Structure Design for Improving the Characteristic Attributes of Extruded Plant-Based Meat Analogues

Exploring new plant-based products: Acceptance of sunflower meal as a protein source in meat alternative products

In response to growing consumer demand for sustainable and plant-based food options, sunflower meal, a byproduct of oil extraction, emerges as a promising protein source. This study explores the potential of sunflower semi-defatted meal to create meat alternative mixes (MAMs) with a balanced nutritional profile and desirable sensory attributes. Two MAM formulations were developed: one incorporating toasted sunflower kernels (MAMk) and the other utilizing texturized protein sunflower (MAMt). Both formulations were enriched with tomato powder, spices, and a lipid matrix comprising sunflower, olive, and linseed oils. The doughs were shaped into mini-burger format and baked. Sensory evaluation revealed a preference for the MAMt formulation, which exhibited superior texture. Physical-chemical analysis confirmed MAMt's nutritional value, highlighting its high lipid (38.15 %) particularly monounsaturated fatty acids (41.98 % of the total lipid composition) and protein (20.10 %) content all essential amino acids (lysine limiting amino acid with 0.8 score). Moreover, MAMt demonstrated significant mineral content, especially iron, zinc, magnesium, and manganese (49 %, 68 %, 95 % and 89 %, respectivally, regarding recommended daily intake). While further refinement is necessary to optimize flavor, the study underscores the potential of sunflower meal to contribute to a more sustainable food system and provide consumers with a nutritious and appealing plant-based protein alternative.

Perforated imprinting on high moisture meat analogue confers long range mechanical anisotropy resembling meat cuts

Meat cuts, when cooked and masticated, separate into fibrous structures because of the long-range mechanical anisotropy (LMA) exhibited by muscle fascicles, which is not fully recapitulated in alternative proteins produced using molecular alignment technology like high moisture extrusion. We have developed a scalable perforated micro-imprinting technology to greatly enhance LMA in high moisture meat analogue (HMMA). By imprinting 1 mm thick HMMA sheets with perforated patterns (optimized by AI), we observed up to 5 × more anisotropic separation of fibrous structures in a one-dimensional pulling LMA analysis, to match the fibrousness of the cooked chicken breast, duck breast, pork loin and beef loin. We stacked and bound imprinted sheets with transglutaminase (TG) to produce imprinted whole-cuts. Controlling fiber separation in the imprinted cuts achieved hardness ranging from 6578 g to 18467 g (2 cm × 2 cm × 1 cm, 50% strain), which matched meats from different species. Imprinted cuts improved meat-like fiber separation over HMMA when masticated, measured by Euclidean distances (0.057 and 0.106 respectively) to animal meat cuts on image features. In sensory evaluation, imprinted cuts improved consumer acceptance by 33.3% and meat-like fibrousness by 20%, by significantly enhancing the HMMA appearance, texture, and mouthfeel.

Plant-based Meat Analogs: Perspectives on Their Meatiness, Nutritional Profile, Environmental Sustainability, Acceptance and Challenges

PURPOSE OF REVIEW

Plant-based meat analogs (PBMAs) have been the subject of interest over the past few years due to consumers' demand for environmentally friendly, healthful, and non-animal-based foods. A better comprehension of the composition, structure, texture, nutrition, and sustainability of these PBMAs is necessary.

RECENT FINDINGS

This review articulates the protein sources and composition of PBMAs and their "meatiness" with respect to texture, structure, and flavor enhancement. The components used in the analogs, such as unsaturated fats, fibers, vitamins, minerals, carbohydrates, and plant-based oils enriching their nutritional profile, are described. The study identifies the environmental and sustainability impact of PBMAs, as crucial to the survival and maintenance of biodiversity. More studies are warranted to scope and underscore the significance of the analogs and comprehend the texture or structure-function relationships. Further product development and testing thereof may ultimately result in quality meat analogs that respect meat taste, health and acceptance of consumers, environmental sustainability, animal welfare, and current challenges.

