U.S. patent application number 11/204454 was filed with the patent office on 2006-02-16 for restructured meat product and process for preparing same.
Invention is credited to Eduardo Godinez, Matthew K. McMindes.
Application Number | 20060035006 11/204454 |
Document ID | / |
Family ID | 35355528 |
Filed Date | 2006-02-16 |
United States Patent
Application |
20060035006 |
Kind Code |
A1 |
McMindes; Matthew K. ; et
al. |
February 16, 2006 |
Restructured meat product and process for preparing same
Abstract
This invention relates to a restructured meat product,
comprising; (A) a soy protein material; (B) a comminuted meat; and
(C) water. In another embodiment, the invention discloses a process
for preparing a restructured meat product, comprising the steps of;
hydrating (A) a soy protein material; and adding (B) a comminuted
meat, wherein the temperature of the comminuted meat is below about
40.degree. C.; and mixing (A) and (B) to produce a homogeneous, and
texturized meat product having a moisture content of at least about
50%.
Inventors: |
McMindes; Matthew K.;
(Chesterfield, MO) ; Godinez; Eduardo;
(Chesterfield, MO) |
Correspondence
Address: |
SOLAE, LLC
PO BOX 88940
ST. LOUIS
MO
63188
US
|
Family ID: |
35355528 |
Appl. No.: |
11/204454 |
Filed: |
August 16, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10919421 |
Aug 16, 2004 |
|
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11204454 |
Aug 16, 2005 |
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Current U.S.
Class: |
426/646 |
Current CPC
Class: |
A23L 13/65 20160801;
A23L 13/60 20160801; A23L 13/67 20160801; A23L 13/426 20160801 |
Class at
Publication: |
426/646 |
International
Class: |
A23L 1/31 20060101
A23L001/31 |
Claims
1. A restructured meat product, comprising; (A) a soy protein
material; (B) a comminuted meat; and (C) water.
2. The restructured meat product of claim 1 wherein the soy protein
material (A) is selected from the group consisting of a soy protein
flour, a soy protein isolate, a soy protein concentrate, and
mixtures thereof.
3. The restructured meat product of claim 1 wherein the soy protein
material (A) is a soy protein isolate.
4. The restructured meat product of claim 3 wherein (A) further
comprises from about 2% to about 20% by weight on a moisture free
basis of a starch and from about 2% to about 20% by weight on a
moisture free basis of at least one selected from the group
consisting of a wheat flour, a wheat gluten, and mixtures
thereof.
5. The restructured meat product of claim 2 wherein (A) further
comprises from about 2% to about 20% by weight on a moisture free
basis of at least one selected from the group consisting of a rice
flour, a gluten free starch, and mixtures thereof.
6. The restructured meat product of claim 2 wherein (A) further
comprises from about 1% to about 20% by weight on a moisture free
basis of a soy cotyledon fiber.
7. The restructured meat product of claim 6 wherein (A) further
comprises from about 10% to about 40% wheat gluten, by weight on a
moisture free basis.
8. The restructured meat product of claim 7 wherein (A) further
comprises from about 5% to about 15% starch, by weight on a
moisture free basis.
9. The restructured meat product of claim 8 wherein (A) contains
from about 30% to about 90% soy protein, by weight on a moisture
free basis.
10. The restructured meat product of claim 8 wherein (A) is an
extrudate having a moisture content of from about 5% to about
80%.
11. The restructured meat product of claim 8 wherein the comminuted
meat has a moisture content of at least about 50% by weight.
12. The restructured meat product of claim 8 further comprising at
least one of a gelling protein; an animal fat; sodium chloride;
sodium tripolyphosphate; a colorant; a curing agent; a flavorant
comprising beef flavor, pork flavor, or chicken flavor; or mixtures
of each with the other.
13. The restructured meat product of claim 12 wherein the gelling
protein is selected from the group consisting of a soy protein
flour, a soy protein isolate and a soy protein concentrate.
14. The restructured meat product of claim 1 wherein the
restructured meat product has a moisture content, before drying, of
at least about 50% and after drying, has a moisture content of from
about 15 to about 45%.
15. A process for preparing a restructured meat product, comprising
the steps of; hydrating (A) a soy protein material; and adding (B)
a comminuted meat, wherein the temperature of the comminuted meat
is below about 40.degree. C.; and mixing (A) and (B) to produce a
homogeneous, and texturized meat product having a moisture content
of at least about 50%.
16. The process for preparing the restructured meat product of
claim 15 wherein the soy protein material (A) is selected from the
group consisting of a soy protein flour, a soy protein isolate, a
soy protein concentrate, and mixtures thereof.
17. The process for preparing the restructured meat product of
claim 15 wherein the soy protein material (A) is a soy protein
isolate.
18. The process for preparing the restructured meat product of
claim 17 wherein (A) further comprises from about 2% to about 20%
by weight on a moisture free basis of a starch and from about 2% to
about 20% by weight on a moisture free basis of at least one
selected from the group consisting of a wheat flour, a wheat
gluten, and mixtures thereof.
19. The process for preparing the restructured meat product of
claim 16 wherein (A) further comprises from about 2% to about 20%
by weight on a moisture free basis of at least one selected from
the group consisting of a rice flour, a gluten free starch, and
mixtures thereof.
20. The process for preparing the restructured meat product of
claim 16 wherein (A) further comprises from about 1% to about 20%
by weight on a moisture free basis of a soy cotyledon fiber.
21. The process for preparing the restructured meat product of
claim 20 wherein (A) further comprises from about 10% to about 40%
wheat gluten, by weight on a moisture free basis.
22. The process for preparing the restructured meat product of
claim 21 wherein (A) further comprises from about 5% to from 15%
starch, by weight on a moisture free basis.
23. The process for preparing the restructured meat product of
claim 22 wherein (A) contains from about 30% to about 90% soy
protein, by weight on a moisture free basis.
24. The process for preparing the restructured meat product of
claim 22 wherein (A) is an extrudate having a moisture content of
from about 5% to about 80%.
25. The process for preparing the restructured meat product of
claim 22 wherein the comminuted meat has a moisture content of at
least about 50% by weight.
26. The process for preparing the restructured meat product of
claim 24 wherein (A) has a moisture content of from about 6% to
about 13%.
27. The process for preparing the restructured meat product of
claim 24 wherein (A) has a moisture content of from about 16% to
about 30%.
28. The process for preparing the restructured meat product of
claim 24 wherein (A) has a moisture content of from about 50% to
about 80%.
29. The process for preparing the restructured meat product of
claim 15 wherein the temperature of the comminuted meat is from
about -4.degree. C. to about 6.degree. C.
30. The process for preparing the restructured meat product of
claim 15 wherein the weight ratio of the soy protein material (A)
on a moisture free basis to the comminuted meat on a moisture free
basis is from about 1:0.25 to about 50.
31. The process for preparing the restructured meat product of
claim 15 wherein the homogeneous meat product is formed into
strips, steaks, cutlets, patties, ground or generally cube-shaped
for kabobs.
32. The process for preparing the restructured meat product of
claim 15 wherein the homogeneous meat product is stuffed into
permeable or impermeable casings.
33. The process for preparing the restructured meat product of
claim 15 further comprising at least one of a gelling protein; an
animal fat; sodium chloride; sodium tripolyphosphate; a colorant; a
curing agent; a flavorant comprising beef flavor, pork flavor, or
chicken flavor; or mixtures of each with the other.
34. The process for preparing the restructured meat product of
claim 33 wherein the gelling protein is selected from the group
consisting of a soy protein flour, a soy protein isolate and a soy
protein concentrate.
35. The process for preparing the restructured meat product of
claim 15 wherein the restructured meat product has a moisture
content, before drying, of at least about 55% and after drying, has
a moisture content of from about 15 to about 45%.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a continuation-in-part patent application of U.S.
patent application Ser. No. 10/919,421, filed on Aug. 16, 2004.
FIELD OF THE INVENTION
[0002] This invention relates to a restructured meat product as
well as a process for preparing the restructured meat product by
the combination of a soy protein material, comminuted meat and
water, such that a value added meat product having a texture
similar to that of intact muscles is obtained. The soy protein
containing material may further contain starches, flour and
fibers.
BACKGROUND OF THE INVENTION
[0003] An important aspect of the present invention is the
development of an untexturized protein product into a texturized
protein product. Particularly, the present invention provides a
product and method for taking an untexturized, paste-like,
batter-like protein product with no visible grain or texture and
converting it into a texturized, protein product with a definite
shape having the consistency of cooked muscle meat.
