High moisture extrusion of wheat gluten: Modeling of the polymerization behavior in the screw section of the extrusion process

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.

Near-infrared spectroscopy to quantify overall thermal process intensity during high-moisture extrusion of soy protein concentrate

High-moisture extrusion (HME) is widely used to produce meat analogues. During HME the plant-based materials experience thermal and mechanical stresses. It is complicated to separate their effects on the final products because these effects are interrelated. In this study we hypothesize that the intensity of the thermal treatment can explain a large part of the physicochemical changes that occur during extrusion. For this reason, near-infrared (NIR) spectroscopy was used as a novel method to quantify the thermal process intensity during HME. High-temperature shear cell (HTSC) processing was used to create a partial least squares (PLS) regression curve for processing temperature under controlled processing conditions (root mean standard error of cross-validation (RMSECV) = 4.00 °C, coefficient of determination of cross-validation (R2CV) = 0.97). This PLS regression model was then applied to HME extrudates produced at different screw speeds (200-1200 rpm) and barrel temperatures (100-160 °C) with two different screw profiles to calculate the equivalent shear cell temperature as a measure for thermal process intensity. This equivalent shear cell temperature reflects the effects of changes in local temperature conditions, residence time and thermal stresses. Furthermore, it can be related to the degree of texturization of the extrudates. This information can be used to gain new insights into the effect of various process parameters during HME on the thermal process intensity and extrudate quality.

Properties of texturized protein and performance of different protein sources in the extrusion process: A review

The need for protein is increasing due to the rapid growth of the global population. However, conventional animal meat production has caused severe environmental, land usage, and other issues. Meat substitutes can provide consumers with a high-quality alternative to protein. Texturized protein (TP) is a critical ingredient in meat substitutes and is mainly obtained through extrusion processing. Therefore, this review first discussed the essential physical properties of TP, including appearance and structure, water-holding capacity (WHC) and oil-holding capacity (OHC), texture, and sensory properties. The performance of plant and novel source proteins in extrusion processing is also summarized. The properties of the desired TP should be considered first before extrusion processing. Under different extrusion parameters, proteins from the same source can exhibit varying properties. Although the novel source proteins can adversely affect TP quality, their high yield and environmental protection are worthy of further study. This paper aims to review the impact of proteins from different sources on the properties of TP during the extrusion process and discuss practical research methods for TP.

Effect of Process Variables and Ingredients on Controlled Protein Network Creation in High-Moisture Plant-Based Meat Alternatives

The market has observed a rapid increase in the demand for plant-based foods as an alternative to animal meat products. Technologies such as high-moisture extrusion (HME) have the potential to develop anisotropic structures using alternative protein ingredients. This article discusses the different possible mechanisms responsible for structure formation and the effect of extrusion process parameters and outlines the recent advances in the long cooling dies (LCDs) used for meat alternative development. The role of different protein ingredients and the impact of combining them with other biopolymers were also evaluated. The underlying mechanism behind anisotropic structure formation during HME is a synergistic effect, with substantial dependence on the source of ingredients and their processing background. Formulation including proteins derived from plants, insects, animals, and microalgae with other biopolymers could pave the way to develop structured meat alternatives and fill nutritional interstices. Dynamic or rotating annular gap cooling dies operating at freely controllable shear and static annular gap dies are recent developments and assist to produce layered or fibrous structures. The complex chemical sites created during the HME of plant protein favour flavour and colour retention. This paper summarises the recent information published in the scientific literature and patents, which could further help researchers to fill the present knowledge gaps.

XRT for visualizing microstructure of extruded meat replacers

X-Ray Tomography (XRT) was used to visualize the microstructure of extruded meat replacers. The high moisture extrudates contained lamella, that became visible upon pulling the extrudate apart. In frozen state, these lamella could be visualized with XRT. The freezing increased the density difference between the water-rich and protein-rich layers, thus increasing the contrast obtained in the XRT. Differences in the physical structure were reflected in the measured structure. In non-frozen samples, no lamella were visible, indicating insufficient contrast. Because of the contrast obtained in frozen samples, we conclude that the XRT technique is a valuable addition to investigate extrudate structure, that can be used to quantify differences in extrudates obtained by for example variation in composition. Here we showed a higher lamella thickness for soy protein isolate (SPI) compared to more fibre-rich soy protein samples.

