Dual textured animal food product and methods of manufacture thereof

Abstract

A co-extruded, dual-texture animal food is provided. The food has a dry outer portion partially surrounding a semi-moist inner portion. The inner portion has a higher or similar moisture content and a softer texture compared to the outer portion which has a lower moisture content and harder texture. The outer portion comprises cereal grain and a legume at about 75-85% of the weight of the outer portion, and an animal-based protein contributing to about 5-10% of the weight or more of the outer portion. The inner portion has animal-derived grease mixed with lactic acid at about 3% by weight of the inner portion, along with at least one meat comprising at least 3% by weight of the inner portion. The composition inhibits moisture transference within and between individual pieces of the food. The food is shelf stable and the inner and outer portions retain their hardness and moisture profiles, post-packaging.

What is claimed is: 
     
         1 . A dual-texture animal food product comprising:
 an outer portion having a first texture with a hardness factor of about 3-10 Newtons, the outer portion comprising at least one cereal grain and a legume at about 75-85% by weight and animal-based protein at about 5-10% by weight, the outer portion comprising a moisture content of about 8-12% by weight of the outer portion; and   an inner portion having a second texture with a hardness factor of about 1-7 Newtons, the inner portion comprising animal-derived grease with lactic acid at about 3% by weight and meat at about 3% or more by weight, the inner portion having a moisture content of about 11-18% by weight of the inner portion;   wherein the inner portion is partially surrounded by the outer portion, and   wherein the hardness factor associated with the inner portion is less than the hardness factor associated with the outer portion.   
     
     
         2 . The animal food product of  claim 1  having animal-derived grease with lactic acid applied to an external surface of the animal food product. 
     
     
         3 . The animal food product of  claim 1  wherein the outer portion has a hardness factor of about 3.5-7 Newtons. 
     
     
         4 . The animal food product of  claim 3  wherein the outer portion has a hardness factor of about 5.5 Newtons. 
     
     
         5 . The animal food product of  claim 1  wherein the inner portion has a hardness factor of about 1.5-7 Newtons. 
     
     
         6 . The animal food product of  claim 5  wherein the inner portion has a hardness factor of about 4.5 Newtons. 
     
     
         7 . The animal food product of  claim 1  wherein the outer portion comprises a moisture content at about 10-12% by weight of the outer portion. 
     
     
         8 . The animal food product of  claim 7  wherein the outer portion comprises a moisture content at about 12% by weight of the outer portion. 
     
     
         9 . The animal food product of  claim 1  wherein the inner portion comprises a moisture content of about 15-17% by weight of the inner portion. 
     
     
         10 . The animal food product of  claim 9  wherein the inner portion comprises a moisture content of about 16% by weight of the inner portion. 
     
     
         11 . The animal food product of  claim 1  wherein the cereal grain is at least one of corn, whole corn, wheat, whole wheat, or wheat middlings. 
     
     
         12 . The animal food product of  claim 1  wherein the legume is soybean or soybean meal. 
     
     
         13 . The animal food product of  claim 1  wherein the meat is beef. 
     
     
         14 . The animal food product of  claim 1  wherein the outer portion comprises at least one of vitamins, a mineral, a flavoring, and a preservative. 
     
     
         15 . The animal food product of  claim 1  wherein the inner portion comprises at least one of a cereal grain, a legume, a humectant, an acid, a vitamin, and a flavoring. 
     
     
         16 . The animal food product of  claim 1  wherein the animal food product is shelf stable. 
     
     
         17 . A shelf-stable, dual-texture pet food product comprising:
 an outer portion co-extruded around an inner portion, the inner portion in contact with and partially surrounded by the outer portion;   the inner portion having a soft texture with a hardness factor in a range of about 1-7 Newtons, the inner portion comprising animal meat at about 3% by weight or more, animal-derived grease with lactic acid, starch, and plant-derived protein; and   the outer portion having a hard texture with a hardness factor in a range of about 3-10 Newtons, the outer portion comprising starch and plant-derived protein;   wherein the hardness factor of the inner portion is less than the hardness factor of the outer portion.   
     
     
         18 . The shelf-stable, dual-texture pet food product of  claim 17  wherein the starch is provided by corn. 
     
     
         19 . The dual-texture pet food product of  claim 17  wherein the plant-derived protein is provided by at least one of wheat, whole wheat, wheat middlings, soybean, or soybean meal. 
     
     
         20 . The dual-texture pet food product of  claim 17  wherein the inner portion comprises at least one of an acid other than lactic acid, a humectant, vitamins, a mineral, and a preservative. 
     
     
         21 . The dual-texture pet food product of  claim 17  wherein the ratio between the hardness factor of the inner portion and the hardness factor of the outer portion is in a range of about 1:1.1 to 1:2.5. 
     
     
         22 . The dual-texture pet food product of  claim 17  wherein the outer portion has a moisture content in a range of about 8-12 wt %. 
     
     
         23 . The dual-texture pet food product of  claim 17  wherein the inner portion has a moisture content in a range of about 15-17 wt %. 
     
     
         24 . A process for manufacturing a dual-textured pet food product, the process comprising:
 forming in a first extruder, a first dough comprising animal meat, a plant-based starch, plant-based protein, animal-derived grease with lactic acid, and a humectant;   forming in a second extruder a second dough comprising at least one cereal grain, meal provided by a legume, and animal-derived protein;   co-extruding the first dough with a second dough to form a co-extrudate, the co-extrudate comprising an inner portion of the first dough and an outer portion of the second dough;   cutting the co-extrudate into pieces of the dual-textured pet food product;   wherein the outer portion has a first texture with a hardness factor of about 3-10 Newtons and the inner portion has a second texture with a hardness factor of about 1-7 Newtons; and   wherein the hardness factor of the inner portion is less than the hardness factor of the outer portion.   
     
     
         25 . The process of  claim 24  wherein the first extruder is a twin-screw extruder. 
     
     
         26 . The process of  claim 24  wherein the second extruder is a single screw extruder having a manifold, further comprising using the manifold to wrap the second dough around the first dough prior to co-extruding the first dough and the second dough to form the co-extrudate. 
     
     
         27 . The process of  claim 24  and further comprising air-drying the pieces of the dual-texture pet food product. 
     
     
         28 . The process of  claim 24  further comprising packaging the pieces of the dual-texture pet food product in commercial packaging, wherein the inner portion and the outer portion substantially retain their moisture content after packaging. 
     
     
         29 . The process of  claim 24  wherein the plant-based starch is provided by cereal grain. 
     
     
         30 . The process of  claim 29  wherein the cereal grain is corn. 
     
     
         31 . The process of  claim 24  wherein the plant-based protein is provided by a cereal grain or a legume. 
     
     
         32 . The process of  claim 31  wherein the cereal grain is selected from at least one of wheat, whole wheat, or wheat middlings. 
     
     
         33 . The process of  claim 31  wherein the legume is soybean or soybean meal.