[0004] The term texture describes a wide variety of physical
properties of a food product. A product of acceptable texture is
usually synonymous with the quality of a product. Texture has been
defined as "the attribute of a substance resulting from a on of
physical properties and perceived by senses of touch, including
kinaestheses feel, sight, and hearing. Texture, as defined by the
International Organization of Standardization, is "all of the
theological and structural (geometric and surface) attributes of a
food product perceptible by means of mechanical, tactual and, where
appropriate, visual and auditory receptors." The following terms
have been used to describe product characteristics falling under
the umbrella "texture": TABLE-US-00001 TABLE I ABRIDGED LIST OF
FOOD TEXTURE ADJECTIVES Adhesive Fleshy Mushy Soft Bouncy Fluffy
Oily Soggy Brittle Foamy Pasty Sparkly Bubbly Fragile Plastic
Splintery Chewy Full-bodied Porous Spongy Clingy Gooey Powdery
Springy Coating Grainy Puffy Sticky Cohesive Gritty Pulpy Stringy
Creamy Gummy Rich Syrupy Crisp Hard Rough Tender Crumbly Heavy
Rubbery Thick Crusty Heterogeneous Runny Thin Dense Juicy Sandy
Tingly Doughy Lean Scratchy Tough Dry Light Short Uniform Elastic
Limp Silky Viscous Fatty Lumpy Slippery Watery Firm Moist Slivery
Waxy Flaky Mouth coating Smooth Wiggly
[0005] Accelerated attention has been given to texture as it
pertains to newer food substances including fabricated and
imitation products, formed meat and fish products, where very
serious efforts are made by processes to duplicate the properties
of the original or other natural food substances. The use of
non-traditional raw materials, synthetic flavors, fillers, and
stretchers all tend to alter certain textural characteristics of
the finished product. Frequently, the imitation of textural
properties is of much greater difficulty in the replication of
taste, odors, and colors. Numerous manipulative processes,
including extrusion texturization, have been developed to simulate
natural textural properties. The processes generally find it
prudent to duplicate the properties of the original substances to
the extent feasible technically and economically in order to
promote early market acceptance. While texture has attributes
related to appearance, it also has attributes related to touch and
also mouth feel or interaction of food when it comes in contact
with the mouth. Frequently, these sensory perceptions involved with
chewing can relate to impressions of either desirability or
undesirability.
[0006] Thus, textural terms include terms relating to the behavior
of the material under stress or strain and include, for example,
the following: firm, hard, soft, tough, tender, chewy, rubbery,
elastic, plastic, sticky, adhesive, tacky, crispy, crunchy, etc.
Secondly, texture terms may be related to the structure of the
material: smooth, fine, powdery, chalky, lumpy, mealy, coarse,
gritty, etc. Third, texture terms may relate to the shape and
arrangement of structural elements, such as: flaky, fibrous,
stringy, pulpy, cellular, crystalline, glassy, spongy, etc. Last,
texture terms may relate to mouth feel characteristics, including:
mouth feel, body, dry, moist, wet, watery, waxy, slimy, mushy,
etc.
[0007] As used herein, "untexturized" and "texturized" describe the
characteristics of the food product as set forth in Table II:
TABLE-US-00002 TABLE II Untexturized Texturized Characteristic
Characteristic Behavior of sticky firm Material under gooey chewy
Stress or Strain plastic Structure of smooth coarse Material Shape
and gelatinous fibrous Arrangement of pulpy crusty Structural
Elements pasty Mouth Feel creamy moist mushy dry with body
SUMMARY OF THE INVENTION
[0008] This invention relates to a restructured meat product,
comprising;
[0009] (A) a soy protein material;
[0010] (B) a comminuted meat; and
[0011] (C) water.
[0012] In another embodiment, the invention discloses a process for
preparing a restructured meat product, comprising the steps of;
hydrating
[0013] (A) a soy protein material; and adding
[0014] (B) a comminuted meat, wherein the temperature of the
comminuted meat is below about 40.degree. C.; and
[0015] mixing (A) and (B) to produce a homogeneous, and texturized
meat product having a moisture content of at least about 50%.
DETAILED DESCRIPTION OF THE INVENTION
[0016] Mechanically deboned meat (MDM) is a meat paste that is
recovered from beef, pork and chicken bones using commercially
available equipment. MDM is a comminuted product that is devoid of
the natural fibrous texture found in intact muscles. The lack of
fibrosity constrains the utility of MDM and most often limits its
use to the manufacture of comminuted sausages such as frankfurters
and bologna.
Definitions
[0017] As used herein, the term "soy material" is defined as a
material derived from whole soybeans which contains no non-soy
derived additives. Such additives may, of course, be added to a soy
material to provide further functionality or nutrient content in an
extruded meat analog containing the soy material. The term
"soybean" refers to the species Glycine max, Glycine soja, or any
species that is sexually cross compatible with Glycine max.
[0018] The term "protein content" as used herein, refers to the
relative protein content of a soy material as ascertained by
A.O.C.S. (American Oil Chemists Society) Official Methods Bc
4-91(1997), Aa 5-91(1997), or Ba 4d-90(1997), each incorporated
herein in its entirety by reference, which determine the total
nitrogen content of a soy material sample as ammonia, and the
protein content as 6.25 times the total nitrogen content of the
sample.
[0019] The Nitrogen-Ammonia-Protein Modified Kjeldahl Method of
A.O.C.S. Methods Bc4-91 (1997), Aa 5-91 (1997), and Ba 4d-90(1997)
used in the determination of the protein content may be performed
as follows with a soy material sample. From 0.0250-1.750 grams of
the soy material are weighed into a standard Kjeldahl flask. A
commercially available catalyst mixture of 16.7 grams potassium
sulfate, 0.6 grams titanium dioxide, 0.01 grams of copper sulfate,
and 0.3 grams of pumice is added to the flask, then 30 milliliters
of concentrated sulfuric acid is added to the flask. Boiling stones
are added to the mixture, and the sample is digested by heating the
sample in a boiling water bath for approximately 45 minutes. The
flask should be rotated at least 3 times during the digestion. 300
milliliters of water is added to the sample, and the sample is
cooled to room temperature. Standardized 0.5N hydrochloric acid and
distilled water are added to a distillate receiving flask
sufficient to cover the end of a distillation outlet tube at the
bottom of the receiving flask. Sodium hydroxide solution is added
to the digestion flask in an amount sufficient to make the
digestion solution strongly alkaline. The digestion flask is then
immediately connected to the distillation outlet tube, the contents
of the digestion flask are thoroughly mixed by shaking, and heat is
applied to the digestion flask at about a 7.5-min boil rate until
at least 150 milliliters of distillate is collected. The contents
of the receiving flask are then titrated with 0.25N sodium
hydroxide solution using 3 or 4 drops of methyl red indicator
solution - 0.1% in ethyl alcohol. A blank determination of all the
reagents is conducted simultaneously with the sample and similar in
all respects, and correction is made for blank determined on the
reagents. The moisture content of the ground sample is determined
according to the procedure described below (A.O.C.S Official Method
Ba 2a-38). The nitrogen content of the sample is determined
according to the formula: Nitrogen (%)=1400.67.times.[[(Normality
of standard acid).times.(Volume of standard acid used for sample
(ml))]-[(Volume of standard base needed to titrate 1 ml of standard
acid minus volume of standard base needed to titrate reagent blank
carried through method and distilled into 1 ml standard acid
(ml)).times.(Normality of standard base)]-[(Volume of standard base
used for the sample (ml)).times.(Normality of standard
base)]]/(Milligrams of sample). The protein content is 6.25 times
the nitrogen content of the sample.
[0020] The term "moisture content" as used herein refers to the
amount of moisture in a material. The moisture content of a
material can be determined by A.O.C.S. (American Oil Chemists
Society) Method Ba 2a-38 (1997), which is incorporated herein by
reference in its entirety. According to the method, the moisture
content of a material may be measured by passing a 1000 gram sample
of the ground material through a 6.times.6 riffle divider,
available from Seedboro Equipment Co., Chicago, Ill., and reducing
the sample size to 100 grams. The 100 gram sample is then
immediately placed in an airtight container and weighed. Five grams
of the sample ("Sample Weight") are weighed onto a tared moisture
dish (minimum 30 gauge, approximately 50.times.20 millimeters, with
a tight-fitting slip cover--available from Sargent-Welch Co.). The
dish containing the sample is placed in a forced draft oven and
dried at 130.+-.3.degree. C. for 2 hours. The dish is then removed
from the oven, covered immediately, and cooled in a dissector to
room temperature. The dish is then weighed to obtain a Dry Weight.
Moisture content is calculated according to the formula: Moisture
content (%)=100.times.[(Sample Weight-Dry Weight)/Sample
Weight].
[0021] The term "weight on a moisture free basis" as used herein
refers to the weight of a material after it has been dried to
completely remove all moisture, e.g. the moisture content of the
material is 0%. Specifically, the weight on a moisture free basis
of a soy material can be obtained by weighing the soy material
after the soy material has been placed in a 45.degree. C. oven
until the soy material reaches a constant weight.
[0022] The term "soy protein isolate" as used herein is used in the
sense conventional to the soy protein industry. Specifically, a soy
protein isolate is a soy material having a protein content of at
least about 90% soy protein on a moisture free basis. "Isolated soy
protein", as used in the art, has the same meaning as "soy protein
isolate" as used herein and as used in the art. A soy protein
isolate is formed from soybeans by removing the hull and germ of
the soybean from the cotyledon, flaking or grinding the cotyledon
and removing oil from the flaked or ground cotyledon, separating
the soy protein and carbohydrates of the cotyledon from the
cotyledon fiber, and subsequently separating the soy protein from
the carbohydrates.
[0023] The term "soy protein concentrate" as used herein is used in
the sense conventional to the soy protein industry. Specifically, a
soy protein concentrate is a soy material having a protein content
of from about 65% to less than about 90% soy protein on a
moisture-free basis. Soy protein concentrate also contains soy
cotyledon fiber, typically from about 3.5% up to about 20% soy
cotyledon fiber by weight on a moisture-free basis. A soy protein
concentrate is formed from soybeans by removing the hull and germ
of the soybean from the cotyledon, flaking or grinding the
cotyledon and removing oil from the flaked or ground cotyledon, and
separating the soy protein and soy cotyledon fiber from the
carbohydrates of the cotyledon.
