Production of vegetarian meat (cheap meat substitute)

Healthy food products are a product with nutritional, organoleptic, and taste properties identical to conventional meat products, such as kebabs, frankfurters, sausages (including smoked ones), schnitzels, hamburgers, etc. products, but consisting of a mixture of vegetable proteins and amino acids in composition close to animal protein, in the form of fats, vegetable oil is used, strengthened with dietary fiber and bound into a single structure, taste, aromatic (smell) and textural properties slightly different from the usual similar meat products.

The binding ingredients of proteins, fats and dietary fiber into a single structure of meat substitutes in a trivial technological scheme are egg white or melange, vegetable starch and water. During the process of technological heat treatment, the ingredients are sintered into the finished product

The Water-Oil Matrix Macro Encapsulation method offers the production of high-quality meat substitutes using binding proteins, fats and dietary fiber into a single structure of meat substitutes hydrocolloid (biopolymers) ingredients and water in accordance with the standards and certificates (HACCP, GMP, BRC) of food production. The absence of egg whites and starches makes the product low-allergenic and low-carbohydrate, which allows expanding the product market for people suffering from allergies and diabetes. Also, the absence of egg whites and starches makes it possible to create products with a low cost of approximately $550-850 per ton of products (not packaged).

High quality meat substitutes

-Wonderful taste and organoleptic qualities

- No carbohydrates in the composition (reduces excess calories and)

- High calcium content (prevent osteoporosis)

- High in Dietary Fiber (reduces excess calories)

- Low Sodium (prevents cardiovascular disease)

- The content of biopolymers helps reduce high stomach acidity, as well as regulate cholesterol and blood sugar levels.

- Promotes improved metabolism and non-formation of blood clots (xanthine and guaroa diet).

- absence of allergens, minimal number of E numbers.

- Possibility of changing the ratio between proteins and fats while maintaining the same qualities of taste and healthy nutrition

- the possibility of replacing vegetable proteins and fats partially or completely with proteins and fats of animal origin maintaining the same taste qualities.

Production process:

The production process is quite trivial, and can be placed in any modern meat processing plant. The production process includes the following main stages:

1. Mix all ingredients with water and stir until dough forms

2. Forming the dough into a product using a molding machine.

3. Conveyor formation of the product

4. 8-12 hour “ripening” of the product in the refrigerator (2-80C)

5. Heat treatment (requirement of the sanitary station)

6. Cooling and blast freezing of finished products

7. Packaging of finished products

Store frozen for six months.

Before use, heat in a microwave oven or any other home cooking device.

The cost of equipment is directly proportional to the planned production volume and process automation.

A manual production site with a capacity of 5 tons of finished product per day would cost approximately $70,000.

A fully automatic production site with a capacity of 25 tons of finished product per day will cost approximately 500,000 US dollars.

As an option, the production line of a conventional meat processing plant can be used.

Today, a walk between the grocery shelves at the supermarket will lead you to a refrigerator stocked with dozens of different types of veggie burgers, chicken-free chicken wings, dairy-free cheese and ice cream, and soy bacon.

In fact, a review of a US food database found that 180 new meat substitutes entered the country's market in 2016-2017. Frozen meat substitutes reached $467 million in sales in 2015, according to market research firm SymphonyIRI Group.

But convincing them that meat substitutes with familiar names such as sausages and schnitzel burgers can be just as tasty is an equally important challenge, he adds: “People need to trust that it will be convenient and tasty. If they don't see that these foods can be enjoyed on the same basis as meat, they won't make the transition." The meat substitute industry appears to have reached a similar conclusion. One of the ways in which companies applied their innovations was to improve the texture of veggie burgers, and another was to imitate the density and chewiness of the real thing with fake meat. Companies like Garden Protein International rely primarily on soy protein and wheat gluten, as well as grain flour, which is used to recreate the density of meat. “Meat-free products used to be either too rubbery or too gelatinous,” Weber says. “Today they are much closer in texture to the meat they are intended to replace.” The growing success of meat-free products is not a loss for the traditional meat processing industry. Some industry publications and websites rate the quality of meat substitutes as "impressive." The authors lament that meat producers do not see new business opportunities in the area of substitutes. It is obvious that some brave companies producing meat products will decide to enter the market of meat analogues.