High-moisture Extrusion Technology Application in the Processing of Textured Plant Protein Meat Analogues: A Review

Advancements in plant based meat analogs enhancing sensory and nutritional attributes

The burgeoning demand for plant-based meat analogs (PBMAs) stems from environmental, health, and ethical concerns, yet replicating the sensory attributes of animal meat remains challenging. This comprehensive review explores recent innovations in PBMA ingredients and methodologies, emphasizing advancements in texture, flavor, and nutritional profiles. It chronicles the transition from soy-based first-generation products to more diversified second- and third-generation PBMAs, showcasing the utilization of various plant proteins and advanced processing techniques to enrich sensory experiences. The review underscores the crucial role of proteins, polysaccharides, and fats in mimicking meat's texture and flavor and emphasizes research on new plant-based sources to improve product quality. Addressing challenges like production costs, taste, texture, and nutritional adequacy is vital for enhancing consumer acceptance and fostering a more sustainable food system.

Digestion behavior of plant-based meat analogs with anisotropic fibrous structure in a semi-dynamic gastric digestion system

Plant-based meat analogs have increasingly attracted the attention of the food industry in recent years. However, the digestion behavior of this innovative solid food in human stomach is poorly understood. In this study, plant-based meat analogs with different internal structures were prepared with/without high-moisture extrusion technology and at different temperatures. A semi-dynamic gastric digestion system which involves the mimic processes of the secretion of gastric juice and the gastric emptying was applied. After extrusion treatment at high temperature (150 ℃), the EHT had the highest anisotropic index (H⊥/H∥=1.90) and an ideal meat-like structure. It was found that particle disintegration and swelling simultaneously occurred in the bolus of the EHT but not in the sample without extrusion treatment (the HLT) in the early stage of gastric digestion. This difference might be attributed to the compact and well-arranged anisotropic structure of the EHT resulting from the extrusion, and leads to difficult enzymatic hydrolyzation unless the particles swell and unfold the polymer chains. The difficulty in particle disintegration in the EHT during gastric digestion is the consequence of the relatively slow gastric emptying rate and the decrease of protein degradation. As a result, the EHT which underwent extrusion treatment at high temperature and possessed the best anisotropic fibrous structure exhibited the slowest gastric digestion. This novel solid food shows good potential as a desired nutritional food for people on diet.

Sensory and Physical Properties of Fibrous Meat Analogs Made from Faba Bean, Pea, and Oat Using High-Moisture Extrusion

Faba bean is a promising source of ingredients for the production of meat analogs. However, sensory properties of faba bean, especially the bitter taste of the protein concentrate, restrict its use. Our aim was to assess the feasibility of two types of faba bean ingredients-flour (from germinated, gently heat-treated beans) and groat (from non-germinated, roasted beans)-in combination with pea protein isolate and oat fiber concentrate for producing meat analogs using high-moisture extrusion. We produced six samples using varying recipes, while maintaining constant process parameters. An untrained panel (55 participants) evaluated the samples for key sensory attributes (check-all-that-apply) and rated their pleasantness. The water absorption capacity and mechanical properties of the samples were assessed using instrumental measurements. The samples were frequently described as 'beany' and 'tasteless', but very rarely as 'bitter'. The most frequently cited attributes for mouthfeel varied between the samples containing 30% ('tough', 'gummy') and 50% ('crumbly', 'floury') of faba bean flour/groat and were associated with corresponding mechanical properties. On average, the sample containing a blend of faba bean groat and pea protein isolate (50% each) appeared to be the most pleasant. Our results suggest that faba bean groat with pea protein isolate enables the production of fibrous meat analogs with acceptable taste and texture, without the bitter off-taste.

Mechanism of l-cysteine-induced fibrous structural changes of soybean protein at different high-moisture extrusion zones

In this study, the fibrous structure formation mechanism of soybean protein during high moisture extrusion processing was investigated using a dead-stop operation, and based on the interaction between soybean protein concentrate (SPC) and L-cysteine (CYS). The thermal properties, SDS-PAGE and particle size distribution of the samples from different extrusion zones were investigated. It was revealed that the addition of a moderate amount of CYS (0.1 %) promoted the fibrous structure formation in the SPC extrudates and optimised the textural properties of the SPC extrudates. In the extruder barrel, addition of CYS (0.1 %) promoted protein depolymerisation and unfolding in the mixing and cooking zones, and facilitated protein aggregation in the die and cooling zones. Protein solubility and raman spectroscopy revealed that disulfide bonds were principally responsible for fibrous structure formation; favoured when the intermolecular disulfide bonds (t-g-t mode) was increased. Finally, the transformation of protein conformation was revealed by secondary structure and surface hydrophobicity, which confirmed that the effect of CYS on protein conformation mainly occurred in the cooling zone. This study provides a theoretical basis for the application of CYS to regulate the fibrous structure of meat analogues.