Meat alternatives: A proofed commodity?

The demand for meat alternatives has been growing in the recent years and it is expected to keep expanding. Motives driving this growth are diverse and are mostly related to the health and ethical concerns over animal welfare and the possible impact of meat production on the environment. Meat alternatives are not anymore a niche market (i.e., vegetarians and vegans) but going mainstream (also consumed by meat eaters and flexitarians). This can be attributed to advances in formulations and ingredients and innovative technologies resulting in improved quality of products. This chapter summarizes the current knowledge about meat alternatives (from plant, fungi or/and algae). Plant-based alternatives are already a proofed commodity with a wide range of products available in the market. The search for more sustainable sources had put the spotlight on other sources such as fungi and algae due to their limited need to land, energy and water for biomass production. Fungi-based alternatives are steps ahead of those algae-based owing to fungi neutral flavor, comparable nutritional profile to meat and no need to masking agents. Consumer acceptance is still a key challenge boosting research and development efforts to ensure a better quality, affordability, and sustainability.

Plant protein-based fibers: Fabrication, characterization, and potential food applications

Proteins from plants have been considered as safer, healthier, and more sustainable resources than their animal counterparts. However, incomplete amino acid composition and relatively poor functionality limit their applications in foods. Structuring plant proteins to fibrous architectures enhances their physicochemical properties, which can favor various food applications. This review primarily focuses on fabrication of fibers from plant proteins via self-assembly, electrospinning, solution blow spinning, wet spinning, and high-temperature shear, as well as on several applications where such fibrous proteins assemble in quality foods. The changes of protein structure and protein-protein interactions during fiber production are discussed in detail, along with the effects of fabrication conditions and protein sources on the morphology and function of the fibers. Self-assembly requires proteolysis and subsequent peptide aggregation under specific conditions, which can be influenced by pH, salt and protein type. The spinning strategy is more scalable and produces uniformed fibers with larger length scales suitable for encapsulation, food packaging and sensor substrates. Significant progress has been made on high-temperature shear (including extrusion)-induced fibers responsible for desirable texture in meat analogues. Structuring plant proteins adds values for broadened food applications, but it remains challenging to keep processes cost-effective and environmentally friendly using food grade solvents.

Comparison of the Rheological Properties of Plant Proteins from Various Sources for Extrusion Applications

Plant proteins in foods are becoming increasingly popular with consumers. However, their application in extruded products remains a major challenge, as the various protein-rich raw materials (e.g., from different plant origins) exhibit very different material properties. In particular, the rheological properties of these raw materials have a distinct influence on the extrusion process and must be known in order to be able to control the process and adjust the product properties. In this study, process-relevant rheological properties of 11 plant-based protein-rich raw materials (differing in plant origin, protein content, and manufacturer) are determined and compared. The results demonstrate distinct differences in the rheological properties, even when plant origin and protein content are identical. Time sweeps reveal not only large differences in development of viscosity over time, but also in magnitude of viscosity (up to 15-fold difference). All materials exhibit gel behaviour and strain thinning behaviour in the strain sweeps, whereas their behaviour in the non-linear viscoelastic range differs greatly. Typical relaxation behaviour of viscoelastic materials could be observed in the stress relaxation tests for all materials. Comparison of the maximum achieved shear stress, which correlates with the elastic properties, reveals an up to 53-fold difference. The results of this study could serve as a starting point for adapting raw material selection and composition to process and product design requirements and help to meet the challenge of applying plant-based proteins in food extrusion.

