Mastering plant-based meat analogues: innovative extrusion with alternative proteins

Food innovators are searching for alternative protein sources to create meat analogues for a sustainable and healthy diet. While in the past mainly soy was used, food producers are looking for other materials that can be sourced locally. Furthermore, the quality of meat analogues has often been related to a gummy texture and a not so attractive soy taste. Within this study, different alternative sources were determined in terms of their performance to create a high-quality meat analogue product. Commonly, meat analogues are made by High Moisture Extrusion (HME) or Low Moisture Extrusion (LME) or a combination of both, to create a meat-like texture. In this study, the samples were made by HME.

Introduction:

Finding alternative and sustainable protein sources for the development of healthy and tasty meat analogues is key to food innovators, who want to develop products without using soy. This study focuses on the performance of alternative protein sources such as peas, oats, hemp, chick peas and faba beans for the creation of high-quality burger patties. Commonly, meat analogues are produced through High Moisture Extrusion (HME), and this research explores the potential of these alternative protein sources to address challenges related to texture and taste in meat analogues.

Experimental:

Materials & Instrumentation: The study employed a lab-scale extrusion process utilising a twin-screw extruder and a modular cooling die for the development of burger patties. The proteins under investigation included those from peas, oats, hemp, chick peas and faba beans and yellow peas, with a binding system from Dutch Proteins & Services. The HME process involved key steps such as shredding of HME stripes, dough mixing, and forming burger patties. Additionally, the water absorption properties of the raw materials were analysed using the Farinograph TS.

Material	Supplier
Oats	hemp naVitalo
Faba beans; yellow peas; red lentils; chick peas	Müller`s Mühle
Binding system	Dutch Proteins & Services

Table 1: Raw materials used

Material	Supplier
Twin screw extruder TwinLab-F 20/40 + modular cooling die	Brabender, a brand of Anton Paar
P600 mixer	Brabender, a brand of Anton Paar
Farinograph TS	Brabender, a brand of Anton Paar

Table 2: Equipment used

Extrusion Process: The High Moisture Extrusion (HME) and the following steps to final burger patties, unfolds through sequential steps:

1. High moisture extrusion (HME)
2. Shredding of HME stripes
3. Dough mixing
4. Precision formation of burger patties

The Farinograph was used to analyse the water absorption properties of the raw materials, offering crucial insights into their functional characteristics.

Results & Discussion:

In the pursuit of understanding the structural capabilities of various proteins for applications in the food and feed industry, our investigation revealed intriguing outcomes. Faba bean, pea, hemp, and oat proteins demonstrated a distinctive ability to create robust and fibrous structures. This structural characteristic holds immense promise for applications requiring stability, texture, and enhanced nutritional profiles.

By contrast, red lentil proteins did not exhibit the same propensity to form fibrous networks. Despite this limitation, our study unveiled an unexpected twist — materials lacking a structured framework demonstrated commendable properties when integrated into mixtures. This unforeseen advantage suggests that even proteins unable to create fibrous structures possess valuable attributes that contribute positively to the overall composition when blended with other materials.

The results highlight the multifaceted nature of protein functionality within food and feed formulations. The ability of certain proteins to create fibrous structures offers exciting possibilities for designing products with improved texture and structural integrity. Simultaneously, the positive attributes observed in proteins that do not form structures provide opportunities for novel applications in composite formulations. These findings provide valuable insights to the ongoing discourse on protein-based innovations in the food and feed industry, paving the way for further exploration and optimisation of diverse protein sources for enhanced product development.

The Farinograph has proven to be a useful tool in assessing the water absorption properties of flours and doughs in the context of food processing. Through precise measurements of dough consistency and behaviour, the Farinograph allows for a comprehensive understanding of how different flours interact with water, impacting hydration and overall dough quality. This information is invaluable for optimising recipes, ensuring consistent product quality, and achieving desired textural attributes in the final food products.

Summary:

In conclusion, the study establishes the viability of alternative protein sources — specifically pea, oat, and faba bean — for the creation of high-quality burger patties. The nuanced performance of proteins in High Moisture Meat Analogue Extrusion (HME) emerges as a critical factor influencing both texture and taste in the final products. The study underscores the significance of protein mixtures, emphasising the superiority of combinations such as faba bean and yellow pea or oat and pea, particularly in optimising taste. The lab-scale extrusion process, facilitated by a twinscrew extruder and a modular cooling die, emerges as a potent tool for research and development, offering insights into raw material ratios and the impact of additional factors, including fibres. The comprehensive analysis of raw materials using the Farinograph contributes to a nuanced understanding of water absorption and mixing properties, aiding in the estimation of the quality of pulse flours within alternative protein sources.

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