Improving the Storage Stability of Soy Protein Isolate through Annealing

This study investigated the effect of annealing treatment on the stability of soy protein isolate (SPI) during storage. Different SPI samples with varying denaturation levels were subjected to varying annealing temperatures and durations before being stored at 37 °C for 12 weeks to assess their stability. Our findings revealed that annealing at 65 °C for 30 min significantly mitigated protein deterioration, improving the stability of highly denatured proteins during storage. Surface hydrophobicity and endogenous fluorescence analyses indicated that this annealing condition induced protein structure unfolding, an initial increase in SPI hydrophobicity, and a blue shift in the maximum absorption wavelength (λmax). The slowest increase in hydrophobicity occurred during storage, along with a red shift in the maximum absorption wavelength by the 12th week. These results suggest that annealing treatment holds promise for mitigating the issue of reduced SPI stability during storage.

Evaluating the Potential Safety Risk of Plant-Based Meat Analogues by Analyzing Microbial Community Composition

Plant-based meat analogues offer an environmentally and scientifically sustainable option as a substitute for animal-derived meat. They contribute to reducing greenhouse gas emissions, freshwater consumption, and the potential risks associated with zoonotic diseases linked to livestock production. However, specific processing methods such as extrusion or cooking, using various raw materials, can influence the survival and growth of spoilage and pathogenic microorganisms, resulting in differences between plant-based meat analogues and animal meat. In this study, the microbial communities in five different types of plant-based meat analogues were investigated using high-throughput sequencing. The findings revealed a diverse range of bacteria, including Cyanobacteria, Firmicutes, Proteobacteria, Bacteroidota, Actinobacteriota, and Chloroflexi, as well as fungi such as Ascomycota, Basidiomycota, Phragmoplastophyta, Vertebrata, and Mucoromycota. Additionally, this study analyzed microbial diversity at the genus level and employed phenotype prediction to evaluate the relative abundance of various bacterium types, including Gram-positive and Gram-negative bacteria, aerobic, anaerobic, and facultative anaerobic bacteria, as well as potential pathogenic bacteria. The insights gained from this study provide valuable information regarding the microbial communities and phenotypes of different plant-based meat analogues, which could help identify effective storage strategies to extend the shelf-life of these products.

High moisture extrusion of plant proteins: advances, challenges, and opportunities

High moisture extrusion is a widely used technology for producing fibrous meat analogues in an efficient and scalable manner. Extrusion of soy, wheat gluten, and pea is well-documented and related products are already available in the market. There has been growing interest to diversify the protein sources used for meat analogues due to concerns over food waste, monocropping and allergenicity. Optimizing the extrusion process for plant proteins (e.g., hemp, mung bean, fava bean) tends to be time consuming and relies on the operators' intuition and experience to control the process well. Simulating the extrusion process has been challenging so far due to the diverse inputs and configurations involved during extrusion. This review details the mechanism for fibrous structure formation and provides an overview of the extrusion parameters used for texturizing a broad range of plant protein sources. Referring to these data reduces the resources needed for optimizing the extrusion process for novel proteins and may be useful for future extrusion modeling efforts. The review also highlights potential challenges and opportunities for extruding plant proteins, which may help to accelerate the development and commercialization of related products.

A review of green methods used in starch-polyphenol interactions: physicochemical and digestion aspects

The interactions of starch with lipids, proteins, and other major food components during food processing are inevitable. These interactions could result in the formation of V-type or non-V-type complexes of starch. The starch-lipid complexes have been intensively studied for over five decades, however, the complexes of starch and polyphenols are relatively less studied and are the subject of recent interest. The interactions of starch with polyphenols can affect the physicochemical properties and its digestibility. The literature has highlighted several green methods such as ultrasound, microwave, high pressure, extrusion, ball-milling, cold plasma etc., to assist interactions of starch with polyphenols. However, comprehensive information on green methods to induce starch-polyphenol interactions is still scarce. Therefore, in light of the importance and potential of starch-polyphenol complexes in developing functional foods with low digestion, this review has summarized the novel green methods employed in interactions of starch with flavonoids, phenolic acids and tannins. It has been speculated that flavonoids, phenolic acids, and tannins, among other types of polyphenols, may have anti-digestive activities and are also revealed for their interaction with starch to form either an inclusion or non-inclusion complex. Further information on the effects of these interactions on physicochemical parameters to understand the chemistry and structure of the complexes is also provided.

