Meat and seafood analogs from plant proteins with twin screw extrusion

The plant protein trend has continued to grow worldwide. In this relatively new market, there are two distinct styles of plant protein products that have emerged: meat and seafood analogs that closely replicate the mouthfeel and texture of animal products, and other foods including snacks, breakfast cereals, and beverages, that utilise plant protein ingredients to provide enhanced nutrition.

We will focus on the technology for converting plant proteins into meat and seafood analogs in this article. Although it is important to note that many consumers of meat analogs are not vegetarian or vegan; they are either meat consumers or flexitarian eaters who are seeking plant-based foods to improve their health or because of their awareness of the environmental impacts of the animal farming industries.

PROCESSING PLANT PROTEIN INTO MEATAND SEAFOOD ANALOGS

Clextral has two processes available to convert plant proteins into meat analogs. One for dry meat analogs, which is calledTexturized Vegetable Protein (TVP). The other one is for wet meat analogs, also called High MoistureExtrusion (HME). The rest of the article will mostly cover the HMEstandpoint.

Twin screw extrusion is one of the most widely accepted processes for protein fibration as the technology is able to produce fibrous plant protein products with sensory characteristics comparable to animal meat muscle. It is high moisture (50-70%) and high temperature (around 140°C) process, also known as HME. Typically, the formulation starts with a plant protein-rich base. Depending on the desired functionality and appearance of the final product, the plant protein base may be in different forms: isolate or concentrate.

There are two stages to the protein fibration process with twin screw extrusion. The first is the thermomechanical processing of the plant protein inside the extruder barrel. In their native state, plant proteins have a complex structure. Inside the extruder, they are subjected to mechanical energy exerted by the twin intermeshing screw elements and thermal energy added through the barrel. Due to the efficient mixing ability of the twin screw extruder, the process requires a very short residence time for the proteins to “unfold” (typically less than one minute). This natural consequence of the process prepares the plant protein for the second stage of fibration. This is completed in the fibrating die. As the extrudate travels through the long, thermoregulated die, the protein melt is cooled and shaped, the proteins crosslink to form covalent and non-covalent bonds and new networks of fibers in the protein matrix are formed.

Forming the plant proteins into the right fibrous textures to mimic different animal muscles is an area that has been subject to years of continuous research and development. Plant proteins contain the building blocks to create products with realistic meat mouthfeel and texture, and the extrusion process enables this transition. Fibration is a key component to successful products. The strength of the fibration is determined and adjusted by manipulating the ingredients, recipes and equipment configuration as well as the operating conditions.

PLANT PROTEIN SOURCES

A variety of plant proteins are used for meat and seafood analogs. These include soybeans, pulses (chickpeas, peas, lentils, fava beans, common beans, and lupine) as well as wheat gluten. Choosing the right plant protein is key to a successful product. Most products can be certified vegetarian and vegan. Gluten-free analogs are made from soybeans or pulses. Fibrated meat and seafood analogs are cholesterol-free, low in fat, high in protein and fiber content, and rich in nutrients.

EXTRUDED MEAT AND SEAFOOD ANALOGS – A GOOD CHOICE

In food safety terms, extrusion is an advantageous process that inherently ensures strict microbiological control of the product. The process also ensures excellent water retention and product stability for high functionality when analogs are incorporated in prepared foods. Finally, extruded meats and seafood analogs are produced at a very competitive cost.

In summary, plant protein fibration with twin screw extrusion is a proven and effective technology to transform protein-rich plants into healthy and well-balanced meat replacements to supply the growing consumer demand. As consumers balance environmentally sustainable food choices with nutrition and health outcomes, innovations in plant-based food manufacturing are becoming increasingly important.

Clextral – https://www.clextral.com/ T-Comm – www.tcom-sa.co.za