WO2012160397A1 - Thermally treated products from processed cephalopods and method of production thereof description - Google Patents

Abstract

Food products of thermal processing of high nutritional value and low fat, styled as "sausages" (cold-cuts, sausages) as well as other formulations (burgers, meatballs, cocktail sausages) produced from processed cephalopods (squids, octopuses, cuttlefish) by the use of transglutaminase enzyme, natural dietary fiber, vegetable oils (olive oil, sesame oil), and natural flavorings (spices, vegetables) and method of production thereof.

Description

THERMALLY TREATED PRODUCTS FROM PROCESSED

CEPHALOPODS AND METHOD OF PRODUCTION THEREOF

DESCRIPTION Current invention presents a new series of food products of high nutritional value and low fat content in various commercial formulations (ham, sausages, burgers etc) manufactured by processed cephalopods (squids, octopuses, cuttlefish) after the implementation of thermal treatment by the use of transglutaminase enzyme, natural dietary fiber, vegetable oils, spices, vegetables and the production methodology thereof.

BACKGROUND OF THE INVENTION

The thermal processed meat products (such as sausages, bacon, Mortadella, ham, etc.) are a class of food products included in the meat preparations, according to European regulation EK/853/2004. Extremely popular to consumers, these products are characterized by a firm and appealing structure, pleasant aroma and a savoury taste. Unfortunately, due to the increased animal fat content, the consumption of processed meat products has been associated with human obesity and obesity- related diseases. Apart from the increased amount of calories, most processed meat products contain high concentrations of saturated fatty acids, which have been attributed to promote negative effects on the cardiovascular system. Nowadays, which more than 1.5 billion adults and 43 million of children under 5 years suffer from obesity, nutritionists often recommend consumers to avoid the consumption of such products, while alternatively encouraging them to increase the consumption of fish and seafood.

With the intention to follow the modern current trends towards a more healthy diet, meat processing industries have reduced the animal fat in their products and in some cases replaced it with oils of vegetable origin. However, 100% removal of animal fat from the meat can not be succeed, since the fat is an indispensable part of the meat structure and thus it can not be removed with any recognized technological processing (e.g. lean pork contains approximately 13% fat).

REFERENCES

1. De Moreno J.E.A., Moreno V.J., Ricci L., Roldan M., Gerpe M., 1998. Variations in the biochemical composition of the squid Illex argentinus from the South Atlantic Ocean. Comparative Biochemistry and Physiology Part B 119: 631-637. 2. Ruxton C. H. S., Reed S.C.,. Simpson M. J. A., Millington K. J., 2004. The health benefits of omega-3 polyunsaturated fatty acids: a review of the evidence. J Hum Nutr Dietet, 17: 449^159

3. a) Namiki M., 1995. The chemistry and physiological functions of sesame. Food Reviews International, 11 : 281 - 329. b) Stark A. H., Madar Z., 2002. Olive Oil as a Functional Food: Epidemiology and Nutritional Approaches. Nutrition Reviews, 60: 170-176. 4. M. Elleuch, Bedigian D., Roiseux O., Besbes S., Blecker C, Attia H., 201 1. Dietary fiber and fiber-rich by-products of food processing: Characterisation, technological functionality and commercial applications: A review. Food Chemistry 124: 411-421.

5. a) Ozogul Y., Duysak O., Ozogul F., Serhat A., Ozkiitttk. A.S., Tureli C, 2008. Seasonal effects in the nutritional quality of the body structural tissue of cephalo- pods. Food Chemistry 108: 847-852. b) Hurtado J.L., Montero P., Borderias J., Solas M.T., 2001. High-pressure/temperature treatment effect on the characteristics of octopus {Octopus vulgaris) arm muscle. Eur Food Res Technol 213:22-29.

6. a) Mizuta S. , Tanaka T., Yoshinaka R., 2003. Comparison of collagen types of arm and mantle muscles of the common octopus (Octopus vulgaris). Food Chemistry 81 : 527-532. b) Sikorski Z.E. & Kolodziejska I., 1986. The Composition and Properties of Squid Meat. Food Chemistry 20: 213-224.