Nordic Crops as Alternatives to Soy-An Overview of Nutritional, Sensory, and Functional Properties

Soy (Glycine max) is used in a wide range of products and plays a major role in replacing animal-based products. Since the cultivation of soy is limited by cold climates, this review assessed the nutritional, sensory, and functional properties of three alternative cold-tolerant crops (faba bean (Vicia faba), yellow pea (Pisum sativum), and oat (Avena sativa)). Lower protein quality compared with soy and the presence of anti-nutrients are nutritional problems with all three crops, but different methods to adjust for these problems are available. Off-flavors in all pulses, including soy, and in cereals impair the sensory properties of the resulting food products, and few mitigation methods are successful. The functional properties of faba bean, pea, and oat are comparable to those of soy, which makes them usable for 3D printing, gelation, emulsification, and extrusion. Enzymatic treatment, fermentation, and fibrillation can be applied to improve the nutritional value, sensory attributes, and functional properties of all the three crops assessed, making them suitable for replacing soy in a broad range of products, although more research is needed on all attributes.

Screening of Acrylamide Content in Commercial Plant-Based Protein Ingredients from Different Technologies

The demand of plant-based protein ingredients (PBPIs) in the food sector has strongly increased over recent years. These ingredients are produced under a wide range of technological processes that impact their final characteristics. This work aimed to evaluate acrylamide contamination in a range of PBPIs produced with different technologies and classified into four categories i.e., flours, dry-fractionated proteins, wet-extracted proteins, and texturized vegetable proteins. The results highlighted a remarkable variability in the acrylamide contamination in all the classes under investigation, with the flours showing the lowest mean acrylamide content (280 µg kg^-1) compared with the wet-extracted proteins that showed the highest (451 µg kg^-1). These differences could likely be associated with the different processing technologies used to obtain the protein ingredients. These findings suggest the need to monitor acrylamide formation during the processing of PBPIs and, consequently, to study mitigation strategies when necessary.

Control of Beany Flavor from Soybean Protein Raw Material in Plant-Based Meat Analog Processing

The development of plant-based meat analogs is currently hindered by the beany flavor generated by raw soybean protein and extrusion processing. Wide concern has led to extensive research on the generation and control of this unwanted flavor, as an understanding of its formation in raw protein and extrusion processing and methods through which to control its retention and release are of great significance for obtaining ideal flavor and maximizing food quality. This study examines the formation of beany flavor during extrusion processing as well as the influence of interaction between soybean protein and beany flavor compounds on the retention and release of the undesirable flavor. This paper discusses ways to maximize control over the formation of beany flavor during the drying and storage of raw materials and methods to reduce beany flavor in products by adjusting extrusion parameters. The degree of interaction between soybean protein and beany compounds was found to be dependent on conditions such as heat treatment and ultrasonic treatment. Finally, future research directions are proposed and prospected. This paper thus provides a reference for the control of beany flavor during the processing, storage, and extrusion of soybean raw materials used in the fast-growing plant-based meat analog industry.

High-moisture extrusion cooking on soybean-wheat protein mixtures: Effect of sodium alginate/xanthan gum/maltodextrin on promoting a fibrous structure

At present, the changes in fibrous structure of plant proteins improved by polysaccharides during high-moisture extrusion cooking (HMEC) are still unclear. In this study, different additions (1, 2, 3, 4, and 5%) of sodium alginate (SA), xanthan gum (XG), and maltodextrin (MD) were used in the preparation of organised protein products based on soybean protein and wheat protein under high moisture extrusion conditions. It was revealed that SA-4%, XG-2%, and MD-2% (w/w) significantly enhanced the structural and physical properties of the fibres. The polysaccharides increased the water distribution of extrudates by enhancing protein-water interactions through hydrogen bonding, with MD-2% having the strongest ability to trap free water. The mechanism by which the polysaccharides improved the fibrous structure of extrudates involved the reorganization of molten proteins from the die head region to the cooling region, formation of new molecular bonds and enhancement of thermal stability. XG-2% significantly increased the β-sheet structure in the molten region (48.9 ± 1.35%) and showed the best thermal stability. Overall, SA-4% was able to better maintain the molecular bonding transformation and strong water absorption, which stabilised the protein conformation and formed the highest fibrous degree (2.1 ± 0.03). This suggests that the properties of the three polysaccharides can be used as modifiers of high water extruded plant proteins to improve the extruded materiality, functional and nutritional properties.

