3D Printing of Textured Soft Hybrid Meat Analogues

State of the art, challenges, and future prospects for the multi-material 3D printing of plant-based meat

The emergence of innovative plant-based meat analogs, replicating the flavor, texture, and appearance of animal meat cuts, is deemed crucial for sustainably feeding a growing population while mitigating the environmental impact associated with livestock farming. Multi-material 3D food printing (MM3DFP) has been proposed as a potentially disruptive technology for manufacturing the next generation of plant-based meat analogs. This article provides a comprehensive review of the state of the art, addressing various aspects of 3D printing in the realm of plant-based meat. The disruptive potential of printed meat analogs is discussed with particular emphasis on protein-rich, lipid-rich, and blood-mimicking food inks. The printing parameters, printing requirements, and rheological properties at the different printing stages are addressed in detail. As food rheology plays a key role in the printing process, an appraisal of this subject is performed. Post-printing treatments are assessed based on the extent of improvement in the quality of 3D-printed plant-based meat analogs. The meat-mimicking potential is revealed through sensory attributes, such as texture and flavor. Furthermore, there has been limited research into food safety and nutrition. Economically, the 3D printing of plant-based meat analogs demonstrates significant market potential, contingent upon innovative decision-making strategies and supportive policies to enhance consumer acceptance. This review examines the current limitations of this technology and highlights opportunities for future developments.

Restructuring plant-derived composites towards the production of meat-analog based coated fried food

This study utilized different plant-based composites to develop restructured meat-analog (MA). Physicochemical, thermal, mechanical, structural, and sensory properties of formulated MA as well as batter-coated fried MAs were studied, and compared with a commercial product. Protein (23.27-24.68 %), moisture (57.05-58.78 %), pH (7.19-7.57), color (L:64.76-66.84, a:0.62-1.98, b:18.84-20.49), and textural (MF:0.22-0.52 N, GF:0.07-0.24 N/sec, FA:0.74-1.92 N.sec) attributes of formulated MAs were substantially impacted by the ratio of soy-protein-isolate (SPI) and wheat-gluten (WG). Incorporation of higher WG and lower SPI resulted in the formation of chicken-like fibrous and porous structure, hence, increased consumers acceptability of MA-based coated fried products. Microporosity (crust:51.14-58.35 %, core: 63.57-71.55 %), surface opening (5.67-14.75 %), and fractal dimension (2.586-2.402) of coated fried MAs were dependent on the formulation of batter-coating. MA-based coated fried products surface moisture-fat (SMR:0.51-187.20 au; SFR: 2.01-20.17 au) profile significantly (p < 0.05) varied with the formulations of batter-coating. Negative glass-transition-temperature (around -23 °C) is prime concern for MA-based fried products stability at room environment.

Protein and protein-polysaccharide composites-based 3D printing: The properties, roles and opportunities in future functional foods

The food industry is undergoing a significant transformation with the advancement of 3D technology. Researchers in the field are increasingly interested in using protein and protein-polysaccharide composite materials for 3D printing applications. However, maintaining nutritional and sensory properties while guaranteeing printability of these materials is challenging. This review examines the commonly used protein and composite materials in food 3D printing and their roles in printing inks. This review also outlines the essential properties required for 3D printing, including extrudability, appropriate viscoelasticity, thixotropic properties, and gelation properties. Furthermore, it explores the wide range of potential applications for 3D printing technology in novel functional foods such as space food, dysphagia food, kid's food, meat analogue, and other specialized food products.

