Measurement of the true melt temperature in a twin-screw extrusion processing of starch based matrices via infrared sensor

High-Moisture Extrusion of a Dietary Protein Blend Impairs In Vitro Digestion and Delays In Vivo Postprandial Plasma Amino Acid Availability in Humans

BACKGROUND

Industrial processing can alter the structural complexity of dietary proteins and, potentially, their digestion and absorption upon ingestion. High-moisture extrusion (HME), a common processing method used to produce meat alternative products, affects in vitro digestion, but human data are lacking. We hypothesized that HME of a mycoprotein/pea protein blend would impair in vitro digestion and in vivo postprandial plasma amino acid availability.

METHODS

In Study A, 9 healthy volunteers completed 2 experimental trials in a randomized, double-blind, crossover design. Participants consumed a beverage containing 25 g protein from a "dry" blend (CON) of mycoprotein/pea protein (39%/61%) or an HME content-matched blend (EXT). Arterialized venous blood samples were collected in the postabsorptive state and regularly over a 5-h postprandial period to assess plasma amino acid concentrations. In Study B, in vitro digestibility of the 2 beverages were assessed using bicinchoninic acid assay and optical fluorescence microscopy at baseline and during and following gastric and intestinal digestion using the INFOGEST model of digestion.

RESULTS

Protein ingestion increased plasma total, essential (EAA), and branched-chain amino acid (BCAA) concentrations (time effect, P < 0.0001) but more rapidly and to a greater magnitude in the CON compared with the EXT condition (condition × time interaction, P < 0.0001). This resulted in greater plasma availability of EAA and BCAA concentrations during the early postprandial period (0-150 min). These data were corroborated by the in vitro approach, which showed greater protein availability in the CON (2150 ± 129 mg/mL) compared with the EXT (590 ± 41 mg/mL) condition during the gastric phase. Fluorescence microscopy revealed clear structural differences between the 2 conditions.

CONCLUSIONS

These data demonstrate that HME delays in vivo plasma amino acid availability following ingestion of a mycoprotein/pea protein blend. This is likely due to impaired gastric phase digestion as a result of HME-induced aggregate formation in the pea protein. This trial was registered at clinicaltrials.gov as NCT05584358.

High-Moisture Extrusion of Plant Proteins: Fundamentals of Texturization and Applications

The growing demand for sustainable and healthy food alternatives has led to a significant increase in interest in plant-based protein products. Among the various techniques used in creating meat analogs, high-moisture extrusion (HME) stands out as a promising technology for developing plant-based protein products that possess desirable texture and mouthfeel. During the extrusion process, plant proteins undergo a state transition, causing their rheological properties to change, thereby influencing the quality of the final extrudates. This review aims to delve into the fundamental aspects of texturizing plant proteins using HME, with a specific focus on the rheological behavior exhibited by these proteins throughout the process. Additionally, the review explores the future of HME from the perspective of novel raw materials and technologies. In summary, the objective of this review is to provide a comprehensive understanding of the potential of HME technology in the development of sustainable and nutritious plant-based protein products.

Effect of extrusion on the protein structure and digestibility of extruded soybean protein

BACKGROUND

Extrusion is the main method for the preparation of plant-based meat. Current studies have focused on the effect of different extrusion parameters on the texture and quality of plant-based meat, but there has been less research on their digestibility. This study determined the textural properties of extruded soybean protein (ESPro) for different extrusion parameters and the digestibility after in vitro simulated digestion experiments. The effect of extrusion on the structure and digestibility of ESPro and the relationship between them were elucidated.

RESULTS

The results demonstrated a significant improvement in the digestibility of ESPro through extrusion, with the highest values for cohesiveness, springiness, chewiness, fibrous degree, digestibility, and proportion of digested peptides with <1 kDa molecular weight at an extrusion temperature of 160 °C and a screw speed of 30 rpm (ESPro1). In addition, β-sheet content in the secondary structure of the ESPro showed a significant negative association with ESPro digestibility.

CONCLUSION

In this study, extrusion could improve the digestibility of ESPro by altering the protein structure. This advancement holds the potential for more effective applications in plant-based meats. © 2023 Society of Chemical Industry.

Effects of Process Variables on the Physicochemical, Textural, and Structural Properties of an Isolated Pea Protein-Based High-Moisture Meat Analog

This study investigated the optimal extrusion conditions required to produce an isolated pea protein (IPP)-based meat analog. High-moisture extrusion cooking (HMEC) was performed. The effects of the moisture content (55 and 60%), barrel temperature (165 and 175 °C), and screw speed (150 and 200 rpm) on the physicochemical, textural, and structural properties of the high-moisture meat analog (HMMA) were determined. The results showed that the moisture content had a significant effect (p < 0.05) on the physicochemical and textural properties of the HMMA. A lower moisture content had significant impact (p < 0.05) on enhancing the texturization of the HMMA and the formation of fibrous structures, thereby increasing the texture profile analysis (TPA) and cutting strength of the HMMA. Protein denaturation during HMEC resulted in a lower protein solubility of the meat analog than the raw material. The content of β-sheets and β-turns in the meat analogs were higher than that in the raw material, while the content of random coils and α-helices is inversely proportional. The process variables had no significant (p > 0.05) effect on the secondary structures. In conclusion, the moisture content is the most important factor affecting the properties of HMMAs. The extrusion process variables for HMMAs are a moisture content of 55%, a barrel temperature of 175 °C, and a screw speed of 200 rpm.