[0024] The term "soy protein flour" as used herein, refers to a
comminuted form of defatted soybean material, preferably containing
less than about 1% oil, formed of particles having a size such that
the particles can pass through a No. 100 mesh (U.S. Standard)
screen. The soy cake, chips, flakes, meal, or mixture of the
materials are comminuted into a soy flour using conventional soy
grinding processes. Soy flour has a soy protein content of about
49% to about 65% on a moisture free basis. Preferably the flour is
very finely ground, most preferably so that less than about 1% of
the flour is retained on a 300 mesh (U.S. Standard) screen.
[0025] Rice is a starchy food containing from about 6% to about 10%
protein. The term "rice flour" as used herein relates to an
inexpensive by-product of rice milling obtained by grinding broken
rice. Conventional milling practices produce rice flour composed
largely of about 80% carbohydrates. Because of the low
concentration of protein in rice and the resulting bulk required to
obtain a satisfactory protein intake, infants and children cannot
eat a sufficient amount to meet their protein requirements.
[0026] The term "starch" as used herein, is intended to include all
starches derived from any native source, any of which may be
suitable for use herein. A native starch as used herein, is one as
it is found in nature. Also suitable are starches derived from a
plant obtained by standard breeding techniques including
crossbreeding, translocation, inversion, transformation or any
other method of gene or chromosome engineering to include
variations thereof. In addition, starch derived from a plant grown
from artificial mutations and variations of the above generic
composition, which may be produced by known standard methods of
mutation breeding, are also suitable herein.
[0027] Typical sources for the starches are cereals, tubers, roots,
legumes and fruits. The native source can be a waxy variety of corn
(maize), pea, potato, sweet potato, banana, barley, wheat, rice,
oat, sago, amaranth, tapioca (cassava), arrowroot, canna, and
sorghum particularly maize, potato, cassava, and rice. As used
herein, the term "waxy" or "low amylose" is intended to include a
starch containing no more than about 10% by weight amylose.
Particularly suitable in the invention are those starches which
contain no more than about 5% amylose by weight.
[0028] The term "gluten free starch" relates to modified tapioca
starch, the main ingredient in many of bakery mix products. Gluten
free or substantially gluten free starches are made from wheat-,
corn-, and tapioca-based starches and are "gluten-free" because
they do not contain gluten from wheat, oats, rye or barley--a
factor of particular importance for people diagnosed with celiac
disease and/or wheat allergies.
[0029] The term "wheat flour" relates to a flour obtained from the
milling of wheat. The particle size of wheat flour typically is
from about 14-120 .mu.m. Wheat flour typically contains from about
11.7 to about 14% protein and from about 3.7 to about 10.9%
fiber.
[0030] The term "gluten" relates to a protein fraction in wheat
flour, that possesses a high protein content as well as unique
structural and adhesive properties. In its freshly extracted wet
state it is known as gum gluten, and when thereafter dried it
becomes a free-flowing powder of high protein content and bland
taste. It is generally used in food processing in that form.
[0031] The term "soy cotyledon fiber" as used herein refers to the
fibrous portion of soy cotyledons containing at least about 70%
fiber (polysaccharide). Soy cotyledon fiber typically contains some
minor amounts of soy protein, but may also be 100% fiber. Soy
cotyledon fiber, as used herein, does not refer to, or include, soy
hull fiber. To avoid confusion the term "fiber" as used herein
(except in this paragraph) refers to fiber formed in the process of
extruding a soy protein material, generally by protein-protein
interactions, not soy cotyledon fiber. To further avoid confusion,
soy cotyledon fiber will be referred to herein only as "soy
cotyledon fiber" and not as "fiber." Soy cotyledon fiber is formed
from soybeans by removing the hull and germ of the soybean from the
cotyledon, flaking or grinding the cotyledon and removing oil from
the flaked or ground cotyledon, and separating the soy cotyledon
fiber from the soy material and carbohydrates of the cotyledon.
[0032] The term "comminuted meat" as used herein refers to a meat
paste that is recovered from an animal carcass. The meat, on or off
the bone is forced through a deboning device such that meat is
separated from the bone and reduced in size. The meat is separated
from the meat/bone mixture by forcing through a cylinder with small
diameter holes. The meat acts as a liquid and is forced through the
holes while the remaining bone material remains behind. The fat
content of the comminuted meat may be adjusted upward by the
addition of animal fat.
The Soy Protein Material
[0033] Component (A) is a soy protein material wherein the soy
protein material (A) is selected from the group consisting of a soy
protein isolate, a soy protein concentrate, a soy protein flour,
and mixtures thereof. The soy protein material (A) may further
comprise components selected from the group consisting of a starch,
gluten free starch, rice flour, wheat flour, wheat gluten, soy
cotyledon fiber, and mixtures thereof.
[0034] When the soy protein material (A) includes a soy protein
isolate as the source of the soy protein, from about 2% to about
20% by weight on a moisture free basis of a starch or gluten free
starch is present along with from about 2% to about 20 % by weight
on a moisture free basis of at least one selected from the group
consisting of a wheat flour, a wheat gluten, and mixtures thereof,
with the remainder being the soy protein isolate.
[0035] When from about 2% to about 20% by weight on a moisture free
basis of at least one selected from the group consisting of a rice
flour, a gluten free starch, and mixtures thereof is used, the
remainder of the soy protein material (A) is at least one selected
from the group consisting of a soy protein isolate, a soy protein
concentrate, a soy protein flour, and mixtures thereof.
[0036] When at least one selected from the group consisting of a
soy protein isolate, a soy protein concentrate, a soy protein
flour, and mixtures thereof is used, the soy protein material (A)
may also include a soy cotyledon fiber that is present in the soy
protein material (A) at about 1% to about 20% by weight on a
moisture free basis with the remainder selected from the group
consisting of the soy protein isolate, the soy protein concentrate,
the soy protein flour, and mixtures thereof.
[0037] When from about 1% to about 20% by weight on a moisture free
basis of a soy cotyledon fiber is used, the soy protein material
(A) may also include from about 10% to about 40% by weight on a
moisture free basis of a wheat gluten, with the remainder selected
from the group consisting of a soy protein isolate, a soy protein
concentrate, a soy protein flour, and mixtures thereof.
[0038] When from about 1% to about 20% by weight on a moisture free
basis of a soy cotyledon fiber and from about 10% to about 40% by
weight on a moisture free basis of a wheat gluten is used, the soy
protein material (A) may also include from about 5% to about 15% by
weight on a moisture free basis of a starch, with the remainder
selected from the group consisting of a soy protein isolate, a soy
protein concentrate, a soy protein flour, and mixtures thereof.
[0039] The soy protein material is produced by extruding one or
more of the soy protein isolate, soy protein concentrate and soy
protein flour with one or more of the above named components of a
starch, gluten free starch, rice flour, wheat flour and wheat
gluten and soy cotyledon fiber. The soy protein material (A) has a
moisture content of from about 5% to about 80%. Moisture conditions
employed in producing the soy protein material (A) are low moisture
soy protein material (A) (about 5% to about 35%) and high moisture
soy protein material (A) (about 50% to about 80%). In producing a
soy protein material (A), the above ingredients are heated along
with water under increasing temperature, pressure and shear
conditions in a cooker extruder, and extruding the ingredient
mixture through a die. Upon extrusion, the extrudate generally
expands to form a fibrous cellular structure as it enters a medium
of reduced pressure (usually atmospheric). Extrusion methods for
forming fibrous cellular structures are well known and disclosed,
for example, in U.S. Pat. No. 4,099,455.
[0040] The soy protein content of the soy protein material (A),
irrespective of being a low moisture soy protein material (A) or a
high moisture soy protein material (A) is from about 30% to about
90% by weight on a moisture free basis. For a low moisture soy
protein material (A), the soy protein content, including the
moisture, is from about 50% to about 75% by weight. For a high
moisture soy protein material (A), the soy protein content,
including the moisture, is from about 25% to about 50% by
weight.
[0041] Furthermore, when a soy protein isolate is used, the soy
protein isolate should not be a highly hydrolyzed soy protein
isolate having a low molecular weight distribution since highly
hydrolyzed soy protein isolates lack the protein chain length to
properly form protein fibers in the process. Highly hydrolyzed soy
protein isolates, however, may be used in combination with other
soy protein isolates provided that the highly hydrolyzed soy
protein isolate content of the combined soy protein isolates is
less than about 40% of the combined soy protein isolates, by
weight.
[0042] The soy protein isolate utilized should have a water holding
capacity sufficient to enable the protein in the isolate to form
fibers upon extrusion. Examples of soy protein isolates that are
useful in the present invention are commercially available, for
example, from Solae, LLC (St. Louis, Mo.), and include SUPRO.RTM.
500E, SUPRO.RTM. EX 33, SUPRO.RTM. 620, SUPRO.RTM. 630 and
SUPRO.RTM. 545.
