Texturisation behaviour of peanut-soy bean/wheat protein mixtures during high moisture extrusion cooking

Effects of different polysaccharide colloids on the structure and physicochemical properties of peanut protein and wheat gluten composite system under extrusion

The structure and physicochemical properties of the complex system of peanut protein and gluten with different concentrations (0 %, 0.5 %, 1 %, and 2 %) of carboxymethyl cellulose (CMC) or sodium alginate (SA) under high-moisture extrusion were studied. The water absorption index and low-field nuclear magnetic resonance showed that adding 0.5 % SA could significantly improve the water uniformity of peanut protein extrudates, while the increase in water absorption was not significant. The texture properties showed that adding CMC or SA increased the hardness, vertical shearing force, and parallel shearing force of the system. Furthermore, adding 0.5 % SA increased approximately 33 % and 75.2 % of the tensile distance and strength of the system, respectively. The secondary structure showed that CMC or SA decreased the proportion of α-helix, β-turn, and random coil, while increased β-sheet proportion. The results of hydrophobicity, unextractable protein, and endogenous fluorescence revealed that CMC and SA reduced the surface hydrophobicity of the system and caused fluorescence quenching in the system. Additionally, it was found that CMC generally increased the free sulfhydryl group content, while SA exhibited the opposite effect.

Flavor of extruded meat analogs: A review on composition, influencing factors, and analytical techniques

Meat analogs are anticipated to alleviate environmental and animal welfare concerns as the demand for meat rises. High moisture extrusion is commonly employed to produce meat analogs, and its flavor could influence consumers' choice. To improve the development and market demand of extruded meat analogs, flavor precursors and natural spices have been used in high moisture extrusion process to directly improve the flavor profile of extruded meat analogs. Although there have been many studies on the flavor of high moisture extruded meat analogs, flavor composition and influencing factors have not been summarized. Thus, this review systematically provides the main pleasant and unpleasant flavor-active substances with 79 compounds, as well as descriptive the influence of flavor-active compounds, chemical reactions (such as lipid oxidation and the Maillard reaction), and fiber structure formation (based on extrusion process, extrusion parameters, and raw materials) on flavor of extruded meat analogs. Flavor evaluation of extruded meat analogs will toward multiple assessment methods to fully and directly characterize the flavor of extruded meat analogs, especially machine learning techniques may help to predict and regulate the flavor characteristics of extruded meat analogs.

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.

The interaction between wheat and pea protein influences the final chemical and sensory characteristics of extruded high moisture meat analogs

Plant-based meat analog products, including those produced by extrusion processing, have become increasingly popular. Complete comprehension of the texturization mechanism and the formation of fibrousness would help improve existing products and extend the variety of plant sources used. Therefore, this study aimed to provide improved insight into the mechanism of texturization during the processing of high-moisture meat analog (HMMA) products. Blends with different wheat and pea protein ratios (100:0, 80:20, 60:40, 40:60, 20:80, and 0:100 wheat:pea) were extruded at a screw speed of 400 rpm, two different moisture contents (50% and 55%), and a feed rate of 90 g/min using a co-rotating twin-screw extruder. Extrudates were analyzed for their texture, free sulfhydryl groups, disulfide bonds, and solubility in different extractants relative to the raw ingredient blends. In addition, a sensory analysis was conducted using the rapid and cost-effective "rate-all-that-apply" (RATA) methodology. The interplay between the two protein types had synergistic effects on the system parameters torque, pressure, and specific mechanical energy, as well as on some textural and sensory parameters. Molecular analyses were not influenced by the interplay between wheat and pea protein as the molecular analyses followed linear trends with the pea inclusion level. Analysis of protein solubility suggests that the texturization mechanism differs slightly depending on the protein type. It is suggested that the texturization of wheat protein depends highly on disulfide bonds, whereas the texturization of pea protein relies on the combination of disulfide bonds and non-covalent interactions. Additionally, RATA was found to be a valuable tool for HMMA products.

