Influence of process parameters on formation of fibrous materials from dense calcium caseinate dispersions and fat

Plant-based seafood alternatives: Current insights on the nutrition, protein-flavour interactions, and the processing of these foods

Fish are an important food source; however, the sustainability of current seafood supplies is a major concern for key stakeholders. The development of plant-based seafood alternatives may be suitable products to alleviate some of the pressures on aquatic ecosystems and help support environmental sustainability. However, the wide-spread adoption of these products weighs heavily on the ingredients used in the formulations which should not only satisfy nutritional and sustainability targets but must also meet consumer approval and functionality. In this review, we highlight recent advances in our understanding of the nutritional quality and sensory challenges in particular flavour (which includes taste and aroma), that have so far proven difficult to overcome in the development of plant-based seafood alternatives. Protein interactions that contribute to flavour development in plant-based seafood alternatives and the factors that impact these interactions are also discussed. We also review the recent advances in the innovative technologies used to improve the texture of products in this emerging food category. Finally, we highlight key areas for targeted research to advance the development of this growing segment of food products.

Construction and Properties of Oil-Loaded Soybean Protein Isolate/Polysaccharide-Based Meat Analog Fibers

Rationally designing the fibrous structure of artificial meat is a challenge in enriching the organoleptic quality of meat analogs. High-quality meat analog fibers have been obtained by wet-spinning technique in our previous study, whereas introducing oil droplets will further achieve their fine design from the insight of microstructure. Herein, in this current work, oil was introduced to the soybean protein isolate/polysaccharide-based meat analog fibers by regulating the oil droplets' size and content, which, importantly, controlled the spinning solution characterization as well as structure-related properties of the meat analog fiber. Results showed that the oil dispersed in the matrix as small droplets with regular shapes, which grew in size as the oil content increased. Considering the effect of oil droplets' size and content on the spinnability of the spinning solution, the mechanical stirring treatment was chosen as the suitable treatment method. Importantly, increasing the oil content has the potential to enhance the juiciness of meat analog fibers through improvements in water-holding capacity and alterations in water mobility. Overall, the successful preparation of oil-loaded plant-based fiber not only mimicked animal muscle fiber more realistically but also provided a general platform for adding fat-soluble nutrients and flavor substances.

Hypotheses concerning structuring of extruded meat analogs

In this paper, we review the physicochemical phenomena occurring during the structuring processes in the manufacturing of plant-based meat analogs via high-moisture-extrusion (HME). After the initial discussion on the input materials, we discuss the hypotheses behind the physics of the functional tasks that can be defined for HME. For these hypotheses, we have taken a broader view than only the scientific literature on plant-based meat analogs but incorporated also literature from soft matter physics and patent literature. Many of these hypotheses remain to be proven. Hence, we hope that this overview will inspire researchers to fill the still-open knowledge gaps concerning the multiscale structure of meat analogs.

Effect of Wheat Gluten and Peanut Protein Ratio on the Moisture Distribution and Textural Quality of High-Moisture Extruded Meat Analogs from an Extruder Response Perspective

Wheat gluten (WG) and peanut protein powder (PPP) mixtures were extruded at high moisture to investigate the potential application of this mixture in meat analog production. Multiple factors, including the water absorption index (WAI), water solubility index (WSI), rheological properties of the mixed raw materials, die pressure, torque and specific mechanical energy (SME) during high moisture extrusion, texture properties, color, water distribution, and water activity of extrudates were analyzed to determine the relationships among the raw material characteristics, extruder response parameters, and extrudate quality. At a WG ratio of 50%, the extrudates have the lowest hardness (2.76 kg), the highest springiness (0.95), and a fibrous degree of up to 1.75. The addition of WG caused a significant rightward shift in the relaxation time of hydrogen protons in the extrudates, representing increased water mobility and water activity. A ratio of 50:50 gave the smallest total color difference (ΔE) (about 18.12). When the added amount of WG was 50% or less, it improved the lightness and reduced the ΔE compared to >50% WG. Therefore, clarifying the relationship among raw material characteristics, extruder response parameters, and extruded product quality is helpful in the systematic understanding and regulation of the fiber textural process of binary protein meat analogs.