[0043] Soy protein isolates useful in the soy protein material (A)
may be produced from soybeans according to conventional processes
in the soy protein manufacturing industry. Exemplary of such a
process, whole soybeans are initially detrashed, cracked, dehulled,
degermed, and defatted according to conventional processes to form
soy flakes, soy flour, soy grits, or soy meal. The soybeans may be
detrashed by passing the soybeans through a magnetic separator to
remove iron, steel, and other magnetically susceptible objects,
followed by shaking the soybeans on progressively smaller meshed
screens to remove soil residues, pods, stems, weed seeds,
undersized beans, and other trash. The detrashed soybeans may be
cracked by passing the soybeans through cracking rolls. Cracking
rolls are spiral-cut corrugated cylinders which loosen the hull as
the soybeans pass through the rolls and crack the soybean material
into several pieces. The cracked soybeans may then be dehulled by
aspiration. The dehulled soybeans are degermed by shaking the
dehulled soybeans on a screen of sufficiently small mesh size to
remove the small sized germ and retain the larger cotyledons of the
beans. The cotyledons are then flaked by passing the cotyledons
through a flaking roll. The flaked cotyledons are defatted by
extracting oil from the flakes by mechanically expelling the oil
from the flakes or by contacting the flakes with hexane or other
suitable lipophilic/hydrophobic solvent. The edible defatted flakes
are then milled, usually in an open-loop grinding system, by a
hammer mill, classifier mill, roller mill or impact pin mill first
into grits, and with additional grinding, to form a soy meal, or a
soy flour, with desired particle sizes. Screening is typically used
to size the product to uniform particle size ranges, and can be
accomplished with shaker screens or cylindrical centrifugal
screeners.
[0044] The defatted soy flakes, soy flour, soy grits, or soy meal
is/are then extracted with an aqueous alkaline solution, typically
a dilute aqueous sodium hydroxide solution having a pH of from 7.5
to 11.0, to extract protein soluble in an aqueous alkaline solution
from insolubles. The insolubles are soy cotyledon fiber which is
composed primarily of insoluble carbohydrates. An aqueous alkaline
extract containing the soluble protein is subsequently separated
from the insolubles, and the extract is then treated with an acid
to lower the pH of the extract to around the isoelectric point of
the soy protein, preferably to a pH of from 4.0 to 5.0, and most
preferably to a pH of from 4.4 to 4.6. The soy protein precipitates
from the acidified extract due to the protein's lack of solubility
in an aqueous solution at or near its isoelectric point. The
precipitated protein curd is then separated from the remaining
extract (whey). Water is added to the precipitated protein curd and
the pH of the curd is adjusted to between about 6.5 and about 7.5.
The separated protein may be washed with water to remove residual
soluble carbohydrates and ash from the protein material. The
separated protein is then dried using conventional drying means
such as spray drying or tunnel drying to form a soy protein
isolate.
[0045] Soy protein concentrate may be blended with the soy protein
isolate to substitute for a portion of the soy protein isolate as a
source of soy protein. Preferably, if a soy protein concentrate is
substituted for a portion of the soy protein isolate, the soy
protein concentrate is substituted for up to about 40% of the soy
protein isolate by weight, at most, and more preferably is
substituted for up to about 30% of the soy protein isolate by
weight.
[0046] Soy protein concentrates useful in the soy protein material
(A) are commercially available. For example, soy protein
concentrates Promine DSPC, Procon, Alpha 12 and Alpha 5800 are
available from Solae.RTM., LLC (St. Louis, Mo.). Soy protein
concentrates useful in the present invention may also be produced
from soybeans according to conventional processes in the soy
protein manufacturing industry. For example, defatted soy flakes,
soy flour, soy grits, or soy meal produced as described above may
be washed with aqueous ethanol (preferably about 60% to about 80%
aqueous ethanol) to remove soluble carbohydrates from the soy
protein and soy fiber. The soy protein and soy fiber containing
material is subsequently dried to produce the soy protein
concentrate. Alternatively, the defatted soy flakes, soy flour, soy
grits, or soy meal may be washed with an aqueous acidic wash having
a pH of from about 4.3 to about 4.8 to remove soluble carbohydrates
from the soy protein and soy fiber. After removing the soluble
carbohydrates, water is added and the pH is adjusted to between
about 6.5 and about 7.5. The soy protein and soy fiber containing
material is subsequently dried to produce the soy protein
concentrate.
[0047] The soy cotyledon fiber utilized in the soy protein material
(A) should effectively bind water when the mixture of soy protein
and soy cotyledon fiber are co-extruded. By binding water, the soy
cotyledon fiber induces a viscosity gradient across the extrudate
as the extrudate is extruded through a cooling die, thereby
promoting the formation of protein fibers. To effectively bind
water for the purposes of the process of the present invention, the
soy cotyledon fiber should have a water holding capacity of at
least 5.50 grams of water per gram of soy cotyledon fiber, and
preferably the soy cotyledon fiber has a water holding capacity of
at least about 6.0 grams of water per gram of soy cotyledon fiber.
It is also preferable that the soy cotyledon fiber has a water
holding capacity of at most about 8.0 grams of water per gram of
soy cotyledon fiber.
[0048] The soy cotyledon fiber is a complex carbohydrate and is
commercially available. For example, FIBRIM.RTM. 1260 and
FIBRIM.RTM. 2000 are soy cotyledon fiber materials that are
commercially available from Solae, LLC (St. Louis, Mo.) that work
well in the process of the present invention. Soy cotyledon fiber
useful in the process of the present invention may also be produced
according to conventional processes in the soy processing industry.
For example, defatted soy flakes, soy flour, soy grits, or soy meal
produced as described above may be extracted with an aqueous
alkaline solution as described above with respect to the production
of a soy protein isolate to separate the insoluble soy cotyledon
fiber from the aqueous alkaline soluble soy protein and
carbohydrates. The separated soy cotyledon fiber is then dried,
preferably by spray drying, to produce a soy cotyledon fiber
product. Soy cotyledon fiber is generally present in the soy
protein material (A) at from about 1% to about 20%, preferably at
from about 1.5% to about 20% and most preferably at from about 2%
to about 5% by weight on a moisture free basis.
[0049] A modest concentration of soy fiber is believed to be
effective in obstructing cross-linking of protein molecules, thus
preventing excessive gel strength from developing in the cooked
extrusion mass exiting the die. Unlike the protein, which also
absorbs moisture, soy fiber readily releases moisture upon release
of pressure at the die exit temperature.
[0050] Wheat gluten may be used as an ingredient to be mixed and
extruded with the soy protein and soy cotyledon fiber. Wheat gluten
provides an economical source of protein, and may be substituted
for a portion of the soy protein. The protein of wheat gluten has a
very low water holding capacity and is ineffective to form
significant protein fibers by itself upon extrusion. Wheat gluten
is a commercially available ingredient. A preferred commercially
available wheat gluten useful in the present invention is Gem of
the Star Gluten, available from Manildra Milling.
[0051] A starch material may also be used as an ingredient to be
mixed and extruded within the soy protein material (A). Starch may
be used to provide texture to the soy protein material (A) that is
produced by extrusion. The starch material used is preferably a
naturally occurring starch. The starch material may be isolated
from a variety of plants such as corn, wheat, potato, rice,
arrowroot, and cassava by well-known, conventional methods. Starch
materials useful in the process of the present invention include
the following commercially available starches: corn, wheat, potato,
rice, high amylose corn, waxy maize, arrowroot, and tapioca.
Preferably the starch material used is a corn starch or a wheat
starch, and most preferably is a commercially available dent corn
starch or native wheat starch. A preferred dent corn starch is
commercially available from A. E. Staley Mfg., Co. sold as Dent
Corn Starch, Type IV, Pearl.
[0052] Preferably, flavor ingredients are also mixed and extruded
with the soy protein material (A). The preferred flavor ingredients
are those that provide a meat-like flavor to the soy protein
material produced by extrusion. Preferred flavor ingredients
include beef flavor, chicken flavor, grill flavor, and malt
extract, all commercially available from flavor ingredient
manufacturers.
[0053] The restructured meat product may also include one or more
optional constituents such as an antioxidant, or an antimicrobial
agent. Antioxidant additives include BHA, BHT, TBHQ, vitamins A, C
and E and derivatives, and various plant extracts such as those
containing carotenoids, tocopherols or flavonoids having
antioxidant properties, may be included to increase the shelf-life
of the restructured meat product.
[0054] Antimicrobial agents include sodium lactate, potassium
lactate, sodium diacetate and potassium diacetate.
[0055] The antioxidants and the antimicrobial agents may have a
combined presence at levels of from about 0.01% to about 10%,
preferably from about 0.05% to about 5%, and more preferably from
about 0.1% to about 2%, by weight of the restructured meat
product.
[0056] A suitable extrusion process for the preparation of a low
moisture soy protein material (A) comprises introducing the
particular ingredients that comprise Component (A) into a mixing
tank (i.e., an ingredient blender) to combine the ingredients and
form a dry bleded soy protein material pre-mix. The dry blended soy
protein material pre-mix is then transferred to a hopper from which
the dry blended ingredients are introduced along with moisture into
a pre-conditioner to form a conditioned soy protein material
mixture. The conditioned soy protein material is then fed to an
extrusion apparatus (i.e., extruder) in which the soy protein
material mixture is heated under mechanical pressure generated by
the screws of the extruder to form a molten extrusion mass. The
molten extrusion mass exits the extruder through an extrusion
die.
[0057] In the pre-conditioner, the particulate solid ingredient mix
is preheated, contacted with moisture, and held under controlled
temperature and pressure conditions to allow the moisture to
penetrate and soften the individual particles. The preconditioning
step increases the bulk density of the particulate fibrous material
mixture and improves its flow characteristics. The preconditioner
contains one or more paddles to promote uniform mixing of the
protein and transfer of the protein mixture through the
preconditioner. The configuration and rotational speed of the
paddles vary widely, depending on the capacity of the
preconditioner, the extruder throughput and/or the desired
residence time of the fibrous material mixture in the
preconditioner or extruder barrel. Generally, the speed of the
paddles is from about 500 to about 1300 revolutions per minute
(rpm).