Relationship between Soybean Protein Isolate and Textural Properties of Texturized Vegetable Protein

To identify the ideal soybean protein isolate for texturized vegetable protein processing, the effect of different soybean protein isolates on texturized vegetable protein composition was studied. Three different types of soybean protein isolates were selected and analyzed for functional properties (water holding capacity (WHC), emulsifying properties, foaming properties), amino acid content, and protein secondary structure. Then, using the same formulation, the soybean protein isolates were extruded to produce texturized vegetable protein, and its textural properties, degree of texturization, microstructure, free sulfhydryl (free SH), and disulfide (S-S) content were determined. Lastly, a correlation analysis was performed to examine the connection between soybean protein isolates and texturized vegetable proteins. After correlation analysis, the soybean protein isolate functional properties that affect the textural properties of the texturized vegetable protein were as follows: the emulsifying property affected the hardness, adhesiveness, springiness, gumminess, and chewiness of the texturized vegetable proteins; and the foaming property affected the gumminess, chewiness, and the degree of texturization of the texturized vegetable proteins. In addition, 16 amino acids including threonine (Thr), methionine (Met), and arginine (Arg) affect texturized vegetable proteins, mainly with respect to adhesiveness, springiness, and free SH. The effects of secondary structure (α-helix, random coil) on texturized vegetable proteins were degree of texturization, resilience, and cohesion, respectively. Therefore, choosing the soybean protein isolate with better emulsifying and foaming properties provides a more suitable approach for processing texturized vegetable protein.

Effect of extrusion process on the obtention of a flour from coffee pulp Coffea arabica variety red Caturra and its use in bakery products

The main waste in the coffee industry is the coffee pulp (CP), an interesting source of fiber and phenolic compounds. An alternative for its harnessing can be its transformation into a flour for human consumption, generating added value for a circular economy. The aim of this study was to obtain flour from CP (CPF) using extrusion and the evaluation of its incorporation into a bakery product. Extrusion treatments to get a flour were explored by a factorial design 23, considering the temperature, moisture, and extruder screw revolutions (rpm). Treatments were evaluated for their effects on the proximal composition, phytic acid, caffeine, and phenolic compounds contents of the flours, and baking characteristics such as water absorption (WAI) and water solubility index (WSI). Once the best extrusion treatment was selected, bread formulations were developed, two wheat-based and two gluten-free, which were evaluated using "Flash Profiling". Extrusion treatment 110 °C, 35% moisture, and 17.5 rpm, was selected as the best one to get a flour with good functional properties (WAI:2.94 ± 0.13, WSI:21.02 ± 3.27) and a content of phenolic compounds: 55.14 mg/g and caffeine:14.23 mg/g. Sensorially, good acceptance, up to 15% substitution by flour, was achieved. Extruded CPF could be a food ingredient, at least in bakery products, contributing in the practice of a circular economy.

Supplementary Information

The online version contains supplementary material available at 10.1007/s13197-023-05797-x.

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.

Preparation of Whole-Cut Plant-Based Pork Meat and Its Quality Evaluation with Animal Meat

Low-moisture (20~40%) and high-moisture (40~80%) textured vegetable proteins (TVPs) can be used as important components of plant-based lean meat, while plant-based fat can be characterized by the formation of gels from polysaccharides, proteins, etc. In this study, three kinds of whole-cut plant-based pork (PBP) were prepared based on the mixed gel system, which were from low-moisture TVP, high-moisture TVP, and their mixtures. The comparisons of these products with commercially available plant-based pork (C-PBP1 and C-PBP2) and animal pork meat (APM) were studied in terms of appearance, taste, and nutritional qualities. Results showed the color changes of PBPs after frying were similar to that of APM. The addition of high-moisture TVP would significantly improve hardness (3751.96~7297.21 g), springiness (0.84~0.89%), and chewiness (3162.44~6466.94 g) while also reducing the viscosity (3.89~10.56 g) of products. It was found that the use of high-moisture TVP led to a significant increase in water-holding capacity (WHC) from 150.25% to 161.01% compared with low-moisture TVP; however, oil-holding capacity (OHC) was reduced from 166.34% to 164.79%. Moreover, essential amino acids (EAAs), the essential amino acids index (EAAI), and biological value (BV) were significantly increased from 272.68 mg/g, 105.52, and 103.32 to 362.65 mg/g, 141.34, and 142.36, respectively, though in vitro protein digestibility (IVPD) reduced from 51.67% to 43.68% due to the high-moisture TVP. Thus, the high-moisture TVP could help to improve the appearance, textural properties, WHC, and nutritional qualities of PBPs compared to animal meat, which was also better than low-moisture TVP. These findings should be useful for the application of TVP and gels in plant-based pork products to improve the taste and nutritional qualities.