Personalized nutrition with 3D-printed foods: A systematic review on the impact of different additives

Three-dimensional (3D) printing is one of the world's top novel technologies in the food industry due to the production of food in different conditions and places (restaurants, homes, catering, schools, for dysphagia patients, and astronauts' food) and the production of personalized food. Nowadays, 3D printers are used in the main food industries, including meat, dairy, cereals, fruits, and vegetables, and have been able to produce successfully on a small scale. However, due to the expansion of this technology, it has challenges such as high-scale production, selection of printable food, formulation optimization, and food production according to the consumer's opinion. Food additives (gums, enzymes, proteins, starches, polyphenols, spices, probiotics, algae, edible insects, oils, salts, vitamins, flavors, and by-products) are one of the main components of the formulation that can be effective in food production according to the consumer's attitude. Food additives can have the highest impact on textural and sensory characteristics, which can be effective in improving consumer attitudes and reducing food neophobia. Most of the 3D-printed food cannot be printed without the presence of hydrocolloids, because the proper flow of the selected formulation is one of the key factors in improving the quality of the printed product. Functional additives such as probiotics can be useful for specific purposes and functional food production. Food personalization for specific diseases with 3D printing technology requires a change in the formulation, which is closely related to the selection of correct food additives. For example, the production of 3D-printed plant-based steaks is not possible without the presence of additives, or the production of food for dysphagia patients is possible in many cases by adding hydrocolloids. In general, additives can improve the textural, rheological, nutritional, and sensory characteristics of 3D printed foods; so, investigating the mechanism of the additives on all the characteristics of the printed product can provide a wide perspective for industrial production and future studies.

Investigation on 3D printing of shrimp surimi under different printing parameters and thermal processing conditions

Improving the printing accuracy and stability of shrimp surimi and finding appropriate printing parameters and suitable thermal processing method can help to develop high value-added 3D printing products of shrimp surimi. It was found that in order to make the 3D printing products of shrimp surimi have higher printing adaptability (printing accuracy and printing stability reach more than 97%), by choosing nozzle diameter of 1.20 mm and setting the printing height of the nozzle to 2.00 mm, the layers of the printed products were better fused with each other, and the printing accuracy of the products could be greatly improved; there was no uneven discharge and filament breakage when the nozzle moved at the speed of 30 mm/s; and the products were internally compact and had good stability when the printing filling rate was 80%. In addition, the deformation rates of steamed, boiled and deep-fried shrimp surimi products were significantly higher than those of oven-baked and microwaved shrimp surimi products (P < 0.05). Microwave heating had a greater effect on the deformation and color of shrimp surimi products, and was not favored by the evaluators. In terms of deformation rate, sensory score, and textural characteristic, the oven-baked thermal processing method was selected to obtain higher sensory evaluation scores and lower deformation rates of shrimp surimi 3D printed products. In the future, DIY design can be carried out in 3D printing products of shrimp surimi to meet the needs of different groups of people for modern food.

3D/4D printed super reconstructed foods: Characteristics, research progress, and prospects

Super reconstructed foods (SRFs) have characteristics beyond those of real system in terms of nutrition, texture, appearance, and other properties. As 3D/4D food printing technology continues to be improved in recent years, this layered manufacturing/additive manufacturing preparation technology based on food reconstruction has made it possible to continuously develop large-scale manufacture of SRFs. Compared with the traditional reconstructed foods, SRFs prepared using 3D/4D printing technologies are discussed comprehensively in this review. To meet the requirements of customers in terms of nutrition or other characteristics, multi-processing technologies are being combined with 3D/4D printing. Aspects of printing inks, product quality parameters, and recent progress in SRFs based on 3D/4D printing are assessed systematically and discussed critically. The potential for 3D/4D printed SRFs and the need for further research and developments in this area are presented and discussed critically. In addition to the natural materials which were initially suitable for 3D/4D printing, other derivative components have already been applied, which include hydrogels, polysaccharide-based materials, protein-based materials, and smart materials with distinctive characteristics. SRFs based on 3D/4D printing can retain the characteristics of deconstruction and reconstruction while also exhibiting quality parameters beyond those of the original material systems, such as variable rheological properties, on-demand texture, essential printability, improved microstructure, improved nutrition, and more appealing appearance. SRFs with 3D/4D printing are already widely used in foods such as simulated foods, staple foods, fermented foods, foods for people with special dietary needs, and foods made from food processingbyproducts.