[0058] Typically, the soy protein material mixture is
pre-conditioned prior to introduction into the extrusion apparatus
by contacting the pre-mix with moisture (i.e., steam and/or water)
at a temperature of at least about 45.degree. C. (110.degree. F.).
It has been observed, however, that higher temperatures (i.e.,
temperatures above about 85.degree. C. (185.degree. F.)) in the
preconditioner may encourage starches to gelatinize, which in turn
may cause lumps to form, which may impede flow of the protein
mixture from the preconditioner to the extruder barrel.
[0059] Typically, the soy protein material pre-mix is conditioned
for a period of about 30 to about 60 seconds, depending on the
speed and the size of the conditioner. The soy protein material (A)
pre-mix is contacted with steam and/or water and heated in the
pre-conditioner at generally constant steam flow to achieve the
desired temperatures. The water and/or steam conditions (i.e.,
hydrates) the soy protein material mixture, increases its density,
and facilitates the flowability of the dried mix without
interference prior to introduction to the extruder barrel where the
proteins are texturized.
[0060] The conditioned pre-mix may contain from about 5% to about
30% (by weight) water. The conditioned pre-mix typically has a bulk
density of from about 0.25 g/cm.sup.3 to about 0.6 g/cm.sup.3.
Generally, as the bulk density of the pre-conditioned protein
mixture increases within this range, the protein mixture is easier
to process. This is presently believed to be due to such mixtures
occupying all or a majority of the space between the screws of the
extruder, thereby facilitating conveying the extrusion mass through
the barrel.
[0061] The conditioned pre-mix is generally introduced to the
extrusion apparatus at a rate of no more than about 10 kilograms
(kg)/min (no more than about 20 lbs/min). Generally, it has been
observed that the density of the extrudate decreases as the protein
rate of pre-mix to the extruder increases.
[0062] Extrusion devices have long been used in the manufacture of
a wide variety of edible products. One suitable extrusion device is
a double-barrel, twin screw extruder as described for example, in
U.S. Pat. No. 4,600,311. Examples of commercially available
double-barrel, twin screw extrusion apparatus include a CLEXTRAL
Model BC-72 extruder manufactured by Clextral, Inc. (Tampa, Fla.);
a WENGER Model TX-57 extruder manufactured by Wenger (Sabetha,
Kans.); and a WENGER Model TX-52 extruder manufactured by Wenger
(Sabetha, Kans.). Other conventional extruders suitable for use in
this invention are described, for example, in U.S. Pat. Nos.
4,763,569, 4,118,164, and 3,117,006, which are incorporated by
reference.
[0063] The screws of a twin screw extruder can rotate within the
barrel in the same or opposite directions. Rotation of the screws
in the same direction is referred to as single flow whereas
rotation of the screws in opposite directions is referred to as
double flow. The speed of the screw or screws of the extruder may
vary depending on the particular apparatus. However, the screw
speed is typically from about 250 to about 350 revolutions per
minute (rpm). Generally, as the screw speed increases, the density
of the extrudate decreases.
[0064] The extrusion apparatus generally comprises a plurality of
heating zones through which the protein mixture is conveyed under
mechanical pressure prior to exiting the extrusion apparatus
through an extrusion die. The temperature in each successive
heating zone generally exceeds the temperature of the previous
heating zone by between about 10.degree. C. and about 70.degree. C.
(between about 15.degree. F. and about 125.degree. F.). In one
embodiment, the conditioned pre-mix is transferred through four
heating zones within the extrusion apparatus, with the protein
mixture heated to a temperature of from about 100.degree. C. to
about 150.degree. C. (from about 212.degree. F. to about
302.degree. F.) such that the molten extrusion mass enters the
extrusion die at a temperature of from about 100.degree. C. to
about 150.degree. C. (from about 212.degree. F. to about
302.degree. F.).
[0065] The pressure within the extruder barrel is not narrowly
critical. Typically the extrusion mass is subjected to a pressure
of at least about 400 psig (about 28 bar) and generally the
pressure within the last two heating zones is from about 1000 psig
to about 3000 psig (from about 70 bar to about 210 bar). The barrel
pressure is dependent on numerous factors including, for example,
the extruder screw speed, feed rate of the mixture to the barrel,
feed rate of water to the barrel, and the viscosity of the molten
mass within the barrel.
[0066] Water is injected into the extruder barrel to hydrate the
soy protein material mixture and promote texturization of the
proteins. As an aid in forming the molten extrusion mass the water
may act as a plasticizing agent. Water may be introduced to the
extruder barrel via one or more injection jets in communication
with a heating zone. Typically, the mixture in the barrel contains
from about 15% to about 30% by weight water. The rate of
introduction of water to any of the heating zones is generally
controlled to promote production of an extrudate having desired
characteristics. It has been observed that as the rate of
introduction of water to the barrel decreases, the density of the
extrudate decreases. Typically, less than about 1 kg of water per
kg of protein is introduced to the barrel. Generally, from about
0.1 kg to about 1 kg of water per kg of protein are introduced to
the barrel.
[0067] The molten extrusion mass in the extrusion apparatus is
extruded through a die to produce an extrudate, which may then
dried in a dryer.
[0068] Extrusion conditions are generally such that the product
emerging from the extruder barrel typically has a moisture content
of from about 20% to about 45% (by weight) wet basis. The moisture
content is derived from water present in the mixture introduced to
the extruder, moisture added during preconditioning and/or any
water injected into the extruder barrel during processing.
[0069] Upon release of pressure, the molten extrusion mass exits
the extruder barrel through the die, superheated water present in
the mass flashes off as steam, causing simultaneous expansion
(i.e., puffing) of the material. The level of expansion of the
extrudate upon exiting of the mixture from the extruder in terms of
the ratio of the cross-sectional area of extrudate to the
cross-sectional area of die openings is generally less than about
15:1. Typically, the ratio of the cross-sectional area of extrudate
to the cross-sectional area of die openings is from about 2:1 to
about 11:1.
[0070] The extrudate is cut after exiting the die. Suitable
apparatus for cutting the extrudate include flexible knives
manufactured by Wenger (Sabetha, Kans.) and Clextral (Tampa,
Fla.).
[0071] The dryer, if one is used for the low moisture soy protein
material (A), to dry the extrudates generally comprises a plurality
of drying zones in which the air temperature may vary. Generally,
the temperature of the air within one or more of the zones will be
from about 135.degree. C. to about 185.degree. C. (from about
280.degree. F. to about 370.degree. F.). Typically, the extrudate
is present in the dryer for a time sufficient to provide an
extrudate having a desired moisture content. This desired moisture
content may vary widely depending on the intended application of
the extrudate and, typically, is from about 5% to about 35% by
weight, more preferably from about 6% to about 13% by weight.
Generally, the extrudate is dried for at least about 5 minutes and,
more generally, for at least about 10 minutes. Suitable dryers
include those manufactured by Wolverine Proctor & Schwartz
(Merrimac, Mass.), National Drying Machinery Co. (Philadelphia,
Pa.), Wenger (Sabetha, Kans.), Clextral (Tampa, Fla.), and Buehler
(Lake Bluff, Ill.).
[0072] The dried extrudates may further be comminuted to reduce the
average particle size of the extrudate. Suitable grinding apparatus
include hammer mills such as Mikro Hammer Mills manufactured by
Hosokawa Micron Ltd. (England).
[0073] Prior to combining the low moisture soy protein material (A)
with the comminuted meat (B), the soy protein material (A) having a
moisture content of from about 6% to about 13% by weight, if dried,
needs to be hydrated in water until the water is absorbed amd the
fibers are separated. If the soy protein material (A) is not dried
or not fully dried, its moisture content is higher, generally from
about 16% to about 30% by weight, on a moisture free basis. The
non-dried or not fully dried soy protein material (A) needs to be
hydrated prior to combining with the comminuted meat. However, when
a non-dried or not fully dried soy protein material (A) is used,
less water is necessary for hydrating the soy protein material (A)
and hydration of the soy protein material (A) occurs much
faster.
[0074] The ingredients employed to make a low moisture soy protein
material (A) of from about 5% to about 35% moisture by weight, are
also used to make a high moisture soy protein material (A) of from
about 50% to about 80% moisture by weight. The soy protein, soy
cotyledon fiber and other ingredients are dry blended and mixed in
a mixing tank to combine the ingredients and form a dry blended soy
protein material pre-mix. Alternatively, the soy protein, soy
cotyledon fiber and other ingredients may be mixed directly with
water to form a dough, without being dry blended first, preferably
in a preconditioner.
[0075] Preferably the dough mixture including the dry ingredients
and the water is conditioned for extrusion in the preconditioner by
heating the dough mixture. Preferably the dough mixture is heated
to a temperature of from about 50.degree. C. to about 80.degree.
C., more preferably from about 60.degree. C. to about 75.degree. C.
in the preconditioner.
[0076] The dough mixture is then fed into a cooking extruder to
heat, shear, and, ultimately, to plasticize the dough mixture. The
cooking extruder may be selected from commercially available
cooking extruders. Preferably the cooking extruder is a single
screw extruder, or more preferably a twin screw extruder, that
mechanically shears the dough with the screw elements. Commercially
available cooking extruders useful in the practice of the present
invention include Clextral extruders, commercially available from
Clextral, Inc., Tampa, Fla.; Wenger extruders, commercially
available from Wenger, Inc, Sabetha, Kans.; and Evolum extruders,
commercially available from Clextral, Inc. A particularly preferred
cooking extruder for the practice of the present invention is a
Clextral BC72 cooking extruder, available from Clextal, Inc.