Recent Advances in the Processing and Manufacturing of Plant-Based Meat

Plant protein technology is a core area of biotechnology to ease the problem of human protein demand. Plant-based meat based on plant protein technology is a growing concern by global consumers in alleviating environmental pollution, cutting down resources consumption, and improving animal welfare. Plant-based meat simulates the texture, taste, and appearance of animal meat by using protein, lipid, carbohydrate, and other plant nutrients as the main substances. This review summarizes the main components of plant-based meat, processing technology, standard formula, market competition, and formula and texture of future research directions. According to the existing methods of plant-based meat fiber forming, the development process and characteristics of four production processes and equipment of plant-based meat spinning, extrusion, shearing, and 3D printing are emphatically expounded. The processing principles and methods of different processing technologies in plant-based meat production are summarized. The production process and equipment of plant-based meat will pay more attention to the joint production of various processes to improve the defects of plant-based meat production process.

Fibrous Structures from Starch and Gluten

Starch is added to meat analogues for binding and water holding. In this study, we investigate whether starch can have an additional role as a structuring agent. Therefore, different types of starch were combined with wheat gluten at various amounts and sheared in a High Temperature Shear Cell to determine how starch influences the structuring behavior of gluten–starch blends. The starches were chosen based on their diverse amylose contents, leading to different technological properties. Remarkable differences were found between the starches investigated. The addition of Amioca starch (containing 1% amylose) had a strong negative influence on the ability of gluten to form fibers. Maize starch (25% amylose) and Hylon VII (68% amylose) formed fibrous materials up to high starch additions. The pre-gelatinizing of maize starch further increased the ability of gluten–starch mixtures to form fibrous structures. The influence of the different types of starch on the hardness, deformability, and stiffness of the sheared samples was also assessed, revealing a spectrum of achievable properties through the addition of starch. Most remarkable was the formation of a material with anisotropy in Young’s modules. This anisotropy is also found in chicken meat, but not in protein-based fibrous materials. Furthermore, it was observed that the pre-gelatinization of starch facilitated fiber formation. A similar effect of pre-gelatinizing the starch was found when using faba bean meal with added wheat gluten, where fibrous structures could even be formed in a recipe that previously failed to produce such structures without pre-treatment.

High-Moisture Shear Processes: Molecular Changes of Wheat Gluten and Potential Plant-Based Proteins for Its Replacement

Nowadays, a growing offering of plant-based meat alternatives is available in the food market. Technologically, these products are produced through high-moisture shear technology. Process settings and material composition have a significant impact on the physicochemical characteristics of the final products. Throughout the process, the unfolded protein chains may be reduced, or associate in larger structures, creating rearrangement and cross-linking during the cooling stage. Generally, soy and pea proteins are the most used ingredients in plant-based meat analogues. Nevertheless, these proteins have shown poorer results with respect to the typical fibrousness and juiciness found in real meat. To address this limitation, wheat gluten is often incorporated into the formulations. This literature review highlights the key role of wheat gluten in creating products with higher anisotropy. The generation of new disulfide bonds after the addition of wheat gluten is critical to achieve the sought-after fibrous texture, whereas its incompatibility with the other protein phase present in the system is critical for the structuring process. However, allergenicity problems related to wheat gluten require alternatives, hence an evaluation of underutilized plant-based proteins has been carried out to identify those that potentially can imitate wheat gluten behavior during high-moisture shear processing.

Reducing Sodium Content in Cheeses While Increasing Salty Taste and Fat Perception Using Aroma

Excess salt (NaCl) and fat intake are major causes of chronic diseases, but reducing such components without affecting acceptability is a major challenge. Here, we set out to examine whether added aroma in lower salt cheese can enhance saltiness and fat perception. Low-salt cheese samples were grated through a homogenizer, and then aroma solution, sardine aroma (salt-associated), butter aroma (fat-associated) and a mix of sardine and butter aromas were added. The results confirmed that grating changes cheese texture, leading to induced taste perception. In addition, a significant saltiness enhancement was induced by sardine aroma and to a lesser extent by butter aroma, while significant fat perception enhancement was only induced by blended aroma. These findings show that aroma addition can be a strategy to compensate for sodium reduction in commercial cheese. Concerning fat perception, the addition of aroma can be a good strategy to compensate for low-fat in commercial cheeses. However, the mechanisms involved seem complex and need to be elucidated.