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.

Application of transglutaminase modifications for improving protein fibrous structures from different sources by high-moisture extruding

Plant proteins can be extruded under high moisture content (above 40 %) to form meat-like fibrous structures, which is the basis for meat-like substitute products. However, the proteins' extrudability from various sources remain challenging in terms of generating fibrous structures under combinations of high-moisture extrusion with transglutaminase (TGase) modifications. In this study, proteins from soy (soy protein isolate, SPI, and soy protein concentrate, SPC), pea (pea protein isolate, PPI), peanut (peanut protein powder, PPP), wheat (wheat gluten, WG), and rice (rice protein isolate, RPI) were texturized using high-moisture extrusion combined with transglutaminase (TGase) modifications to enact changes in protein structure and extrusion capabilities. The results showed that soy proteins (SPI or SPC) responsed to torque, die pressure and temperature during extrusion, and this phenomenon was more pronounced at a higher protein content (SPI). In contrast, rice protein exhibited poor extrudability, leading to large losses of thermomechanical energy. TGase significantly affects the orientation of protein fibrous structures along the extrusion direction by impacting the rate of protein gelation during the high-moisture extrusion process, with the impact mainly occurring in the cooling die. Globulins (mainly 11S) played a major role in forming fibrous structures and the aggregation of globulins or reduction of gliadins under TGase modification impacted the orientation of the fibrous structure along the extrusion direction. Some thermomechanical treatment during high-moisture extrusion results in protein conversion from compact structure into more extended or stretched state, and the increase of random coil structures for proteins derived from wheat and rice would lead to these looser structures in the extrudates. Thus, TGase can be combined with high-moisture extrusion to regulate the formation of plant protein fibrous structures, dependent on the specific protein source and content.

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.

High-Moisture Extrusion of Mixed Proteins from Soy and Surimi: Effect of Protein Gelling Properties on the Product Quality

The high-moisture extrusion of proteins from plant and animal sources should be a new way for developing alternative protein products with meat-like texture. The protein gelling properties are considered an important factor for the meat-like texture formation during the high-moisture extrusion processing. In this study, the mixed protein gelling properties from soy protein isolate (SPI) and surimi at different ratios (90:10, 80:20, 70:30, 60:40 and 50:50) were investigated to relate to the high-moisture (70%) extruding product textural properties, correspondingly. Results showed that at SPI–surimi ratio 60:40, the heat-induced gelation time was clearly extended and the gel strength became much weaker. During the high-moisture extrusion processing, at SPI–surimi ratio 80:20, the extrudate showed the higher hardness, chewiness, gel strength and fibrous degree, while excessive surimi (more than 40%) in the blends would hinder the fibrous-oriented structure formation. It suggested that SPI may act as the continuous phase that is dispersed by surimi during the high-moisture extrusion processing. Interestingly, it was found that the gel strength of SPI–surimi blends was nonlinearly correlated with the specific mechanical energy (SME) and product textural properties. The study would be helpful for improving the textural properties of alternative protein products from soy and surimi.

Effect of Hydrothermal Cooking Combined with High-Pressure Homogenization and Enzymatic Hydrolysis on the Solubility and Stability of Peanut Protein at Low pH

A novel method combining high-pressure homogenization with enzymatic hydrolysis and hydrothermal cooking (HTC) was applied in this study to modify the structure of peanut protein, thus improving its physicochemical properties. Results showed that after combined modification, the solubility of peanut protein at a pH range of 2–10 was significantly improved. Moreover, the Turbiscan stability index of modified protein in the acidic solution was significantly decreased, indicating its excellent stability in low pH. From SDS-PAGE (Sodium Dodecyl Sulfate PolyAcrylamide Gel Electrophoresis), the high molecular weight fractions in modified protein were dissociated and the low molecular weight fractions increased. The combined modification decreased the particle size of peanut protein from 74.82 to 21.74 μm and shifted the isoelectric point to a lower pH. The improvement of solubility was also confirmed from the decrease in surface hydrophobicity and changes in secondary structure. This study provides some references on the modification of plant protein as well as addresses the possibility of applying peanut protein to acidic beverages.

