Protein product and method for forming same

A method of converting soybean meal into a fibrous meat-simulating product, comprising the steps of:

• providing a soybean meal having a protein content of at least about 50% and a fat content of no more than a minor amount;
• moistening the meal to a moisture content of at least about 20% by weight;
• controlling the pH of the meal to a value between approximately 5 and 8;
• mechanically working the moistened soybean meal while simultaneously heating it to a temperature of at least about 212.degree. F. and also applying an elevated pressure thereto to change the material to one capable of forming a fibrous structure upon release of the pressure;
• and then extruding the material through restricted orifice means into an environment of a pressure substantially lower than said elevated pressure to form an expanded material having a fibrous structure.

A method of forming a porous fibrous food product from a predominantly protein containing vegetable material wherein said material has a fat content of no more than a minor amount comprising the steps of:

• providing said protein-containing vegetable material having a protein content of at least about that of solvent-extracted soybean meal;
• adjusting the moisture content of said vegetable material to a content of at least about 25% by weight;
• mechanically working the moistened protein-containing vegetable material under temperatures in excess of 212.degree.F. and elevated pressures;
• forcing the heated, pressurized, mechanically worked material through first restricted orifice means, into an elongated zone of confinement while maintaining the material in confinement under elevated temperatures and pressures;
• advancing the material through said elongated zone of confinement for a period of time sufficient to cause the material to have a fibrous nature as it is finally discharged;
• and then discharging the material by extruding it through second restricted orifice means into an environment of a pressure substantially lower than said elevated pressures, causing expansion of the product with moisture evaporation and the formation of meat-simulating fiber structure.

A method of forming a fibrous food product from a predominantly protein containing vegetable material, wherein said material has a fat content of no more than a minor amount, comprising the steps of:

• providing said protein-containing vegetable material having a protein content of at least about that of solvent-extracted soybean meal;
• adjusting the moisture content of said vegetable material to a content of at least about 25% by weight;
• mechanically working the moistened protein-containing vegetable material under temperatures substantially above 212.degree.F. and elevated pressures;
• forcing the heated, pressurized, mechanically worked material through first restricted orifice means into an elongated zone of confinement while maintaining the material in confinement under elevated temperatures and pressures;
• advancing the material through said elongated zone of confinement for a period of time sufficient to cause the material to have a fibrous nature as it is finally discharged;
• and then discharging the material by extruding it thorugh second restricted orifice means into an environment of a pressure substantially lower than said elevated pressures, causing expansion of the product with moisture evaporation and resulting in the formation of meat-simulating fiber structure.

The method of restructuring a solvent-extracted soybean meal to form a food product comprising the steps of mixing the soybean meal with water, the added water being in the range of 20-30% of the resulting mixture;

• maintaining the pH of the mixture in a range which is slightly above or slightly below the neutral point of soybean meal;
• introducing the mixture into a confined chamber and increasing the pressure on the mixture into the range of 300-600 psi and increasing the temperature of the mixture into the range of 212.degree.-310.degree.F.;
• mechanically working the mixture in the confined chamber until the mixture, upon release of the pressure, is capable of becoming a fibrous structure;
• forcing the mechanically worked, heated mixture under pressure through a restricted orifice upon discharge from which the pressure is released whereby the mixture is restructured into a puffed product of reduced density having a meat-like texture.

The method of restructuring a solvent-extracted soybean meal to form a food product comprising the steps of adding water to the solvent-extracted soybean meal, the added water being in the range of 20-30% of the resulting mixture;

• maintaining the pH of the mixture in a range which is slightly above or slightly below the neutral point of the soybean meal;
• introducing the mixture into a confined chamber and increasing the pressure on the mixture into the range of 300-600 psi and increasing the temperature of the mixture into a range substantially above 212.degree.F.;
• mechanically working the mixture in the confined chamber until the mixture, upon release of the pressure, is capable of becoming a fibrous structure;
• forcing the mechanically worked, heated mixture under pressure through a pair of spaced restricted orifices upon discharge from the second of which orifices the pressure is suddenly released, whereby the mixture is restructured into a puffed product of reduced density having a meat-like texture.