A Critical review focusing the effect of ingredients on the textural properties of plant-based meat products

Plant-based meat alternatives have been studied for decades, but have recently gained more attraction in the food industries and research communities. Concern about animal welfare, health, environment and moral beliefs acts as a driving force for the growth of plant-based meat products. The most challenging task in the development of meat analog is to imitate the texture of conventional meat products. The fabrication of plant-based meat product requires a wise selection and formulation of ingredients to perfectly mimic the fibrous structure of meat. Top-down and bottom-up approaches are the two most commonly used structuring techniques for the preparation of plant-based meat products. Development of comminuted meat product is easy as compared to the whole-muscle type plant-based meat products. Several plant-based ingredients such as texturized and non-texturized proteins, fats, binding agents, flavoring and coloring agents accompanied with different processing techniques (extrusion, shear cell, wet spinning, electrospinning, and freeze structuring) are used in the preparation of meat analogs. This paper aims to discuss the impact of ingredients on the textural properties of plant-based meat products.

Meat analogs: Protein restructuring during thermomechanical processing

Increasing awareness of inefficient meat production and its future impact on global food security has led the food industry to look for a sustainable approach. Meat products have superior sensorial perception, because of their molecular composition and fibrous structure. Current understanding in the science of food structuring has enabled the utilization of alternative or nonmeat protein ingredients to create novel structured matrices that could resemble the textural functionality of real meat. The physicochemical and structural changes that occur in concentrated protein systems during thermomechanical processing lead to the creation of a fibrous or layered meat-like texture. Phase transitions in concentrated protein systems during protein-protein, protein-polysaccharide, protein-lipid, and protein-water interactions significantly influence the texture and the overall sensory quality of meat analogs. This review summarizes the roles of raw materials (moisture, protein type and concentration, lipids, polysaccharides, and air) and processing parameters (temperature, pH, and shear) in modulating the behavior of the protein phase during the restructuring process (structure-function-process relationship). The big challenge for the food industry is to manufacture concept-based (such as beef-like, chicken-like, etc.) meat analogs with controlled structural attributes. This information will be useful in developing superior meat analogs that fulfill consumer expectations when replacing meat in their diet.

Thermo-mechanical processing of plant proteins using shear cell and high-moisture extrusion cooking

Consumption of plant-based meat analogues offers a way to reduce the environmental footprint of the human diet. High-moisture extrusion cooking (HMEC) and shear cell processing both rely on thermo-mechanical treatment of proteins to product fibrous meat-like products. However, the mechanisms underlying these processes are not well understood. In this review we discuss the effect of thermo-mechanical processing on the physicochemical properties and phase behavior of proteins and protein mixtures. The HMEC and shear cell processes are comparable in their basic unit operations, which are (1) mixing and hydration, (2) thermo-mechanical treatment, and (3) cooling. An often overlooked part of the extruder that could be crucial to fibrillation is the so-called breaker plate, which is situated between the barrel and die sections. We found a lack of consensus on the effect of heat on protein-protein interactions, and that the experimental tools to study protein-protein interactions are limited. The different mechanisms for structure formation proposed in literature all consider the deformation and alignment of the melt. However, the mechanisms differ in their underlying assumptions. Further investigation using novel and dedicated tools is required to fully understand these thermo-mechanical processes.

The influence of temperature- and divalent-cation-mediated aggregation of β-casein on the physical and microstructural properties of β-casein-stabilised emulsions