Another preferred cooking extruder for the practice of the present
invention is an EV32 twin screw extruder from Evolum.
[0077] The dough mixture is subjected to shear and pressure by the
cooking extruder to plasticize the dough mixture. The screw
elements of the cooking extruder shear the dough mixture as well as
create pressure in the extruder by forcing the dough mixture
forward though the extruder and through the die. The screw motor
speed determines the amount of shear and pressure applied to the
dough mixture by the screw(s). Preferably the screw motor speed is
set to a speed of from about 200 rpm to about 500 rpm, and more
preferably from about 300 rpm to about 400 rpm, which moves the
dough mixture through the extruder at a rate of at least about 20
kilograms per hour, and more preferably at least about 40 kilograms
per hour. Preferably the cooking extruder generates an extruder
barrel exit pressure of from about 500 to about 1500 psig, and more
preferably an extruder barrel exit pressure of from about 600 to
about 1000 psig is generated.
[0078] The dough mixture is heated by the cooking extruder as it
passes through the extruder. Heating denatures the protein in the
dough mixture enabling the dough mixture to plasticize. The cooking
extruder includes a means for heating the dough mixture to
temperatures of from about 100.degree. C. to about 180.degree. C.
Preferably the means for heating the dough mixture in the cooking
extruder comprises extruder barrel jackets into which heating or
cooling media such as steam or water may be introduced to control
the temperature of the dough mixture passing through the extruder.
The cooking extruder may also include steam injection ports for
directly injecting steam into the dough mixture within the
extruder. The cooking extruder preferably includes multiple heating
zones that can be controlled to independent temperatures, where the
temperatures of the heating zones are preferably set to increase
the temperature of the dough mixture as the dough mixture proceeds
through the extruder. For example, the cooking extruder may be set
in a four temperature zone arrangement, where the first zone
(adjacent the extruder inlet port) is set to a temperature of from
about 80.degree. C. to about 100.degree. C., the second zone is set
to a temperature of from about 100.degree. C. to 135.degree. C.,
the third zone is set to a temperature of from 135.degree. C. to
about 150.degree. C., and the fourth zone (adjacent the extruder
exit port) is set to a temperature of from 150.degree. C. to
180.degree. C. The cooking extruder may be set in other temperature
zone arrangements, as desired. For example, the cooking extruder
may be set in a five temperature zone arrangement, where the first
zone is set to a temperature of about 25.degree. C., the second
zone is set to a temperature of about 50.degree. C., the third zone
is set to a temperature of about 95.degree. C., the fourth zone is
set to a temperature of about 130.degree. C., and the fifth zone is
set to a temperature of about 150.degree. C.
[0079] A long cooling die is attached to the cooking extruder so
the plasticized dough mixture flows from the extruder through the
cooling die upon exiting the extruder exit port. The dough mixture
forms a melted plasticized mass in the cooking extruder that flows
from the cooking extruder into the die. The cooling die cools and
shapes the hot dough mixture as it exits cooking extruder. Fiber
formation is induced in the plasticized dough mixture by the
cooling effect of the cooling die to form the fibrous meat analog
product. The fibrous material exits the cooling die through at
least one aperture in the die face, which may be a die plate
affixed to the die. The fibrous material extrudate is cut into
desired lengths with a cutting knife positioned adjacent the die
aperture(s) to cut the extrudate as it exits the die
aperture(s).
[0080] The cooling die is maintained at a temperature significantly
cooler than the temperature in the cooking extruder in the final
temperature zone of the extruder adjacent the die. The cooling die
includes means for maintaining the temperature at a temperature
significantly cooler than the exit temperature of the cooking
extruder. Preferably the cooling die includes inlet and outlet
ports for circulating media for maintaining the die temperature.
Most preferably, constant temperature water is circulated through
the cooling die as the circulating media for maintaining the
desired die temperature. Preferably, the cooling die is maintained
at a temperature of from about 80.degree. C. to about 110.degree.
C., more preferably the cooling die is maintained at a temperature
of from about 85.degree. C. to about 105.degree. C., and most
preferably the cooling die is maintained at a temperature of from
about 90.degree. C. to about 1 00.degree. C.
[0081] The cooling die is preferably a long cooling die to ensure
that the plasticized dough material is cooled sufficiently in
transit through the die to induce proper fiber formation. In a
preferred embodiment, the die is at least about 200 millimeters
long, and more preferably is at least about 500 millimeters long.
Long cooling dies useful in the practice of the process of the
present invention are commercially available, for example from
Clextral, Inc., E. I. duPont de Nemours and Company, and Kobe
Steel, Ltd.
[0082] The width and height dimensions of the cooling die
aperture(s) are selected and set prior to extrusion of the dough
mixture to provide the fibrous material extrudate with the desired
dimensions. The width of the die aperture(s) may be set so that the
extrudate resembles from a cubic chunk of meat to a steak filet,
where widening the width of the die aperture(s) decreases the cubic
chunk-like nature of the extrudate and increases the filet-like
nature of the extrudate. Preferably the width of the cooling die
aperture(s) is/are set to a width of from about 10 millimeters to
about 40 millimeters, and most preferably from about 25 millimeters
to about 30 millimeters.
[0083] The height dimension of the cooling die aperture(s) may be
set to provide the desired thickness of the extrudate. The height
of the aperture(s) may be set to provide a very thin extrudate or a
thick extrudate. A novel feature of the present invention is that
the height of the aperture(s) may be set to at least about 12
millimeters, and the resulting extrudate is fibrous across the
entirety of any cross-section of the extrudate. Prior to the
present invention, high moisture extrudates having a thickness of
at least about 12 millimeters (as determined by the height of the
cooling die aperture(s)) gelled in the center of the extrudate, and
were not fibrous across the entirety of a transverse cross-section
of the extrudate. Preferably, the height of the cooling die
aperture(s) may be set to from about 1 millimeter to about 30
millimeters, and more preferably from about 12 millimeters to about
25 millimeters, and most preferably from about 15 millimeters to 20
about millimeters.
[0084] Due to the high moisture content of the dough mixture,
little dissipation of energy and expansion occurs in the soy
protein material (A) extrudate as it exits the die aperture(s). As
a result, the soy protein material (A) is relatively dense compared
to a low moisture extrudate, since few air vacuoles are introduced
into the soy protein material (A) extrudate by expansion of the
extrudate upon extrusion from the die.
[0085] One example of a soy protein material (A) containing soy
protein and soy cotyledon fiber for use in the restructured meat
product described herein is FXP MO339, available from The Solae Co.
(St. Louis, Mo.). FXP MO339 is an extruded dry textured soy protein
product with suitable fibrosity and texture, and a suitable amount
of soy protein. Specifically, FXP MO339 comprises 56.2% by weight
soy protein, 1.9% by weight of fiber, 24.7% by weight of wheat
gluten, 9.6% by weight of starch, 1.9% L-cysteine, 0.5% dicalcium
phosphate and 5.2% by weight moisture. Another example of a soy
protein material (A) containing soy protein and soy cotyledon fiber
for use in the restructured meat product described herein is VETEX
1000, available from Stentorian Industries Company Limited
(Taiwan).
(B) The Comminuted Meat
[0086] It is well known in the art to produce mechanically deboned
or separated raw meats using high-pressure machinery that separates
bone from animal tissue, by first crushing bone and adhering animal
tissue and then forcing the animal tissue, and not the bone,
through a sieve or similar screening device. The animal tissue in
the present invention comprises muscle tissue, organ tissue,
connective tissue and skin. The process forms an untexturized,
paste-like blend of soft animal tissue with a batter-like
consistency and is commonly referred to as mechanically deboned
meat or MDM. This past-like blend has a particle size of from about
0.25 to about 10 millimeters, preferably up to about 5 millimeters
and most preferably up to about 3 millimeters.
[0087] Although the animal tissue, also known as raw meat, is
preferably provided in at least substantially frozen form so as to
avoid microbial spoilage prior to processing, once the meat is
ground, it is not necessary to freeze it to provide cuttability
into individual strips or pieces. Unlike meat meal, raw meat has a
natural high moisture content of above about 50% and the protein is
not denatured.
[0088] The raw meat used in the present invention may be any edible
meat suitable for human consumption. The meat may be non-rendered,
non-dried, raw meat, raw meat products, raw meat by-products, and
mixtures thereof. The meat or meat products are comminuted and
generally supplied daily in a completely frozen or at least
substantially frozen condition so as to avoid microbial spoilage.
Generally the temperature of the comminuted meat is below about
40.degree. C., preferably below about 10.degree. C. more preferably
is from about -4.degree. C. to about 6.degree. C. and most
preferably from about -2.degree. C. to about 2.degree. C. While
refrigerated or chilled meat may be used, it is generally
impractical to store large quantities of unfrozen meat for extended
periods of time at a plant site. The frozen products provide a
longer lay time than do the refrigerated or chilled products. Beef,
pork, chicken, and turkey are preferred meat products intended for
human consumption. Specific examples of animal food products which
may be used in the process of the present invention include pork
shoulder, beef shoulder, beef flank, turkey thigh, beef liver, ox
heart, pigs heart, pork heads, pork skirt, beef mechanically
deboned meat, pork mechanically deboned meat and chicken
mechanically deboned meat. Mechanically deboned beef, mechanically
deboned pork and mechanically deboned chicken are preferred.