Towards Sustainable Protein Sources: The Thermal and Rheological Properties of Alternative Proteins

Reducing meat consumption reduces carbon emissions and other environmental harms. Unfortunately, commercial plant-based meat substitutes have not seen widespread adoption. In order to enable more flexible processing methods, this paper analyzes the characteristics of commercially available spirulina, soy, pea, and brown rice protein isolates to provide data for nonmeat protein processing that can lead to cost reductions. The thermal and rheological properties, as well as viscosity, density, and particle size distribution, were analyzed for further study into alternative protein-based food processing. The differential scanning calorimetry analysis produced dry amorphous-shaped curves and paste curves with a more distinct endothermic peak. The extracted linear temperature ranges for processing within food production were 70-90 °C for spirulina, 87-116 °C for soy protein, 67-77 °C for pea protein, and 87-97 °C for brown rice protein. The viscosity analysis determined that each protein material was shear-thinning and that viscosity increased with decreased water concentration, with rice being an exception to the latter trend. The obtained viscosity range for spirulina was 15,100-78,000 cP, 3200-80,000 cP for soy protein, 1400-32,700 cP for pea protein, and 600-3500 cP for brown rice protein. The results indicate that extrusion is a viable method for the further processing of protein isolates, as this technique has a large temperature operating range and variable screw speed. The data provided here can be used to make single or multi-component protein substitutes.

Challenges and Prospects of Plant-Protein-Based 3D Printing

Three-dimensional (3D) printing is a rapidly developing additive manufacturing technique consisting of the deposition of materials layer-by-layer to produce physical 3D structures. The technique offers unique opportunities to design and produce new products that cater to consumer experience and nutritional requirements. In the past two decades, a wide range of materials, especially plant-protein-based materials, have been documented for the development of personalized food owing to their nutritional and environmental benefits. Despite these benefits, 3D printing with plant-protein-based materials present significant challenges because there is a lack of a comprehensive study that takes into account the most relevant aspects of the processes involved in producing plant-protein-based printable items. This review takes into account the multi-dimensional aspects of processes that lead to the formulation of successful printable products which includes an understanding of rheological characteristics of plant proteins and 3D-printing parameters, as well as elucidating the appropriate concentration and structural hierarchy that are required to maintain stability of the substrate after printing. This review also highlighted the significant and most recent research on 3D food printing with a wide range of plant proteins. This review also suggests a future research direction of 3D printing with plant proteins.

An Overview of Ingredients Used for Plant-Based Meat Analogue Production and Their Influence on Structural and Textural Properties of the Final Product

Plant-based meat analogues are food products made from vegetarian or vegan ingredients that are intended to mimic taste, texture and appearance of meat. They are becoming increasingly popular as people look for more sustainable and healthy protein sources. Furthermore, plant-based foods are marketed as foods with a low carbon footprint and represent a contribution of the consumers and the food industry to a cleaner and a climate-change-free Earth. Production processes of plant-based meat analogues often include technologies such as 3D printing, extrusion or shear cell where the ingredients have to be carefully picked because of their influence on structural and textural properties of the final product, and, in consequence, consumer perception and acceptance of the plant-based product. This review paper gives an extensive overview of meat analogue components, which affect the texture and the structure of the final product, discusses the complex interaction of those ingredients and reflects on numerous studies that have been performed in that area, but also emphasizes the need for future research and optimization of the mixture used in plant-based meat analogue production, as well as for optimization of the production process.