Physical Properties of Extrudates with Fibrous Structures Made of Faba Bean Protein Ingredients Using High Moisture Extrusion

Faba bean is a potential ingredient due to its high protein yield and its possible cultivation in colder climate regions. In this study, meat analogues made from faba bean protein isolate (FPI) and concentrate (FPC) blends were produced using high moisture extrusion. The aim of this study was to investigate the effect of the FPI content (FPIc), feed water content (FWC), and temperature of the long cooling die (LT) during extrusion on the mechanical and physicochemical properties as well as on the structure of the meat analogues. Increased FPIc resulted in higher values in hardness, gumminess, chewiness, and cutting strengths as well as in darker colour and decreased water absorption capacity. The effect of increased FWC on these properties was weaker and the opposite. Images from microtomography revealed that higher FPIc led to a less organised fibrous structure. In conclusion, fibrous structures can be achieved by utilising a mixture of faba bean protein ingredients, and a higher FPC content seemed to promote fibre formation in the meat analogue.

Blending Proteins in High Moisture Extrusion to Design Meat Analogues: Rheological Properties, Morphology Development and Product Properties

High moisture extrusion (HME) of meat analogues is often performed with raw materials containing multiple components, e.g., blends of different protein-rich raw materials. For instance, blends of soy protein isolate (SPI) and another component, such as wheat gluten, are used particularly frequently. The positive effect of blending on product texture is well known but not yet well understood. Therefore, this work targets investigating the influence of blending in HME at a mechanistic level. For this, SPI and a model protein, whey protein concentrate (WPC), were blended at three different ratios (100:0, 85:15, 70:30) and extruded at typical HME conditions (55% water content, 115/125/133 °C material temperature). Process conditions, rheological properties, morphology development, product structure and product texture were analysed. With increasing WPC percentage, the anisotropic structures became more pronounced and the anisotropy index (AI) higher. The achieved AI from the extrudates with a ratio of 70:30 (SPI:WPC) were considerably higher than comparable extrudates reported in other studies. In all extrudates, a multiphase system was visible whose morphology had changed due to the WPC addition. The WPC led to the formation of a much smaller dispersed phase compared to the overlying multiphase structure, the size of which depends on the thermomechanical stresses. These findings demonstrate that targeted mixing of protein-rich raw materials could be a promising method to tailor the texture of extruded meat analogues.

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.

Extrusion cooking of protein-based products: potentials and challenges

Extrusion cooking is receiving increasing attention as technology applied for the production of protein-based products. Researchers in this field showed that proteins from several sources are barely consumed because of their poor functionality and lack of acceptability related to the presence of some antinutritional factors. In this regard, extrusion is becoming of key importance thanks to its ability to improve protein functional properties. Based on this remarkable advantage, several studies have been published so far providing evidence of the enhanced functional, physicochemical and sensory properties of protein-based extruded products. The objective of the present review is to give a detailed overview of the potential of extrusion for the production of protein-based products. More specifically, the work describes all the studies published so far on vegetable and animal proteins including those recently released applying the technology on insect proteins. The aspects related to the functional properties of the extrudates together with the quality changes occurring during the process are also described to highlight the potential of the technology for future applications.

Converting Peanut Protein Biomass Waste into "Double Green" Meat Substitutes Using a High-Moisture Extrusion Process: A Multiscale Method to Explore a Process for Forming a Meat-Like Fibrous Structure

Converting peanut protein biomass waste into environmentally friendly meat substitutes by a high-moisture extrusion process can help solve both resource and waste problems and be "double green". A multiscale method combined with some emerging techniques such as atomic force microscopy-based infrared spectroscopy and X-ray microscopy was used to make the whole extrusion process visible to show the process of forming a meat-like fibrous structure using two-dimensional and three-dimensional perspectives. The results showed that the protein molecules underwent dramatic structural changes and unfolded in the extruder barrel, which created favorable conditions for molecular rearrangement in the subsequent zones. It was confirmed that the meat-like fibrous structure started to form at the junction of the die and the cooling zone and that this structure was caused by the phase separation and rearrangement of protein molecules in the cooling zone. Moreover, the interactions between hydrogen bonds and disulfide bonds formed in the cooling zone maintained the meat-like fibrous structure with an α-helix > β-sheet > β-turn > random coil. Of the two main peanut proteins, arachin played a greater role in forming the fibrous structure than conarachin, especially those subunits of arachin with a molecular weight of 42, 39, and 22 kDa.