[0089] In lieu of frozen comminuted meat, the comminuted meat may
be freshly prepared for the preparation of the restructured meat
product, as long as the freshly prepared comminuted meat meets the
temperature conditions of not more than about 40.degree. C.
[0090] The moisture content of the raw frozen or unfrozen meat is
generally at least about 50% by weight, and most often from about
60% by weight to about 75% by weight, based upon the weight of the
raw meat. In embodiments of the invention, the fat content of the
raw frozen or unfrozen meat may be at least 2% by weight, generally
from about 15% by weight to about 30% by weight. In other
embodiments of the invention, meat products having a fat content of
less than about 10% by weight and defatted meat products may be
used.
[0091] The frozen or chilled meat may be stored at a temperature of
about -18.degree. C. to about 0.degree. C. It is generally supplied
in 20 kilogram blocks. Upon use, the blocks are permitted to thaw
up to about 10.degree. C., that is, to defrost, but in a tempered
environment. Thus, the outer layer of the blocks, for example up to
a depth of about 1/4', may be defrosted or thawed but still at a
temperature of about 0.degree. C., while the remaining inner
portion of the blocks, while still frozen, are continuing to thaw
and thus keeping the outer portion at below about 10.degree. C.
[0092] The term "meat" is understood to apply not only to the flesh
of cattle, swine, sheep and goats, but also horses, whales and
other mammals, poultry and fish. The term "meat by-products" is
intended to refer to those non-rendered parts of the carcass of
slaughtered animals including but not restricted to mammals,
poultry and the like and including such constituents as are
embraced by the term "meat by-products" in the Definitions of Feed
Ingredients published by the Association of American Feed Control
Officials, Incorporated. The terms "meat," and "meat by-products,"
are understood to apply to all of those animal, poultry and marine
products defined by said association.
[0093] Examples of meat which may be used are mammalian meat such
as beef, veal, pork, and horsemeat, and the fleshy tissue from
bison, cows, deer, elk, and the like. Poultry meat which may be
used includes chicken, turkey, duck, or goose and the like.
Embodiments of the invention may also utilize the flesh of fish and
shell fish. Meat includes striated muscle which is skeletal or that
which is found, for example, in the tongue, diaphragm, heart, or
esophagus, with or without accompanying overlying fat and portions
of the skin, sinew, nerve and blood vessels which normally
accompany the meat flesh. Examples of meat by-products are organs
and tissues such as lungs, spleens, kidneys, brain, liver, blood,
bone, partially defatted low-temperature fatty tissues, stomachs,
intestines free of their contents, and the like. Poultry
by-products include non rendered clean parts of carcasses of
slaughtered poultry such as heads, feet, and viscera, free from
fecal content and foreign matter.
Water
[0094] Employed as water (C), is tap water, distilled water or
deionized water. The purpose of the water is to hydrate the
ingredients of soy protein, soy cotyledon fiber, wheat gluten and
starch contained within the soy protein material (A) such that
these ingredients absorb the water and that the soy cotyledon
fibers contained within the soy protein material (A) become
separated. Typically, the ratio of soy protein material (A) on a
moisture free basis to the hydration water is from about 1:0.5 to
about 10, preferably from about 1:1 to about 7 and most preferably
from about 1:2 to about 5. More water for hydration is employed
when a low moisture soy protein material (A) is utilized in the
restructured meat product. Less water for hydration is employed
when a high moisture soy protein material (A) is utilized in the
restructured meat product. The temperature of the water may range
from 0.degree. C. up to about 30.degree. C. Hydration time may be
from about 30 minutes up to several hours, depending upon the
moisture content of the soy protein material (A), the amount of
water utilized and the temperature of the water.
[0095] The restructured meat product is prepared by a process
comprising the steps of; hydrating
[0096] (A) a soy protein material; and adding
[0097] (B) a comminuted meat, wherein the temperature of the
comminuted meat is below about 40.degree. C.; and
[0098] mixing (A) and (B) to produce a homogeneous, fibrous and
texturized meat product having a moisture content of at least about
50%.
[0099] As discussed above, the soy protein material (A) may also
contain the previously described soy protein flour, soy protein
concentrate, soy protein isolate, starch, gluten free starch, rice
flour, wheat flour, wheat gluten, and soy cotyledon fiber.
[0100] Prior to hydration of the at least one of a soy protein
isolate, soy protein concentrate and a soy protein flour, the
weight ratio of soy protein material (A) on a moisture free basis
to the comminuted meat (B) on a moisture free basis is generally
from about 1:0.25 to about 50, preferably from about 1:1 to about
40 and most preferably from about 1:2 to about 20. The hydrated soy
protein material (A) and the comminuted meat (B) are combined in a
mixing device and mixed to give a homogeneous restructured meat
product.
[0101] The product and process of this invention are completed by
combining Components (A), (B) and (C) as per the disclosed ratios
of (A):(B) and (A):(C). The soy protein material (A) is first
hydrated with water (C). When hydration is complete, the comminuted
meat (B) is added and the contents are mixed until a homogeneous
mass of a restructured meat product is obtained. At this point, the
homogeneous restructured meat product may be formed into strips,
steaks, cutlets, patties, ground or generally cube-shaped for
kabobs, either by hand or by machine. The homogenous restructured
meat product may also be stuffed into permeable or impermeable
casings.
[0102] The restructured meat product may also further comprise at
least one of a gelling protein; an animal fat; sodium chloride;
sodium tripolyphosphate; a colorant; a curing agent; a flavorant
comprising beef flavor, pork flavor, or chicken flavor; or mixtures
of each with the other.
[0103] The gelling protein is selected from the group consisting of
a soy protein flour, a soy protein isolate and a soy protein
concentrate. These are the same soy proteins that are utilized in
the preparation of the soy protein material (A). The soy protein
isolate useful as a gelling protein is a high viscosity and/or
medium/high gelling isolated soy protein. The gelling protein
provides a gelling matrix within the restructured meat product.
Suitable sources of high viscosity and/or medium/high gelling
isolated soy protein (i.e., unhydrolyzed) for use as the gelling
protein includes SUPRO.RTM. 620, SUPRO.RTM. 500E, SUPRO.RTM. 630,
and SUPRO.RTM. EX33 available from The Solae Company (St. Louis,
Mo.); PROFAM 981 available from Archer Daniels Midland (Decatur,
Ill.); and PROLISSE soy protein isolate available from Cargill Soy
Protein Solutions, Inc. (Minneapolis, Minn.). The gelling protein
is present at from about 2% to about 10% by weight, on a moisture
free basis.
[0104] Animal fats are triglycerides with a highly saturated
character. Typically animal fats are solids or waxy in nature at
room temperature. The purpose of animal fats is to function as a
gelling agent in the restructured meat product in the uncooked
state and as a flavoring aid in the cooked state. The animal fats
are generally present at from about 1% to about 30% by weight, on a
moisture free basis and preferably at from about 2% to about 10% by
weight, on a moisture free basis.
[0105] The sodium chloride and sodium phosphates are salts that are
mixed into the restructured meat product to extract/solubilize
myfibriller protein in the comminuted meat. These salts, used
singly or in combination, in addition to being flavor enhancers,
also help to bind the comminuted meat within the restructured meat
product. These salts are generally present at from about 0.1% to
about 4.0% by weight, on a moisture free basis and at from about
0.1% to about 1.0% by weight, on a moisture free basis,
respectively. Preferably these salts are present at from about 0.5%
to about 2.0% by weight, on a moisture free basis and at from about
0.2% to about 0.5% by weight, on a moisture free basis,
respectively.
[0106] Colorants provide eye appeal to the restructured meat
product. Colorants provide a red color to the restructured meat
product in the uncooked state, as well as a brown color in the
cooked state. Examples of colorants are edible colorings such as
caramel color, paprika, cinnamon and FD & C (Food, Drug and
Cosmetic) Red No. 3 (A.K.A. Food Red 14 and Erythrosine BS), FD
& C Yellow No. 5 (A.K.A. Food Yellow 4 and Tartrazine), FD
& C Yellow No. 6 (A.K.A. Food Yellow 3 and Sunset Yellow FCF),
FD & C Green No. 3 (A.K.A. Food Green 3 and Fast Green FCF), FD
& C Blue No. 2 (A.K.A. Food Blue 1 and Indigo Carmine), FD
& C Blue No. 1 (A.K.A. Food Blue 2 and Brilliant Blue FCF), and
FD & C Violet No. 1 (A.K.A. Food Violet 2 and Violet B6), as
well as sodium nitrite, the latter of which also functions as a
curing agent. Preferred is caramel, which can come in various color
ranges.
[0107] By caramel it is meant an amorphous, dark brown,
deliquescent powder or a thick liquid having a bitter taste, a
burnt sugar odor and a specific gravity of approximately 1.35. It
is soluble in water and dilute alcohol. Caramel is prepared by the
careful, controlled heat treatment of carbohydrate or saccharide
materials such as dextrose, invert sugar, lactose, malt syrup,
molasses, sucrose, starch hydrolysates and fractions thereof. Other
materials which may be employed during heat treatment to assist
caramelization include acids (e.g. acetic acid, citric acid,
phosphoric acid, sulfuric acid and sulfurous acid); and salts (e.g.
ammonium, sodium or potassium carbonates, bicarbonates, dibasic
phosphates or mono-basic phosphates).