3D printable vegan plant-based meat analogue: Fortification with three different mushrooms, investigation of printability, and characterization

In this study, a meat analogue formulation prepared using different protein sources as a printable ink for 3D printers and fortified with three different mushroom cultivars (reishi, Ganoderma lucidum (GL); saffron milk-cap, Lactarius deliciosus (LD); and oyster, Pleurotus ostreatus (PO)). 3D printing performance of the prepared inks was evaluated by factorial design in terms of nozzle height, printing speed, and flow compensation. New methods of maximum layer height and reprintability of plant-based meat analogues were conducted for the first time. Inks were characterized by analyzing rheological properties, microstructure, color characteristics, texture profile, cooking loss, amino acid content, and sensory evaluation. Results showed that the nozzle height and printing speed were found to be most effective on accuracy of prints and smoothness of layers. All inks (C, GL, LD and PO) represented shear-thinning and gel-like viscoelastic behavior (G' > G″) with predominant elasticity (tan δ < 1). Therefore they were suited for 3D printing and possessed supporting the following layers for additive manufacturing as well as meeting the criteria for a stable structure. Meat analogue was printed successfully without perceived defects in all formulations, except the GL was looking linty. LD and PO inks brought the advantage of recycling as a result of their re-printability whereas GL could not. Moreover, mushroom fortification reduced hardness, stiffness, springiness, and chewiness properties of the meat analogues whereas it increased the juiciness with reasonable overall acceptance. Mushroom fortification also enhanced the nutritional value and improved release of umami amino acids. The findings of the study demonstrated that mushrooms could be a functional and nutritious candidate for 3D printable plant-based meat analogues.

Addressing Clean Label Trends in Commercial Meat Processing: Strategies, Challenges and Insights from Consumer Perspectives

BACKGROUND

The concept of a clean label is difficult to define, even in common language, as the interpretation of what a "clean" food is differs from one person to another and from one organisation to another. The lack of a unique definition and regulations of what the term "clean" means, along with the growing consumer demand for more "natural" and healthier foods, is posing new challenges for manufacturers and ingredient producers. The meat industry, in particular, has been affected by this new movement owing to negative attitudes and feelings consumers associate with consuming processed meat products. Scope and approach: The review scope is to describe attributes and associations around the "clean" label term by analysing the most recent ingredients, additives and processing methods currently available for meat manufacturers. Their application in meat, plant-based alternatives and hybrid meat/plant products, current limitations and challenges presented in consumer perception, safety and potential impacts on product quality are also presented.

KEY FINDINGS AND CONCLUSIONS

The availability of a growing number of "clean" label ingredients provides a new suite of approaches that are available for application by meat processors to help overcome some of the negative connotations associated with processed meat products and also support plant-based meat alternatives and hybrids.

Physico-chemical and Textural Properties of 3D Printed Plant-based and Hybrid Soft Meat Analogs

This study investigated the physico-chemical and textural properties of 3D-printed pea protein-only and pea protein-chicken-based hybrid meat analogs. Both pea protein isolate (PPI)-only and hybrid cooked meat analogs had a similar moisture content of approximately 70%, which was similar to that of chicken mince. However, the protein content increased significantly with the amount of chicken in the hybrid paste undergoing 3D printing and cooking. Significant differences were observed in the hardness values of the non-printed cooked pastes and the 3D printed cooked counterparts, suggesting that the 3D printing process reduces the hardness of the samples and is a suitable method to produce a soft meal, and has significant potential in elderly health care. Scanning electron microscopy (SEM) revealed that adding chicken to the plant protein matrix led to better fiber formation. PPI itself was not able to form any fibers merely by 3D printing and cooking in boiling water. Protein-protein interactions were also studied through the protein solubility test, which indicated that hydrogen bonding was the major bonding that contributed to the structure formation in cooked printed meat analogs. In addition, disulfide bonding was correlated with improved fibrous structures, as observed through SEM.

Integrated design of micro-fibrous food with multi-materials fabricated by uniaxial 3D printing

Owing to the interest in sustainable foods, a new approach known as 3D food printing is being employed to make fibrous foods for meat and fish substitutes. In this study, we developed a filament structure with a multi-material ink comprising fish surimi-based ink (SI) and plant-based ink (PI), using single-nozzle printing and steaming. PI and an SI + PI mix collapsed after printing owing to their low shear modulus, although both PI and SI showed gel-like rheological behaviors. However, unlike the control, the objects printed with two and four columns per filament remained stable and fiberized after steaming. Each SI and PI sample gelatinized irreversibly at approximately 50 °C. The different rheological values of these inks after cooling resulted in relatively strong (PI) and weak (SI) fibers, which constructed a filament matrix. A cutting test demonstrated that the transverse strength of the fibrous structure of the printed objects was higher than the longitudinal strength, in contrast to that of the control. The degree of texturization increased with the fiber thickness based on the column number or nozzle size. Thus, we successfully designed a fibrous system using printing and post-processing and substantially broadened the application opportunities for creating fibril matrices for sustainable food analogs.

