System and method for producing an extruded protein product

A method for producing an extruded protein product having a thickness and fibers that are oriented in a generally parallel orientation throughout the thickness of the extruded protein product, the method comprising:

• producing a stream comprising a proteinaceous composition having a protein component that can form oriented fibers, the proteinaceous composition having a protein content of about 15% to about 90% based on dry weight of the proteinaceous composition, the stream having a moisture content of at least 27%;
• directing the stream through an elongated channel of a die to form oriented fibers from the protein component in a generally parallel orientation to form the extruded protein product, the die including an inner portion and an outer portion forming the elongated channel, and a support supporting the inner portion within the outer portion at one or more points along a length of the die, the elongated channel having a length, an outer diameter, an inner surface, and a cooling apparatus configured to cool the inner surface, the elongated channel having a gap thickness between the inner surface and the outer diameter, and having a generally constant transverse cross-section that is a continuous loop along substantially the entire length of the die, the die having a ratio of the length of the elongated channel to a gap thickness of the elongated channel between about 30:1 and about 1000:1, the outer diameter being between about 200 mm and about 750 mm, and the gap thickness being between 5 mm and about 30 mm, and
• cooling the stream at a rate sufficient to provide the oriented fibers throughout the thickness of the extruded protein product,
• such that the extruded protein product exits the die having a transverse cross-section that is a continuous loop.