7. M. Griffin, R. Casadio., Bergamini C. M., 2002. Transglutaminases : Nature's biological glues (review article) Biochem. J. 368, 377-396.

8. Georgakis S.A., Vareltzis KP, Amvrosiadis J.A., 2000. Food Technology of animal origin. Modern Education Publications, Thessaloniki, Greece. GENERAL DISCRIPTION OF THE INVENTION

Present invention aims to introduce a novel series of products which use cephalopods and simulate meat sausages and other thermally processed meat products, by excluding the use of meat or other animal products. Therefore the new products are considered healthy, given that they contain a low calorie and saturated fat content. Since they consist 0% of meat, they are suitable for vegetarians, fasting diets, and other special dietary practices of non-meat nutrition (for example Islamic or Kosher diet). For the present invention, a systematic enquiry for an alternative raw material that retains favourable nutritional aspects and is not included in the class of animal products was performed. We resulted with the selection of the seafood class of cephalopods (squid, octopus, cuttlefish), which are naturally low in fat 1-2% and additionally contain minimum levels of saturated fatty acids. In addition, cephalopods combine multiple beneficial nutritional characteristics, since they are considered a good natural source of high quality protein, niacin, zinc, riboflavin, vitamin B12, iron, phosphorus, copper and selenium (ref. 1).

Second and most important stage of the invention is the development of a new method for the production of a coherent product form, presenting a perfect stability, high consistency and durability during thermal processing, being also able to simulate the physicochemical and sensory properties of meat paste. The difficulty in this invention step was to successfully use the cephalopods' tissue, which differs significantly in its physical and chemical composition than meat. In particular, the water content of cephalopod tissue can reach 84% and can be removed very easily by the implementation of the thermal treatment, shrinking by approximately 50% (ref. 1, 5). In contrast, the pork tissue holds 65% moisture and can sustain a large amount of water content in regular pasteurization temperatures up to 70 ° C, owing to its particular protein composition.

Another key difference between the cephalopod and the meat composition is the quantity and quality of the collagen, which is the key feature for the preparation of an acceptable structure and a successful sausage paste. The pork contains 12 to 18% collagen, which is significantly higher than the 1-3% cephalopod percentage. Besides that, the cephalopods' collagen tends to denaturate at low temperatures, usually lower than 50° C (ref. 6). Apart from the collagen structure and thermal behaviour, the total protein concentration of cephalopods is significantly lower than meat, with an approximate average of 4-5%. Cephalopod proteins behave also differently during thermal processing. It was therefore difficult to use cephalopods and successfully produce thermally processed products, such as "sausage" type products and other cold-cut products, having into consideration to completely exclude the addition of meat, fish and other animal derived products such as the milk casein, egg proteins, proteins and collagen from meat or fish.

In order to overcome the structural and physicochemical difficulties, functional ingredients such as the enzyme transglutaminase and natural fibers have been selected. The enzyme transglutaminase creates new bonds between certain amino acids of proteins (mainly between glutamine-lysine) and can significantly strengthen the structure of the products (ref. 7). The natural fiber derives from dried fruit products, vegetables, grains and other plant species (eg orange, peas, wheat, bamboo, etc.). This functional ingredient has the ability to entrap a high percentage of water and other liquid substances, whereas it can also increase the viscosity of the products' paste (ref . 4).

The presented invention provides a new method of effective utilization of cephalopods by combining all the chemical properties of the selected raw materials, based on the proper choice of the concentration, with the aim of creating a synergistic structural and sensory effect, along with the selection of appropriate technological features. STAGES OF PRODUCTION PROCESS

1. Quality inspection and washing of cephalopods. Cephalopods tend to develop a slimy texture on the surface during thawing, which prevents the enzyme of transglutaminase to act successfully. If slimy texture occurs after thawing, cephalopods must be thoroughly washed before further processing.