Comparison of Binding Properties of a Laccase-Treated Pea Protein-Sugar Beet Pectin Mixture with Methylcellulose in a Bacon-Type Meat Analogue

A bacon-type meat analogue consists of different structural layers, such as textured protein and a fat mimetic. To obtain a coherent and appealing product, a suitable binder must glue those elements together. A mixture based on pea protein and sugar beet pectin (r = 2:1, 25% w/w solids, pH 6) with and without laccase addition and a methylcellulose hydrogel (6% w/w) serving as benchmark were applied as binder between textured protein and a fat mimetic. A tensile strength test, during which the layers were torn apart, was performed to measure the binding ability. The pea protein-sugar beet pectin mixture without laccase was viscoelastic and had medium and low binding strength at 25 °C (F ≤ 3.5 N) and 70 °C (F ≈ 1.0 N), respectively. The addition of laccase solidified the mixture and increased binding strength at 25 °C (F ≥ 4.0 N) and 70 °C (F ≈ 2.0 N), due to covalent bonds within the binder and between the binder and the textured protein or the fat mimetic layers. Generally, the binding strength was higher when two textured protein layers were glued together. The binding properties of methylcellulose hydrogel was low (F ≤ 2.0 N), except when two fat mimetic layers were bound due to hydrophobic interactions becoming dominant. The investigated mixed pectin-pea protein system is able serve as a clean-label binder in bacon-type meat analogues, and the application in other products seems promising.

Food extrusion: An advanced process for innovation and novel product development

Extrusion is a versatile process capable of producing a variety of new and novel foods and ingredients, thus increasing manufacturing opportunities. Further, it could provide nutritious, safe, sustainable, and affordable foods, especially directed at individualized consumer needs. In addition to past research efforts, more investigations should be conducted in order to refine, redesign, or develop new extrusion processing technologies. The present review highlights the current advances made in new and novel food product development by considering the extrusion process, the influencing parameters, and product characteristics and properties; the most promising extrusion processes that can be used in novel food product and ingredient development, such as extrusion cooking, hot-melt extrusion, reactive extrusion, and extrusion-based 3D printing; the possibilities of using various raw materials in relation to process and product development; and the needs for product development modeling along with extrusion process design and modeling. In correlation with extruded product development, topics that merit further investigation may include structure formation, plant and animal biopolymers functionalization, biopolymer reactions, process simulation, modeling and control, engineering and mechanical aspects of extruders, analysis of pre-processing treatments, as well as prototyping, risk analysis, safety, sensory and consumer acceptance.

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.

Incorporation of Mycelium (Pleurotus eryngii) in Pea Protein Based Low Moisture Meat Analogue: Effect on Its Physicochemical, Rehydration and Structural Properties

The protein content of a plant-based ingredient is generally lower than its animal food counterpart, and research into novel alternative protein is required that can provide similar protein content, texture and appearance as meat. This work investigates a mycelium-based low moisture meat analogue (LMMA) approach, by incorporating 0 to 40% w/w mycelium (MY) into pea protein isolate (PPI) via extrusion using a twin-screw extruder at 140 °C die temperature, 40 rpm screw speed, and 10 rpm feeder speed (0.53-0.54 kg/h). Physicochemical, rehydration, and structural properties of LMMA were assessed. The MY incorporation led to a significant change in color attributes due to Maillard reaction during extrusion. Water solubility index and water absorption capacity increased significantly with MY addition, owing to its porous structure. Oil absorption capacity increased due to increased hydrophobic interactions post-extrusion. Protein solubility decreased initially (upto 20% w/w MY), and increased afterwards, while the water holding capacity (WHC) and volumetric expansion ratio (VER) of LMMA enhanced with MY addition upto 30% w/w. Conversely, WHC and VER decreased for 40% w/w which was verified with the microstructure and FTIR analysis. Overall, MY (30% w/w) in PPI produced a fibrous and porous LMMA, showing future potential with an increasingly plant-based product market and decreasing carbon footprint of food production activities.

