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

Toward Diverse Plant Proteins for Food Innovation

This review highlights the development of plant proteins from a wide variety of sources, as most of the research and development efforts to date have been limited to a few sources including soy, chickpea, wheat, and pea. The native structure of plant proteins during production and their impact on food colloids including emulsions, foams, and gels are considered in relation to their fundamental properties, while highlighting the recent developments in the production and processing technologies with regard to their impacts on the molecular properties and aggregation of the proteins. The ability to quantify structural, morphological, and rheological properties can provide a better understanding of the roles of plant proteins in food systems. The applications of plant proteins as dairy and meat alternatives are discussed from the perspective of food structure formation. Future directions on the processing of plant proteins and potential applications are outlined to encourage the generation of more diverse plant-based products.

Structural and functional properties of a high moisture extruded mixture of pea proteins (Pisum sativum), amaranth flour (Amaranthus hypochondriacus), and oat flour (Avena sativa)

Textured vegetable proteins (TVP) are an alternative to meet the increasing demand for non-animal food. This study aimed to develop a TVP from mixtures with 45 % pea protein isolate (PPI) enriched with amaranth (AF) and oat (OF) flours using high-moisture extrusion technology (HME) varying the moisture (50-70 %) and the temperature in the second heating zone of the extruder (110-140 °C). After extrusion, all samples demonstrated higher values of water absorption capacity (WAC) than non-extruded mixtures. Mixture of AF:OF:PPI (40:15:45 %) extruded at 60 % moisture and 135 °C showed promising functional properties with WAC and WSI values of 3.2 ± 0.2 g H2O/g and 24.89 ± 2.31 %, respectively, and oil absorption capacity (OAC) of 1.3 g oil/g. The extrusion process altered the thermal and structural properties of proteins promoting a desirable fibrous structure. This confirms the feasibility of using HME to develop TVP based on PPI, AF, and OF.

The impact of temperature gradient, apparent shear rate, and inferred phase transition timing on extruded high moisture meat analog quality

Scalability of the cooling die unit operation is critical to lowering the manufacturing cost of high moisture meat analogs(HMMA), but it is unclear what scale-up criteria are important. An experiment consisting of two cooling die cross-section geometries (tall and narrow or short and wide), two production rates (2.7 or 4.5 kg/hr) and 4 cooling media inlet temperatures (36, 48, 60, and 72 °C) was employed to study their effect on product texture, anisotropy, and extrusion system parameters. Comprehensive temperature measurements were made along the dies to observe the product temperature gradient and to quantify the energy balance associated with cooling. It was found that textural hardness had a positive relationship with axial temperature gradient (p < 0.05), while anisotropy had a negative and positive relationship with axial temperature gradient and die height, respectively (p < 0.05). Extruder motor torque and die inlet pressure were found to be functions of the cooling media inlet temperature and apparent Newtonian shear rate applied to the material in the die (p < 0.05). The energy balance indicated that enhanced anisotropy is associated with more exothermic in-situ phase changes, which are controlled by the product formulation and applied die conditions. There are likely 3 scalable variables most relevant to controlling the HMMA product quality: 2 critical phase transition temperatures, and the axial product temperature gradient. Therefore, scaling up HMMA cooling dies will require balancing the heat transfer rate away from the product such that an optimal product temperature profile can be maintained at scale.

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.

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.

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.

Techno-functional properties of dry-fractionated plant-based proteins and application in food product development: a review