2. Fine cutting of cephalopods at temperatures <0 ° C.

3. Mixing of finely cut cephalopods with salt and polyphosphates at concentrations from 0.2 to 0.5% for at least 15 minutes, till the proteins are extracted from the interior of the tissues. Polyphosphates have the ability to break the cross-bridges formed by the protein cluster of aktomyosinis resulting in better decoupling of the protein molecules of the muscle filaments, better calcium binding, thus increasing the lessening of the muscle fibrils. This stage favours the "activation" of proteins, thus improving both an improved water- holding capacity and a successful fat emulsification (Ref. 8). The raw material must have been mixed along with the salt and phosphates till a protein layer covers the surface of particles of the cephalopods, forming a gelatinous elastic protein layer on which the enzyme will act.

4. Addition of the enzyme transglutaminase in 0,1 - lO U / g (units enzyme activity / g cephalopods) and continuous mixing for at least 10 minutes. This stage is especially critical for the formation of a coherent product "paste". For this reason the following parameters must be accurately controlled: the weighing of the appropriate enzyme concentration for enzyme activity of 0,1 - 10 U / g cephalopods, the temperature of the raw material (0 - 5 ° C) and the direct contact of the enzyme with the amino acids of proteins. The enzyme is added directly and uniformly throughout the mass of finely cut cephalopods without any prior dilution in water.

5. Addition of the vegetable oil (sesame oil, olive oil etc) and the Omega 3 fatty acids at a ratio of 2 to 8%.

6. Addition of spices, vegetables (onion, leek, parsley, dill, etc.) and vegetable proteins (pea protein, soy, wheat, etc.) and natural colour extracts to provide a desired colour.

7. Addition of Gluconate D-Lactone in concentrations from 0.1 to 1% in order to lower the pH value of the product below 6.5. The Gluconate D-Lactone known as GDL, is a gluconic acid anhydride and derives from glucose. In contact with water, GDL is converted to gluconic acid. This reaction rapidly decreases the value of pH and improves the colour of the products. GDL use is of a great importance for the shelf life of preserved products such as "sausages" (Ref. 13).

8. Addition of the natural fibers at proportions from 0.2 to 5% and afterwards stirring the mixture for at least 5 minutes.

9. Addition of starch at a percentage of 1 to 5% at temperatures> 0 ° C.

10. Mixing until complete homogenization of the mixture. The final temperature of the paste should be <8 ° C.

11. Storage of the paste in cool temperature for at least 6 to 8 hours. This stage is particularly important for the enzyme action and affects the consistency of the paste during thermal treatment.

12. Product forming by sausage casing or other format, depending on the desired type of the final product (e.g. cold cut sausages, bologna type, "wurst" sausages, cocktail, burgers, meatballs, etc.), with complete exclusion of the use of natural animal intestines.

13. Heat treatment up to center the temperature reaches 71 ⁰ C (1 ■ 3 hours depending on the shape and size of the product).

14. Cooling in a cold chamber at a temperature <5 ° C.

15. Packaging and preserving in temperature <5 ° C. The stability of the products is significantly influenced by:

-The concentration and action time of the enzyme

-The mixing stage of the raw material prior the enzyme addition

-The concentration of fiber, the timing of the fiber addition and the further mixing -The combination of other materials added (vegetables - vegetable protein - spices - starch)

-The storage conditions of the mixture before thermal processing (temperature - time) and

-The concentration and the timing point of the GDL addition

The food products that are produced from cephalopods according to this invention demonstrate an excellent stability during thermal treatment, present a high consistency with no water or other liquid ingredient leak and tend to keep the favourable sensory characteristics of the materials added (spices, oils, vegetables). The final products simulate the form and the desirable textural characteristics of the customary meat products.

Moreover, the products of the present invention sustain the following advantageous nutrition aspects:

1. 100% without the use of meat or fish, meat or fish fat, or other products from meat, milk, eggs, or fish such as collagen, protein, fat, skin, etc.