Ingredients and Process Affect the Structural Quality of Recombinant Plant-Based Meat Alternatives and Their Components

Recombinant plant-based meat alternatives are a kind of product that simulates animal meat with complete structure by assembling plant-tissue protein and other plant-based ingredients. The market is growing rapidly and appears to have a promising future due to the broad culinary applicability of such products. Based on the analysis and summary of the relevant literature in the recent five years, this review summarizes the effects of raw materials and production methods on the structure and quality of specific components (tissue protein and simulated fat) in plant-based meat alternatives. Furthermore, the important roles of tissue and simulated fat as the main components of recombinant plant-based meat alternatives are further elucidated herein. In this paper, the factors affecting the structure and quality of plant-based meat alternatives are analyzed from part to whole, with the aim of contributing to the structural optimization and providing reference for the future development of the plant meat industry.

The texture of plant protein-based meat analogs by high moisture extrusion: A review

Meat analogs produced by high moisture extrusion (HME) are considered to be one of the products that have great potential for replacing real meat. The key issue as a meat analog is whether the texture can meet the standards of real meat. Nowadays, there have been some advances in the textural characterization of meat analogs, which are discussed in detail in this review. Firstly, this review describes the current characterizations of meat analogs in terms of fiber structure, hardness, springiness, tensile resistant force and sensory evaluation. Then, methods for analyzing the texture of meat analogs, such as texture analyzer, microstructure-based methods and other methods for characterizing fiber structure, are summarized. In addition, these characterizations are discussed in relation to the factors that influence the texture of meat analogs during HME. Finally, we propose priorities and some promising methods for future meat analogs conformation studies.

Effective Use of Plant Proteins for the Development of "New" Foods

Diversity in our diet mirrors modern society. Affluent lifestyles and extended longevity have caused the prevalence of diabetes and sarcopenia, which has led to the increased demand of low-carb, high-protein foods. Expansion of the global population and Westernization of Asian diets have surged the number of meat eaters, which has eventually disrupted the supply–demand balance of meat. In contrast, some people do not eat meat for religious reasons or due to veganism. With these multiple circumstances, our society has begun to resort to obtaining protein from plant sources rather than animal origins. This “protein shift” urges food researchers to develop high-quality foods based on plant proteins. Meanwhile, patients with food allergies, especially gluten-related ones, are reported to be increasing. Additionally, growing popularity of the gluten-free diet demands development of foods without using ingredients of wheat origin. Besides, consumers prefer “clean-label” products in which products are expected to contain fewer artificial compounds. These diversified demands on foods have spurred the development of “new” foods in view of food-processing technologies as well as selection of the primary ingredients. In this short review, examples of foodstuffs that have achieved tremendous recent progress are introduced: effective use of plant protein realized low-carb, high protein, gluten-free bread/pasta. Basic manufacturing principles of plant-based vegan cheese have also been established. We will also discuss on the strategy of effective development of new foods in view of the better communication with consumers as well as efficient use of plant proteins.

The Protein Composition Changed the Quality Characteristics of Plant-Based Meat Analogues Produced by a Single-Screw Extruder: Four Main Soybean Varieties in China as Representatives

Plant-based meat analogues (PBMs) are increasingly interesting to customers because of their meat-like quality and contribution to a healthy diet. The single-screw extruder is an important method for processing PBMs, and the characteristics of the product are directly affected by the composition of the raw materials; however, little research focuses on this issue. To explore the effect of protein composition on the quality characteristics of PBMs produced by a single-screw extruder, four soybean varieties used in China (Heihe 43 (HH 43), Jiyu 86 (JY 86), Suinong 52 (SN 52), and Shengfeng 5 (SF 5)) were selected. The 11S/7S ratios for these varieties ranged from 1.0: 1 to 2.5: 1 in order to produce PBMs with different protein compositions. The structure, processing, nutrition, and flavor characteristics were explored to analyze their differences. The results showed that protein composition affected the structure of PBMs, but the correlation was not significant. Meanwhile, a lower 11S/7S ratio (HH 43) did not prove to be a favorable characteristic for the processing of PBMs. From the perspective of nutrition and flavor, it seems acceptable to use a moderate 11S/7S ratio (JY 86 and SN 43) to produce PBMs. This study proved that the protein composition of raw materials affects the characteristics of PBM products produced by a single-screw extruder. To produce PBMs of higher quality, soybeans with a markedly different 11S/7S ratio should not be selected.