Texturization of a Blend of Pea and Destarched Oat Protein Using High-Moisture Extrusion

Grain protein fractions have great potential as ingredients that contain high amounts of valuable nutritional components. The aim of this study was to study the rheological behavior of destarched oat and pea proteins and their blends in extrusion-like conditions with a closed cavity rheometer. Additionally, the possibility of producing fibrous structures with high-moisture extrusion from a blend of destarched oat and pea protein was investigated. In the temperature sweep measurement (60-160 °C) of the destarched oat protein concentrate and pea protein isolate blend, three denaturation and polymerization sections were observed. In addition, polymerization as a function of time was recorded in the time sweep measurements. The melting temperature of grain proteins was an important factor when producing texturized structures with a high-moisture extrusion. The formation of fibrillar structures was investigated with high-moisture extrusion from the destarched oat and pea protein blend at temperatures ranging from 140 to 170 °C. The protein-protein interactions were significantly influenced in the extruded samples. This was due to a decrease in the amount of extractable protein in selective buffers. In particular, there was a decrease in non-covalent and covalent bonds due to the formation of insoluble protein complexes.

Co-extruded wheat/okra composite blends result in soft, cohesive and resilient crumbs rich in health-promoting compounds

This work investigates the partial solubilization of cell wall polysaccharides in okra flours and the changes in the profile of free and bound phenolics through twin-screw extrusion. The comparison between extruded wheat flour-native okra flour (EWF-OF) and extruded wheat flour-extruded okra flour (EWF-EOF) composite blends revealed that extrusion led to an increase of soluble dietary fiber from 7.76 to 10.02 g/100 g. Extrusion of okra also resulted in a significant increase of free and bound phenolic acids, the latter consisting mostly of ferulic acid, as well as the thermal degradation of free epigallocatechin, and the binding of a small portion of quercetin-3-O-glucoside likely to a carbohydrate fraction. Bread crumbs from EWF-EOF (at 15% replacement level) exhibited a significantly lower hardness and higher elasticity, cohesiveness and resilience (from 28.28 N, 0.94, 0.49 and 0.17 to 7.54 N, 0.99, 0.70 and 0.35, respectively), which closely resembled the textural attributes of wheat bread.

Proteins from Agri-Food Industrial Biowastes or Co-Products and Their Applications as Green Materials

A great amount of biowastes, comprising byproducts and biomass wastes, is originated yearly from the agri-food industry. These biowastes are commonly rich in proteins and polysaccharides and are mainly discarded or used for animal feeding. As regulations aim to shift from a fossil-based to a bio-based circular economy model, biowastes are also being employed for producing bio-based materials. This may involve their use in high-value applications and therefore a remarkable revalorization of those resources. The present review summarizes the main sources of protein from biowastes and co-products of the agri-food industry (i.e., wheat gluten, potato, zein, soy, rapeseed, sunflower, protein, casein, whey, blood, gelatin, collagen, keratin, and algae protein concentrates), assessing the bioplastic application (i.e., food packaging and coating, controlled release of active agents, absorbent and superabsorbent materials, agriculture, and scaffolds) for which they have been more extensively produced. The most common wet and dry processes to produce protein-based materials are also described (i.e., compression molding, injection molding, extrusion, 3D-printing, casting, and electrospinning), as well as the main characterization techniques (i.e., mechanical and rheological properties, tensile strength tests, rheological tests, thermal characterization, and optical properties). In this sense, the strategy of producing materials from biowastes to be used in agricultural applications, which converge with the zero-waste approach, seems to be remarkably attractive from a sustainability prospect (including environmental, economic, and social angles). This approach allows envisioning a reduction of some of the impacts along the product life cycle, contributing to tackling the transition toward a circular economy.