[0108] In one process of manufacturing caramel described in U.S.
Pat. No. 3,733,405, a liquid sugar, either cane or corn, is pumped
into a reactor vessel along with one or a combination of the
reagents authorized by the U.S. Food and Drug Administration and
the mixture is heated. Temperatures ranging from about 250.degree.
C. to about 500.degree. C. are maintained and the product is held
between about 15 and about 250 pounds per square inch pressure
(psi) while the polymerization takes place. When processing is
completed the product is discharged to a flash cooler which drops
the temperature to about 150.degree. F. It is then filtered, cooled
and pumped to storage.
[0109] It is preferred that the colorant be present in the
restructured meat product in the range of between about 0.1% to
about 2%, preferably in the range of from about 0.2% to about 1%
and most preferably in the range of from about 0.25% to about 0.75%
by weight of the restructured meat product when a liquid is
used.
[0110] Even though the restructured meat product is derived from a
meat source, it is advantageous to add a flavorant to the
restructured meat product to enhance its aroma and taste. The
flavorants comprise beef flavor, pork flavor or chicken flavor. A
beef flavor is preferred. The flavorants are generally present at
from about 0.1% to about 5.0% by weight, on a moisture free basis
and preferably at from about 0.5% to about 3.0% by weight, on a
moisture free basis.
[0111] When the restructured meat product further comprises at
least one of a gelling protein; an animal fat; sodium chloride;
sodium tripolyphosphate; a colorant; a curing agent; a flavorant
comprising beef flavor, pork flavor, or chicken flavor; or mixtures
of each with the other the product and process are completed in a
procedure similar to the product and process of only the (A), (B)
and (C) components. The soy protein material (A) is first hydrated
with water (C). When hydration is complete, a colorant is added.
The comminuted meat (B) and water (C) is added and the contents are
mixed until a homogeneous mass is obtained. This is followed by the
addition of an animal fat, a flavorant, sodium chloride, and sodium
tripolyphosphate, and the gelling protein. The homogeneous
restructured meat product may be formed into strips, steaks,
cutlets, patties, ground or generally cube-shaped for kabobs,
either by hand or by machine. The homogenous restructured meat
product may also be stuffed into permeable or impermeable
casings.
[0112] The restructured meat product, either with or without a
gelling protein, may be dried, e.g. as a jerky, or partially dried,
e.g. as a salami. Preferably the restructured meat product has a
moisture content of at least about 50% before drying. If dried or
partially dried, the restructured meat product has a moisture
content of from about 15 to about 45%. An example of a dried meat
product is a jerky product.
[0113] The restructured meat product once formed is either cooked,
partially cooked for finishing at a later time or frozen either in
an uncooked state, partially cooked state or cooked state. Cooking
includes frying either as sauteing or as deep frying or baking.
[0114] Jerky products of the present invention may be produced in a
variety of shapes such as bone shaped, chop shaped, round,
triangular, chicken bone shaped, square, rectangular, strip shaped,
and the like. The different shapes may be produced simultaneously
by using variously shaped molds or cavities upon a single die roll.
Furthermore, the pieces may be embossed or impressed with a logo or
design contained in the cavities or molds of the die roll.
[0115] The jerky products of the present invention exhibit shelf
stability under unrefrigerated conditions of at least about six
months, preferably at least about twelve months in proper moisture
proof packaging, such as foil-lined bags.
[0116] The restructured meat product (before drying, partially
dried, dried, cooked or uncooked) may be packaged as is. Further
processing of the restructured meat product (before drying,
partially dried, dried, cooked or uncooked) may be shock-frozen,
for example in a freeze tunnel, and subsequent automatic portion
packaging in containers of a suitable type, for example, plastic
pouches or the like. Said type of further processing and packaging
is suitable if the product is intended for fast-food outlets or for
food service applications, where the product is usually deep-fried
or baked before consumption.
[0117] Alternatively, after the formation of the restructured meat
product (before drying, partially dried, dried, cooked or
uncooked), it is also possible to spray the surface of the product
with carbohydrate solutions or related substances in order to
obtain uniform browning during deep frying or baking. Subsequently,
the product can now be shock frozen and sold portion packed (i.e.
in pouches). The restructured meat product can also be baked or
processed in a convection oven by the consumer, instead of deep
frying. Further, the restructured meat product also can be breaded
prior to or after cooking, or coated with another type of
coating.
[0118] The restructured meat product either cooked or uncooked may
also be packed and sealed in cans in a conventional manner and
employing conventional sealing procedures. Normally, the cans at
this stage are maintained at a temperature of between 65.degree. C.
and 77.degree. C. and are carried to a retort or cooking stage as
quickly as possible to prevent there being any risk of
microbiological spoilage during the time between canning and
sterilization during the retort or cooking stage.
[0119] The invention having been generally described above, may be
better understood by reference to the examples described below. The
following examples represent specific but non-limiting embodiments
of the present invention.
EXAMPLE 1
[0120] Added to a mixing vessel are 3625 grams of tap water at
about 10.degree. C. and while stirring 1160 grams of a dried, low
moisture (about 7% to about 12%) soy protein material (A)
comprising a soy protein isolate, soy cotyledon fiber, wheat gluten
and starch is added until the soy protein material (A) is hydrated
and the fibers are separated. Added to the mixer are 5216 grams of
a comminuted meat of mechanically deboned chicken having a moisture
content of at least about 50%. The mechanically deboned chicken is
at a temperature of from about 2 to about 4.degree. C. The contents
are mixed until a homogeneous restructured meat product is
obtained. The restructured meat product is transferred to a
Hollymatic forming machine where the restructured meat product is
formed into steaks or cutlets which are then frozen.
EXAMPLE 2
[0121] The procedure of Example 1 is repeated, except that 1500
grams of a non-dried low moisture (about 28-about 35%) soy protein
material (A) comprising a soy protein isolate, soy cotyledon fiber,
wheat gluten and starch is hydrated with 3175 grams water. The
restructured meat product is transferred to a stuffing machine
where the restructured meat product is stuffed into impermeable
casings, which are then frozen. Stuffing machines are available
from various commercial manufacturers including, but not limited
to, HITEC Food Equipment, Inc., located in Elk Grove Village, Ill.,
Townsend Engineering Co., located in Des Moines, Iowa, Robert
Reiser & Co., Inc., located in Canton, Mass., and Handtmann,
Inc., located in Buffalo Grove, Ill.
EXAMPLE 3
[0122] Added to a first mixing vessel are 2127 grams of tap water
at about 12.degree. C. and while stirring 1000 grams of a dried,
low moisture (about 7% to about 12%) soy protein material (A)
comprising a soy protein isolate, soy cotyledon fiber, wheat gluten
and starch is added until the soy protein material (A) is hydrated
and the fibers are separated. Caramel coloring, 43 grams, is then
added to the hydrated soy protein material (A). At about 2.degree.
C., 4500 grams of a comminuted meat of mechanically deboned chicken
having a moisture content of about 50% is added. Then added are 100
grams sodium chloride and 30 grams of sodium trypolyphosphate to
extract/solubilize myofibriller protein in the comminuted meat for
binding. As mixing is continued, 500 grams beef fat and 100 grams
beef flavor are added and mixing is continued. In a second mixing
vessel, a gelling protein of 600 grams of Supro.RTM. 620 is
hydrated in 1000 grams water and is added to the first mixing
vessel. The contents are mixed until a homogeneous restructured
meat product is obtained. The restructured meat product is
transferred to a Hollymatic forming machine where the restructured
meat product is formed into patties, which are then frozen.
EXAMPLE 4
[0123] Added to a mixing vessel are 3000 grams of tap water at
about 10.degree. C. and while stirring 1500 grams of a soy protein
material (A) of Supro.RTM. 620 is added until the soy protein
material (A) is hydrated. Added to the mixer are 5000 grams of a
comminuted meat of mechanically deboned chicken having a moisture
content of about 50%. The mechanically deboned chicken is at a
temperature of from about 2 to about 4.degree. C. The contents are
mixed until a homogeneous restructured meat product is obtained.
The restructured meat product is transferred to a Hollymatic
forming machine where the restructured meat product is formed into
steaks or cutlets which are then frozen.
EXAMPLE 5
[0124] The procedure of Example 4 is repeated except that the soy
protein material (A) comprises a soy protein isolate, rice flour,
and a gluten free starch.
EXAMPLE 6
[0125] The procedure of Example 4 is repeated except that the soy
protein material (A) comprises a soy protein isolate and rice
flour.
EXAMPLE 7
[0126] The procedure of Example 4 is repeated except that the soy
protein material (A) comprises a soy protein isolate and a gluten
free starch.
EXAMPLE 8
[0127] The procedure of Example 4 is repeated except that the soy
protein material (A) comprises a soy protein isolate, wheat flour
and starch.
EXAMPLE 9
[0128] The procedure of Example 4 is repeated except that the soy
protein material (A) comprises a soy protein isolate and soy
cotyledon fiber.
EXAMPLE 10
[0129] The procedure of Example 4 is repeated except that the soy
protein material (A) comprises a soy protein isolate, soy cotyledon
fiber, and wheat gluten.
[0130] While the invention has been explained in relation to its
preferred embodiments, it is to be understood that various
modifications thereof will become apparent to those skilled in the
art upon reading the description. Therefore, it is to be understood
that the invention disclosed herein is intended to cover such
modifications as fall within the scope of the appended claims.
* * * * *