Dry-fractionated protein concentrates are gaining attention because they are produced using a versatile and sustainable technology, which can be applied to a wide range of plant material. To facilitate their utilization in new product development, it is crucial to obtain a comprehensive overview of their techno-functional properties. The present review aims to examine the techno-functional properties of dry-fractionated protein concentrates and describe their primary applications in food products, considering the published works in the last decade. The techno-functional properties of proteins, including water absorption capacity, emulsifying and foaming properties, gelling ability or protein solubility, are relevant factors to consider during food formulation. However, these properties are significantly influenced by the extraction technology, the type of protein and its characteristics. Overall, dry-fractionated proteins are characterized by high protein solubility, high foaming ability and foam stability, and high gelling ability. Such properties have been exploited in the development of food, such as bakery products and pasta, with the aim of increasing the protein content and enhancing the nutritional value. Additionally, innovative foods with distinctive textural and nutritional characteristics, such as meat and dairy analogues, have been developed by using dry-fractionated proteins. The results indicate that the study of these ingredients still needs to be improved, including their application with a broader range of plant materials. Nevertheless, this review could represent an initial step to obtaining an overview of the techno-functional properties of dry-fractionated proteins, facilitating their use in foods. © 2023 The Authors. Journal of The Science of Food and Agriculture published by John Wiley & Sons Ltd on behalf of Society of Chemical Industry.

B Vitamins in Legume Ingredients and Their Retention in High Moisture Extrusion

Legumes have been recognised as healthy and environmentally friendly protein sources. Knowledge about the vitamin B contents in legume ingredients and extrudates is scarce. In this study, we investigated thiamin, riboflavin, niacin, and folate in various faba bean, lupin, and pea ingredients. Further, the retention of B vitamins in high moisture extrusion was studied. Prior to liquid chromatographic determinations of thiamin, riboflavin, niacin, and folate, vitamins were extracted by acid hydrolysis (niacin), enzymatic treatment (folate), or their combination (thiamin and riboflavin). The contents (on a dry matter basis) varied greatly among different ingredients: the thiamin content was 0.2-14.2 µg/g; riboflavin, 0.3-5.9 µg/g; niacin, 8.8-35.5 µg/g, and folate, 45-1453 ng/g. Generally, the highest levels were in flours and protein concentrates, whereas low levels were observed in isolates. The retention of B vitamins was excellent in high moisture extrusion, except for folate in faba bean, where the folate contents were 42-67% lower in the extrudates than in the respective ingredient mixtures. In terms of both vitamin B contents and their retention, extrudates containing substantial amounts of flour or protein concentrate are promising plant-based sources of thiamin, riboflavin, niacin, and folate.

Characterization of the mechanical properties of high-moisture meat analogues using low-intensity ultrasound: Linking mechanical properties to textural and nutritional quality attributes

Plant-based meat analogues offer possible alternatives to meat consumption. However, many challenges remain to produce a palatable meat analogue as well as to understand the roles of different processing steps and ingredients on both the texture and nutritional properties of the final product. The goal of this paper is to help with addressing these challenges by using a low-intensity ultrasonic transmission technique, both online and 24 h after production, to investigate high-moisture meat analogues made from a blend of soy and wheat proteins. To understand the ultrasonic data in the context of traditional characterization methods, physical properties (meat analogue thickness, density, peak cutting force) and protein nutritional quality attributes of the meat analogues were also characterized separately. The ultrasonic velocity was found to decrease with the feed moisture content and to be strongly correlated (r = 0.97) with peak cutting force. This strong correlation extends over a wide range of moisture contents from 58% to 70%, with the velocity decreasing from about 1730 m/s to 1660 m/s over this range. The protein quality was high for all moistures, with the highest amino acid score and in vitro protein digestibility being observed for the highest moisture content treatment. The accuracy of the ultrasonic measurements was enhanced by the development of an innovative non-contact method, suitable for materials exhibiting low ultrasonic attenuation, to measure the meat analogue thickness ultrasonically and in a sanitary fashion - an advance that is potentially useful for online monitoring of production problems (e.g., extruder barrel-fill and cooling-die temperature issues). This study demonstrates, for the first time, the feasibility of using ultrasonic transmission techniques to measure both velocity and sample thickness simultaneously and provide information in real time during production that is well correlated with some textural and nutritional attributes of meat analogues.