A method of producing a porous expanded food product having meat simulating textural characteristics, from a protein-containing vegetable material comprising, the steps of:

• providing a protein-containing vegetable material of the group consisting of soybean meal, cotton seed meal, and peanut meal, having a fat content of no more than a minor amount and a protein content between about 30% and 75% by weight;
• moistening such material to a moisture content between about 20% and 40% by weight;
• controlling the pH of the meal to a value between about 5 and 12;
• mechanically working the moistened protein-containing vegetable material while simultaneously applying elevated pressures thereto and also heating it to elevated temperatures above 212.degree. F. for a time period sufficient to convert said meal into a flowable substance;
• and then extruding the heated, pressurized, mechanically worked material through restricted orifice means into an environment of a substantially lower pressure, causing expansion of the material and formation of an expanded network structure therein having textural, chewing and mouth feel characteristics similar to those of meat.

A method of treating a protein-containing vegetable material to form a porous palatable and nutritious food product that bears resemblance to meat in appearance, physical structure and texture, and chewing characteristics, comprising the steps of:

• providing a protein-containing vegetable material of the group consisting of soybean meal, peanut meal, and cotton seed meal, having a fat content of no more than a minor amount and a protein content between about 30% and 75% by weight;
• moistening such material to a moisture content between about 20% and 40% by weight;
• controlling the pH of the material to a value between 5 and 12;
• mechanically working the moistened protein-containing vegetable material while simultaneously heating it to elevated temperatures above 212.degree. F. and also applying elevated pressures for a time period sufficient to convert said meal into a flowable substance;
• then forcing the heated, pressurized, mechanically worked material through first restricted orifice means, maintaining the material under elevated temperatures and pressures as it emerges from said first restricted orifice means;
• and then extruding the material through second restricted orifice means into an environment of a pressure substantially lower than said elevated pressures causing expansion of the product with moisture evaporation and the formation of meat simulating structure having textural, chewing and mouth feel characteristics similar to those of meat.

A method of converting a protein containing material into a palatable and nutritious product that bears resemblance to meat in appearance, physical structure and texture, and chewing characteristics, comprising the steps of:

• providing a material from the group consisting of soybean meal, peanut meal, and cotton sead meal, having a protein content of between about 30% and 75% by weight, and a fat content of no more than a minor amount;
• moistening the meal to a moisture content of at least about 20% by weight but less than about 40% by weight, and also adding to the meal a pH altering edible electrolyte while controlling the pH of the meal to a value between 5 and 12;
• mechanically working the moistened soybean meal while simultaneously heating it to a temperature of at least above 212.degree. F. for a period of time sufficient to convert said meal into a flowable substance while also applying an elevated pressure thereto;
• and then extruding the mechanically worked, heated, and pressurized material through restricted orifice means into an environment of a pressure substantially lower than said elevated pressure to expand the material into a porous structure having textural, chewing and mouth feel characteristics similar to those of meat.

A method of converting soybean meal into a palatable and nutritious meat simulating product comprising the steps of:

• providing soybean meal having about 2% or less by weight of oil or fat, a protein content between about 30% and 75% by weight, and an added carbohydrate content less than about 5% by weight;
• controlling the pH of the meal to a value between 6 and 9;
• adding moisture to the meal to form a mixture having a moisture content of about 20%-40% by weight of the mixture;
• mechanically working the mixture while simultaneously applying elevated pressures and also heating it to elevated temperatures within the range of about 270.degree.-310.degree. F. for a time sufficient to convert it to a flowable substance;
• and then immediately extruding said flowable substance through restricted orifice means into an environment of substantially lower pressure, causing expansion of the substance and formation of a lace network formation in the product having textural, chewing and mouth feel characteristics similar to those of meat.