2. Significantly lower amount of animal fat by using cephalopods instead of meat, a class of seafood particularly low in fat (1%) and saturated fatty acids (<500mg/kg).

3. Significantly lower in calories than the customary sausage meat products.

4. Enriched with Omega-3 polyunsaturated fatty acids that contribute to the recruitment of cardiovascular disease and other multiple beneficial effects (ref. 2).

5. Enriched with vegetable oils with high nutritional value such as sesame and olive oils, which are rich in monounsaturated fatty acids, vitamins, phenolic compounds and other substances with antioxidant, anti-hypertensive and other valuable nutritional properties (ref. 3).

6. Enriched with natural fiber, known to act beneficially in the correct function of the gastrointestinal system.

Claims

CLAIMS 1. Food product of thermal treatment (at 70-75 ° C for 1-3 hours) that is characterized by comprising:

a) cephalopods (squids, octopuses, cuttlefish), treated in the presence of the enzyme transglutaminase at concentrations 0,1 - lO U / g (units enzyme activity / g cephalopods)

b) vegetable oil of high nutritional quality (olive oil, sesame oil) and Omega 3 fatty acids, at total concentration of 2 to 8%

c) spices, vegetables (onion, leek, parsley, dill)

d) vegetable protein such as pea, soybeans and wheat protein

e) natural fiber in concentrations of 0,2 - 5%,

f) starch in concentrations of 1 to 5%.

2. Food product of thermal treatment as described in claim 1, formed in sausage casing, formulated as in "ham" or "cold cut", or "Mortadella", or other type "sausages", without the use of auxiliary materials of animal origin (e.g. natural casing of animal origin).

3. Food product of thermal treatment as described in claim 1, formed into products such as "burger", "meatballs", or "cocktail".

4. Food product of thermal treatment as described in claims 1-3, packaged, stored and shipped at temperatures <5 ° C.

5. Method of production with thermal treatment as described in claims 1-4, characterized by the sequence of steps:

a) Thorough washing and fine cut of cephalopods at temperatures <0 ° C.

b) Mixing the finely cut material with the addition of table salt and polyphosphates at concentrations from 0.2 to 0.5% for at least 15 minutes so as to extract the proteins outside from the tissues. The raw material must be thoroughly mixed along with the salt and phosphates until the proteins cover the surface of cephalopods forming a gelatinous elastic protein layer, allowing the transglutaminase enzyme to act.

c) Direct addition of the enzyme transglutaminase, in activity units of 0, 1 - 10 U / g cephalopods and continuous mixing for at least 10 minutes at 0 - 5 ° C.

d) Addition of the vegetable oil (sesame oil, olive oil etc) and Omega 3 fatty acids at a rate of 2 to 8%.

e) Addition of spices, vegetables (onion, leek, parsley, dill, etc.) vegetable proteins (pea protein, soy, wheat, etc.) and natural colour extracts to provide the desired colour.

f) Addition of Gluconate D-Lactone 0.1 to 1% for the pH reduction below 6.5. g) Addition of the fiber at percentage from 0.2 to 5% and mixture for at least 5 minutes.

h) Addition the starch at a rate of 1 to 5% at temperatures >0°C. i) Mixing until complete homogenization of the material and retaining the final temperature of the paste <8 ° C.

k) Storage of the paste for at least 6 to 8 hours. 1) Product forming, depending on the desired format of the final product (e.g. cold cut type, bologna, sausages in casings, cocktail, burgers, meatballs, etc.), with complete exclusion of the use of animal casing or other material. m) Thermal treatment till the temperature center reaches 71 ° C (1 - 3 hours depending on the shape and size of the product).

n) Cooling and storing in a cold chamber at a temperature <5 ° C.

6. Using food products of thermal processing, as described in claims 1-5 in healthy, vegetable, special and low-calorie diets, due to the high nutritional aspects of the cephalopods, the vegetable oils, the Omega-3 fats and the natural fibers, with the complete exclusion of meat, meat derived products or animal fat.