The development process of plant-based meat alternatives: raw material formulations and processing strategies

With the rapid growth of the world's population, the demand for meat is gradually increasing. The emergence and development of plant-based meat alternatives (PBMs) offer a good alternative to solve the environmental problems and disease problems caused by the over-consumption of meat products. Soybean is now the primary material for the production of PBMs due to its excellent gelation properties, potential from fibrous structure, balanced nutritional value, and relatively low price. Extrusion is the most widely used process for producing PBMs, and it has a remarkable effect on simulating the fibrous structure of real meat products. However, interactions related to phase transitions in protein molecules or fibrous structures during extrusion remain a challenge. Currently, PBMs do not meet people's demand for realistic meat in terms of texture, taste, and flavor. Therefore, the objectives of this review are to explore how to improve fiber structure formation in terms of raw material formulation and processing technology. Factors to improve the taste and texture of PBMs are summarized in terms of optimizing process parameters, changing the composition of raw materials, and enriching taste and flavor. It will provide a theoretical basis for the future development of PBMs.

Rheological properties of transglutaminase-treated concentrated pea protein under conditions relevant to high-moisture extrusion processing

At present, the structural changes of extruded materials under thermal-mechanical stress during high-moisture extrusion are still unclear. In this study, the transglutaminase (TG) treatments on the structure of pea protein isolate (PPI) under conditions relevant to high-moisture extrusion processing (50 wt% PPI at 30°C, 120°C and heated to 120°C and subsequently cooled to 30°C) was studied by using a closed cavity rheometer. Strain and frequency sweeping were carried out under various temperature conditions, and the information obtained was drawn into a texture map. Lissajous curves combined with energy dissipation ratio were introduced to characterize the nonlinear response of the samples. The results showed that the storage modulus of PPI increased with the increase of TG concentration during heat treatment. After cooling to 30°C, PPI with 0.25-1%TG could enhance the elasticity, but treating by 2% TG could inhibit the formation of disulfide bonds, the uniform development of the protein network, thus showing the "tough" character. These findings can help to better understand the relationships of material-structure during the extrusion process, and also provide help for further optimization of the quality of meat substitutes.

Machine learning assisted optimization of blending process of polyphenylene sulfide with elastomer using high speed twin screw extruder

Random forest regression was applied to optimize the melt-blending process of polyphenylene sulfide (PPS) with poly(ethylene-glycidyl methacrylate-methyl acrylate) (E-GMA-MA) elastomer to improve the Charpy impact strength. A training dataset was constructed using four elastomers with different GMA and MA contents by varying the elastomer content up to 20 wt% and the screw rotation speed of the extruder up to 5000 rpm at a fixed barrel temperature of 300 °C. Besides the controlled parameters, the following measured parameters were incorporated into the descriptors for the regression: motor torque, polymer pressure, and polymer temperatures monitored by infrared-ray thermometers installed at four positions (T1 to T4) as well as the melt viscosity and elastomer particle diameter of the product. The regression without prior knowledge revealed that the polymer temperature T1 just after the first kneading block is an important parameter next to the elastomer content. High impact strength required high elastomer content and T1 below 320 °C. The polymer temperature T1 was much higher than the barrel temperature and increased with the screw speed due to the heat of shear. The overheating caused thermal degradation, leading to a decrease in the melt viscosity and an increase in the particle diameter at high screw speed. We thus reduced the barrel temperature to keep T1 around 310 °C. This increased the impact strength from 58.6 kJ m⁻² as the maximum in the training dataset to 65.3 and 69.0 kJ m⁻² at elastomer contents of 20 and 30 wt%, respectively.

Twin-Screw Melt Granulation for Oral Solid Pharmaceutical Products

This article highlights the advantages of pharmaceutical continuous melt granulation by twin-screw extrusion. The different melt granulation process options and excipients are described and compared, and a case is made for expanded use of twin-screw melt granulation since it is a flexible and continuous process. Methods for binder selection are profiled with a focus on rheology and physical stability impacts. For twin-screw melt granulation, the mechanism of granulation and process impact on granule properties are described. Pharmaceutical applications of melt granulation ranging from immediate release of soluble and insoluble APIs, taste-masking, and sustained release formulation are reviewed, demonstrating the range of possibilities afforded by twin-screw melt granulation.