Non-animal proteins as cutting-edge ingredients to reformulate animal-free foodstuffs: Present status and future perspectives

Consumer interest in protein rich diets is increasing, with more attention being paid to the protein source. Despite the occurrence of animal proteins in the human diet, non-animal proteins are gaining popularity around the world due to their health benefits, environmental sustainability, and ethical merit. These sources of protein qualify for vegan, vegetarian, and flexitarian diets. Non-animal proteins are versatile, derived mainly from cereals, vegetables, pulses, algae (seaweed and microalgae), fungi, and bacteria. This review's intent is to analyze the current and future direction of research and innovation in non-animal proteins, and to elucidate the extent (limitations and opportunities) of their applications in food and beverage industries. Prior knowledge provided relevant information on protein features (processing, structure, and techno-functionality) with particular focus on those derived from soy and wheat. In the current food landscape, beyond conventionally used plant sources, other plant proteins are gaining traction as alternative ingredients to formulate animal-free foodstuffs (e.g., meat alternatives, beverages, baked products, snack foods, and others). Microbial proteins derived from fungi and algae are also food ingredients of interest due to their high protein quantity and quality, however there is no commercial food application for bacterial protein yet. In the future, key points to consider are the importance of strain/variety selection, advances in extraction technologies, toxicity assessment, and how this source can be used to create food products for personalized nutrition.

Functionality of Ingredients and Additives in Plant-Based Meat Analogues

Meat analogue research and development focuses on the production of sustainable products that recreate conventional meat in its physical sensations (texture, appearance, taste, etc.) and nutritional aspects. Minced products, like burger patties and nuggets, muscle-type products, like chicken or steak-like cuts, and emulsion products, like Frankfurter and Mortadella type sausages, are the major categories of meat analogues. In this review, we discuss key ingredients for the production of these novel products, with special focus on protein sources, and underline the importance of ingredient functionality. Our observation is that structuring processes are optimized based on ingredients that were not originally designed for meat analogues applications. Therefore, mixing and blending different plant materials to obtain superior functionality is for now the common practice. We observed though that an alternative approach towards the use of ingredients such as flours, is gaining more interest. The emphasis, in this case, is on functionality towards use in meat analogues, rather than classical functionality such as purity and solubility. Another trend is the exploration of novel protein sources such as seaweed, algae and proteins produced via fermentation (cellular agriculture).

Methods for Testing the Quality Attributes of Plant-Based Foods: Meat- and Processed-Meat Analogs

The modern food system is seeing a change in consumption patterns provoked by several drivers—including ethical, health, and environmental concerns—that are increasing the sales of meat analog foods. This change is accompanied by increased research and development activities in the area of plant-based meats. The aim of the present review is to describe methods that are being employed by scientists to analyze and characterize the properties of meat alternatives and to propose standardized methods that could be utilized in the future. In particular, methods to determine the proximate composition, microstructure, appearance, textural properties, water-holding properties, cooking resilience, and sensory attributes, of plant-based meat are given. The principles behind these methods are presented, their utility is critically assessed, and practical examples will be discussed. This article will help to guide further studies and to choose appropriate methods to assess raw materials, processes, products, and consumption behavior of meat analogs.

Neural Modeling of the Distribution of Protein, Water and Gluten in Wheat Grains during Storage

An important requirement in the grain industry is to obtain fast information on the quality of purchased and stored grain. Therefore, it is of great importance to search for innovative solutions aimed at the monitoring and fast assessment of quality parameters of stored wheat The results of the evaluation of total protein, water and gluten content by means of near infrared spectrometry are presented in the paper. Multiple linear regression analysis (MLR) and neural modeling were used to analyze the obtained results. The results obtained show no significant changes in total protein (13.13 ± 0.15), water (10.63 ± 0.16) or gluten (30.56 ± 0.54) content during storage. On the basis of the collected data, a model artificial neural network (ANN) MLP 52-6-3 was created, which, with the use of four independent features, allows us to determine changes in the content of water, protein and gluten in stored wheat. The chosen network returned good error values: learning, below 0.001; testing, 0.015; and validation, 0.008. The obtained results and their interpretation are an important element in the warehouse industry. The information obtained in this way about the state of the quality of stored grain will allow for a fast reaction in case of the threat of lowering the quality parameters of the stored grain.