as set forth in  claim 77  wherein said powder has an average particle size of less than about 5 microns.  
   
   
       79 . A protein extrudate as set forth in  claim 78  wherein said extrudate comprises from about 0.001% to about 5% fiber on a moisture free basis.  
   
   
       80 . A protein extrudate as set forth in  claim 79  wherein said extrudate comprises from about 1% to about 3% by weight fiber on a moisture free basis.  
   
   
       81 . A functional food ingredient comprising from about 40% to about 95% by weight meat material and up to about 4% by weight of a soy protein product on a total weight basis, the soy protein product comprising at least about 70% by weight soy protein on a moisture-free basis and having a density of from about 0.10 g/cm 3  to about 0.40 g/cm 3 .  
   
   
       82 . A functional food ingredient as set forth in  claim 81  wherein said meat material is present at a concentration of from about 50% to about 90% by weight.  
   
   
       83 . A functional food ingredient as set forth in  claim 81  wherein said meat material is present at a concentration of from about 60% to about 85% by weight.  
   
   
       84 . A functional food ingredient as set forth in  claim 81  wherein said soy protein product is present at a concentration of up to about 3% by weight.  
   
   
       85 . A functional food ingredient as set forth in  claim 81  wherein said soy protein product is present at a concentration of from about 1% to about 3% by weight.  
   
   
       86 . A low density snack food product including a majority solids component and a water component with the majority solids component including at least protein, said food product comprising: 
 protein in the range of between about 25% and about 95% by weight of majority solids component and water, said protein being derived from seed crops selected from the groups of cereal grains and legumes;    water in the range of between about 1% and about 7% by weight of solids and water;    and said product being characterized by having a crisp texture, a density in the range of between about 0.02 g/cm 3  and about 0.5 g/cm 3  based on the weight of solids component and water.    
   
   
       87 . A food product as set forth in  claim 86  wherein said product is further characterized by having a non-fibrous eating texture.  
   
   
       88 . A food product as set forth in  claim 86  wherein the majority solids component includes filler present in a ratio of filler to protein in the range of between about 5:95 and about 75:25.  
   
   
       89 . A food product as set forth in  claim 88  wherein the protein includes a majority of soy protein.  
   
   
       90 . A food product as set forth in  claim 89  wherein the soy protein includes at least partially hydrolyzed soy protein and unhydrolyzed soy protein.  
   
   
       91 . A food product as set forth in  claim 90  wherein the at least partially hydrolyzed soy protein includes at least partially hydrolyzed soy isolates and the unhydrolyzed soy protein includes at least one of soy isolates, soy concentrates and soy flour wherein the at least partially hydrolyzed soy protein is present in the ratio of between about 80:20 and about 55:45 to the unhydrolyzed soy protein.  
   
   
       92 . A food product as set forth in  claim 91  wherein at least a majority of the filler is starch.  
   
   
       93 . A food product as set forth in  claim 92  wherein the starch is present in a ratio to protein in the range of between about 5:95% and about 75:25% by weight of protein, filler and water.  
   
   
       94 . A food product as set forth in  claim 93  wherein the density of the food product is in the range of between about 0.02 g/cm 3  and about 0.1 g/cm 3 .  
   
   
       95 . A food product as set forth in  claim 94  wherein the density of the food product is in the range of between about 0.02 g/cm 3  and about 0.05 g/cm 3 .  
   
   
       96 . A food product as set forth in  claim 94  wherein the moisture content of the food product is in the range of between about 3% and about 5% by weight of protein, filler and water.  
   
   
       97 . A low density, low moisture content proteinaceous food product comprising a principal solid component and containing between about 1% and about 7% water, said principal solid component comprising protein in a concentration between about 25% and about 95% by weight of the sum of the water content of said product and the dry basis weight of said principal solid component, said product being characterized by a crisp texture and a density in the range between about 0.02 g/cm 3  and about 0.5 g/cm 3  based on the weight of said principal solid component and water.  
   
   
       98 . A food product as set forth in  claim 97  wherein said principal solid component further comprises a filler in a weight ratio to protein between about 5:95 and about 75:25.  
   
   
       99 . A food product as set forth in  claim 98  wherein more than half the protein content consists of soy protein.  
   
   
       100 . A food product as set forth in  claim 99  wherein the soy protein includes at least partially hydrolyzed soy protein and unhydrolyzed soy protein.  
   
   
       101 . A low density, low moisture content proteinaceous food product comprising a proteinaceous solid matrix and containing between about 1% and about 7% water, said matrix comprising protein in a concentration between about 25% and about 95% by weight of the sum of the water content of said product and the dry basis weight of said matrix, said product being characterized by a crisp texture, a density in the range between about 0.02 g/cm 3  and about 0.5 g/cm 3 .  
   
   
       102 . A food product as set forth in  claim 101  wherein said matrix further comprises a filler in a weight ratio to protein between about 5:95 and about 75:25.  
   
   
       103 . A food product as set forth in  claim 102  wherein more than half the protein content consists of soy protein.  
   
   
       104 . A food product as set forth in  claim 103  wherein the soy protein includes at least partially hydrolyzed soy protein and unhydrolyzed soy protein.  
   
   
       105 . A low density, low moisture content proteinaceous food product comprising a proteinaceous solid extrudate and containing between about 1% and about 7% water, said extrudate comprising protein in a concentration between about 25% and about 95% by weight of the sum of the water content of said product and the dry basis weight of said extrudate, said product being characterized by a crisp texture, a density in the range between about 0.02 g/cm 3  and about 0.5 g/cm 3 .  
   
   
       106 . A food product as set forth in  claim 105  wherein said extrudate further comprises a filler in a weight ratio to protein between about 5:95 and about 75:25.  
   
   
       107 . A food product as set forth in  claim 106  wherein more than half the protein content consists of soy protein.  
   
   
       108 . A food product as set forth in  claim 107  wherein the soy protein includes at least partially hydrolyzed soy protein and unhydrolyzed soy protein.  
   
   
       109 . A low density, low moisture content proteinaceous food product comprising between about 1% and about 7% water and between about 25% and about 95% by weight of protein, wet basis, said product being characterized by a crisp texture, a density in the range between about 0.02 g/cm 3  and about 0.5 g/cm 3 .