Effects of Feed Moisture Content on the Physical and Nutritional Quality Attributes of Sunflower Meal-based High-Moisture Meat Analogues

Adding value to food industry by-products, like sunflower meal (SFM), through their utilization as ingredients in new food products can improve sustainability of food systems. This research investigated extrusion cooking to produce high-moisture meat analogues (HMMAs) made from blends of soy protein isolate and expeller-pressed SFM. The effects of feed moisture content [FMC] (60, 65, and 70%, wet basis) and SFM concentration (37.5, 50, and 62.5%, total blend weight basis) on physical and protein nutritional quality attributes of HMMAs were investigated. The processing temperatures (including cooling die), screw speed and feed rate were kept constant at 60-80-115-125-50-25 °C (from feeder to the die end), 200 rpm and 0.5 kg/h (dry basis), respectively. An increase in SFM concentration and FMC significantly (p < 0.05) reduced the mechanical energy requirements for extrusion. Cutting strength and texture profile analysis of HMMAs indicated softer texture with increases in SFM and FMC. X-ray microcomputed tomography analysis revealed that the microstructure of the HMMAs at the centre and towards the surface was different and affected by SFM concentration and FMC. The in vitro-protein digestibility corrected amino acid score of the HMMAs ranged between 85 and 91% and did not show significant (p < 0.05) changes as a function of FMC or SFM concentration. HMMAs produced from 37.5% SFM at 70% FMC showed no deficiency in essential amino acids for all age categories except for infants, suggesting the high potential of SFM and soy protein blends for creating nutritious meat alternative products. Overall, this work provided valuable insights regarding the effects of soy protein replacement by SFM on the textural, microstructural and nutritional quality of HMMA applications, paving the way for value-addition to this underutilized food industry by-product.

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.

Characterization of texturized meat analogues containing native lupin flour and lupin protein concentrate/isolate

Lupin is a nutritious, yet undervalued grain used as a fodder and food crop. In the present study, native lupin flour (LF), lupin protein concentrate (LPC), and lupin protein isolate (LPI) were combined (70% LPI:LPC blend ratios [30:70, 50:50, and 70:30] and 30% LF constant fraction), extruded at high moisture (45-55%), and shaped with a long cooling die (800 mm) to obtain texturized meat analogues (TMAs) with fibrous structures. The characteristics of TMAs (e.g., hardness, water hydration capacity) depended heavily on water content, blend ratios (LPI:LPC), and to a lesser extent, the long cooling die temperature. Color changes (i.e., L*, b*) were mostly attributed to variations in blend ratios (LPI:LPC). Microstructure analysis showed that TMAs with higher water content (55%) were more likely to have thinner walls and smaller void thickness. Fluorescence imagery revealed that TMAs with lower LPI content presented more homogeneous structures. These findings show that reasonable amounts (30% d.m.) of native lupin flour can be incorporated into meat analogues by maintaining a sufficiently high protein content (>50% d.m.) to trigger the formation of fibrous structures.

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.

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.

Fermentation Conditions Affect the Synthesis of Volatile Compounds, Dextran, and Organic Acids by Weissella confusa A16 in Faba Bean Protein Concentrate

Fermentation with Weissella confusa A16 could improve the flavor of various plant-based sources. However, less is known about the influence of fermentation conditions on the profile of volatile compounds, dextran synthesis and acidity. The present work investigates the synthesis of potential flavor-active volatile compounds, dextran, acetic acid, and lactic acid, as well as the changes in viscosity, pH, and total titratable acidity, during fermentation of faba bean protein concentrate with W. confusa A16. A Response Surface Methodology was applied to study the effect of time, temperature, dough yield, and inoculum ratio on the aforementioned responses. Twenty-nine fermentations were carried out using a Central Composite Face design. A total of 39 volatile organic compounds were identified: 2 organic acids, 7 alcohols, 8 aldehydes, 2 alkanes, 12 esters, 3 ketones, 2 aromatic compounds, and 3 terpenes. Long fermentation time and high temperature caused the formation of ethanol and ethyl acetate and the reduction of hexanal, among other compounds linked to the beany flavor. Levels of dextran, acetic acid, and lactic acid increased with increasing temperature, time, and dough yield. Optimal points set for increased dextran and reduced acidity were found at low temperatures and high dough yield. Such conditions would result in hexanal, ethyl acetate and ethanol having a relative peak area of 35.9%, 7.4%, and 4.9%, respectively.

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.