Fermentation for Designing Innovative Plant-Based Meat and Dairy Alternatives

Fermentation was traditionally used all over the world, having the preservation of plant and animal foods as a primary role. Owing to the rise of dairy and meat alternatives, fermentation is booming as an effective technology to improve the sensory, nutritional, and functional profiles of the new generation of plant-based products. This article intends to review the market landscape of fermented plant-based products with a focus on dairy and meat alternatives. Fermentation contributes to improving the organoleptic properties and nutritional profile of dairy and meat alternatives. Precision fermentation provides more opportunities for plant-based meat and dairy manufacturers to deliver a meat/dairy-like experience. Seizing the opportunities that the progress of digitalization is offering would boost the production of high-value ingredients such as enzymes, fats, proteins, and vitamins. Innovative technologies such as 3D printing could be an effective post-processing solution following fermentation in order to mimic the structure and texture of conventional products.

Production of Fish Analogues from Plant Proteins: Potential Strategies, Challenges, and Outlook

Fish products are consumed by human beings as a high-quality protein source. However, overfishing, and pollution puts out an urgent call to seek a new strategy to substitute fish protein for secure eco-sustainability. Plant-based fish analogs, which mimic the structure, texture, and flavor of fish meat products, are a rapid-growing segment of the food products. The purpose of this review is to discuss the feasibility and potential strategies for developing plant-based fish analog. The nutritional properties, especially the protein quality of plant-based fish analogs, were discussed. Furthermore, a thorough comparison was made between fish and terrestrial animal muscle structures, including both macroscopical and microscopical structures. Potential processing technologies for producing plant-based fish analogs from plant proteins and approaches for the characterization of the fish analog structures were elaborated. Comparing all the current processing techniques, extrusion is the predominately used technique in the current industry. At the same time, 3D-printing and electrospinning have shown the prominent potential of mimicking fish muscle structure as bottom-up approaches. Finally, key challenges and future research were discussed for the potential commercialization of plant-based fish analogues. The primary focus of this review covers the innovative works that were indexed in the Web of Science Core Collection in the past five years.

Consumer acceptance of new food trends resulting from the fourth industrial revolution technologies: A narrative review of literature and future perspectives

The growing consumer awareness of climate change and the resulting food sustainability issues have led to an increasing adoption of several emerging food trends. Some of these trends have been strengthened by the emergence of the fourth industrial revolution (or Industry 4.0), and its innovations and technologies that have fundamentally reshaped and transformed current strategies and prospects for food production and consumption patterns. In this review a general overview of the industrial revolutions through a food perspective will be provided. Then, the current knowledge base regarding consumer acceptance of eight traditional animal-proteins alternatives (e.g., plant-based foods and insects) and more recent trends (e.g., cell-cultured meat and 3D-printed foods) will be updated. A special focus will be given to the impact of digital technologies and other food Industry 4.0 innovations on the shift toward greener, healthier, and more sustainable diets. Emerging food trends have promising potential to promote nutritious and sustainable alternatives to animal-based products. This literature narrative review showed that plant-based foods are the largest portion of alternative proteins but intensive research is being done with other sources (notably the insects and cell-cultured animal products). Recent technological advances are likely to have significant roles in enhancing sensory and nutritional properties, improving consumer perception of these emerging foods. Thus, consumer acceptance and consumption of new foods are predicted to continue growing, although more effort should be made to make these food products more convenient, nutritious, and affordable, and to market them to consumers positively emphasizing their safety and benefits.

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.