The objective of this study was to assess the influence of self-association of β-casein (β-CN) induced by both increasing temperature (5-55 °C) and divalent cation addition (Ca²⁺ or Mg²⁺) on the properties of β-CN-stabilised emulsions. The particle size of 0.5% (w/w) β-CN in 10 mM imidazole/HCl buffer (pH 6.8) was determined as a function of temperature and addition of divalent cations. Addition of CaCl₂ caused a greater increase in protein particle size than MgCl₂. Oil-in-water emulsions stabilised with 0.5% (w/w) β-CN, β-CN with added CaCl₂ or MgCl₂ (β-CN/Ca and β-CN/Mg, respectively) were also investigated as a function of temperature using light scattering, analytical centrifugation, rheology and confocal laser scanning microscopy (CLSM). Emulsions prepared with β-CN/Ca flocculated after incubation at 55 °C for 20 min and displayed significantly different physical properties (p < 0.05) compared to emulsions stabilised with β-CN or β-CN/Mg in the temperature range 5-55 °C. Based on CLSM analysis and analysis of the interfacial protein load, this flocculation was attributed to the interaction of adsorbed β-CN between droplets and the interaction of adsorbed and non-adsorbed β-CN aggregates in the aqueous phase via calcium bridges. Furthermore, the flocculation of β-CN/Ca emulsions was reversible upon cooling, which is similar to that of β-CN/Ca in solution. In conclusion, the temperature-dependent behaviour of β-CN-stabilised emulsions correlated to the temperature-induced aggregation of β-CN, particularly in the presence of Ca²⁺. Hence, the stability of β-CN-stabilised emulsions can be predicted from the extent of β-CN aggregation in aqueous solution (i.e., aggregate size).

Understanding the role of air and protein phase on mechanical anisotropy of calcium caseinate fibers

Calcium caseinate dispersions can be transformed into anisotropic, fibrous materials using the concept of shear-induced structuring. The aim of this study is to further investigate the relative importance of air bubbles and protein on the mechanical anisotropy of calcium caseinate material. In this study, the effect of air on mechanical anisotropy of these fibrous materials was described with a load-bearing model, with the void fraction, and the bubble length and width as input parameters. The anisotropy of the protein phase was estimated using materials obtained from deaerated dispersions after shearing at different shear rates. We concluded that the deformation of air bubbles can only partly explain the mechanical anisotropy; the anisotropy of the protein phase is more important. Based on all results, we further concluded that the anisotropy of the protein phase was affected by the air bubbles present during the structuring process. This effect was explained by locally higher shear rate in the protein matrix during the structuring process.

Strain hardening and anisotropy in tensile fracture properties of sheared model Mozzarella cheeses

We studied the tensile fracture properties of model Mozzarella cheeses with varying amounts of shear work input (3.3-73.7 kJ/kg). After manufacture, cheeses were elongated by manual rolling at 65°C followed by tensile testing at 21°C on dumbbell-shaped samples cut both parallel and perpendicular to the rolling direction. Strain hardening parameters were estimated from stress-strain curves using 3 different methods. Fracture stress and strain for longitudinal samples did not vary significantly with shear work input up to 26.3 kJ/kg and then decreased dramatically at 58.2 kJ/kg. Longitudinal samples with shear work input <30 kJ/kg demonstrated significant strain hardening by all 3 estimation methods. At shear work inputs <30 kJ/kg, strong anisotropy was observed in both fracture stress and strain. After a shear work input of 58.2 kJ/kg, anisotropy and strain hardening were absent. Perpendicular samples did not show strain hardening at any level of shear work input. Although the distortion of the fat drops in the cheese structure associated with the elongation could account for some of the anisotropy observed, the presence of anisotropy in the elongated nonfat samples reflected that shear work and rolling also aligned the protein structure.

Shear structuring as a new method to make anisotropic structures from soy-gluten blends

The concept of shear-induced structuring was applied to concentrated blends of soy protein isolate (SPI) and wheat gluten (WG) to create novel semi-solid food textures. Concurrent simple shear deformation and heating (95°C) of the protein blends generated original structures consisting of fibers or layers. The ratio of SPI to vital WG and the final concentration determined the morphology of the structure. It is hypothesized that the spatial distribution of the SPI-rich phase and the WG-rich phase in a blend was altered by the shear flow. When both phases became aligned horizontally in the shear cell, a fibrous structure was formed; when they became aligned vertically in the shear cell, a layered structure was formed. The structures obtained were analyzed visually and using texture analysis and scanning electron microscopy.

Soft matter approaches to food structuring

We give an overview of the many opportunities that arise from approaching food structuring from the perspective of soft matter physics. This branch of physics employs concepts that build upon the seminal work of van der Waals, such as free volume, the mean field, and effective temperatures. All these concepts aid scientists in understanding and controlling the thermodynamics and (slow) dynamics of structured foods. We discuss the use of these concepts in four topics, which will also be addressed in a forthcoming Faraday Discussion on food structuring.