Effect of sonoprocessing on the quality of plant-based analog foods: Compatibility to sustainable development goals, drawbacks and limitations

Sonoprocessing (US), as one of the most well-known and widely used green processing techniques, has tremendous benefits to be used in the food industry. The urgent call for global sustainable food production encourages the usage of such techniques more often and effectively. Using ultrasound as a hurdle technology synergistically with other green methods is crucial to improving the efficiency of the protein shift as well as the number of plant-based analog foods (PBAFs) against conventional products. It was revealed that the US has a significant impact when used as an assistant tool with other green technologies rather than being used alone. It increases the protein extraction efficiencies from plant biomasses, improves the techno-functional properties of food compounds, and makes them more applicable for industrial-scale alternative food production in the circular economy. The US aligns well with the objectives outlined in the UN's Sustainable Development Goals (SDGs), and Planetary Boundaries (PBs) framework, demonstrating promising outcomes in life cycle assessment. However, several challenges such as uncontrolled complex matrix effect, free radical formation, uncontrolled microbial growth/germination or off-flavor formation, removal of aromatic compounds, and Maillard reaction, are revealed in an increased number of studies, all of which need to be considered. In addition to a variety of advantages, this review also discusses the drawbacks and limitations of US focusing on PBAF production.

Isolation and characterization of nettle (Urtica dioica L.) seed proteins: Conversion of underutilized by-products of the edible oil industry into food emulsifiers

This study aimed to upcycle a byproduct of the edible oil industry, cold-pressed nettle seed meal (CPNSM), into a plant-based emulsifier, thereby increasing the sustainability of the food system. The protein content of the nettle seed protein (NSP) powder was 48.3% with glutamic acid (16.6%), asparagine (10.7%), and arginine (9.7%) being the major amino acids. NSPs had a denaturation temperature of 66.6 °C and an isoelectric point of pH 4.3. They could be used as emulsifiers to form highly viscous coarse corn oil-in-water emulsions (10% oil, 4% NSP). Nevertheless, 10-fold diluted emulsions exhibited rapid creaming under different pH (2-9), salt (0-500 mM NaCl) and temperature (>40 °C) conditions, but they were relatively stable to aggregation. Our findings suggest that NSPs could be used as emulsifiers in highly viscous or gelled foods, like dressings, sauces, egg, cheese, or meat analogs.

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.

A Comprehensive Review on Harnessing Soy Proteins in the Manufacture of Healthy Foods through Extrusion

The global development of livestock production systems, accelerated by the growing demand for animal products, has greatly contributed to land-use change, greenhouse gas emissions, and pollution of the local environment. Further, excessive consumption of animal products has been linked with cardiovascular diseases, digestive system diseases, diabetes, and cancer. On the other hand, snacks, pasta, and bread available on the market are made from wheat, fat, salt, and sugar, which contribute to the risk of cardiovascular diseases. To counter these issues, a range of plant protein-based food products have been developed using different processing techniques, such as extrusion. Given the easy scalability, low cost of extrusion technology, and health benefits of soy proteins, this review focuses on the extrusion of soy protein and the potential application of soy protein-based extrudates in the manufacture of healthy, nutritious, and sustainable meat analogs, snacks, pasta products, and breakfast cereals. This review discusses the addition of soy protein to reformulate hypercaloric foods through extrusion technology. It also explores physical and chemical changes of soy proteins/soy protein blends during low and high moisture extrusion. Hydrogen bonds, disulfide bonds, and hydrophobic interactions influence the properties of the extrudates. Adding soy protein to snacks, pasta, breakfast cereals, and meat analogs affects their nutritional value, physicochemical properties, and sensory characteristics. The use of soy proteins in the production of low-calorie food could be an excellent opportunity for the future development of the soybean processing industry.

Development of plant-based whole egg analogs using emulsion technology

RuBisCO is a plant protein that can be derived from abundant and sustainable natural resources (such as duckweed), which can be used as both an emulsifying and gelling agent. Consequently, it has the potential to formulate emulsion gels that can be used for the development of plant-based replacements of whole eggs. In this study, we investigated the ability of RuBisCO-based emulsion gels to mimic the desirable properties of whole eggs. The emulsion gels contained 12.5 wt% RuBisCO and 10 wt% corn oil to mimic the macronutrient composition of real whole eggs. Initially, an oil-in-water emulsion was formed, which was then heated to convert it into an emulsion gel. The impact of oil droplet diameter (∼15, 1, and 0.2 μm) on the physicochemical properties of the emulsion gels was investigated. The lightness and hardness of the emulsion gels increased as the droplet size decreased, which meant that their appearance and texture could be modified by controlling droplet size. Different concentrations of curcumin (3, 6, and 9 mg/g oil) were incorporated into the emulsions using a pH-driven approach. The curcumin was used as a natural dual functional ingredient (colorant and nutraceutical). The yellow-orange color of curcumin allowed us to match the appearance of raw and cooked whole eggs. This study shows that whole egg analogs can be formulated using plant-based emulsion gels containing natural pigments.

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.

Development of patty meat analogue using anchovy protein isolate (Stolephorus insularis) as a binding agent

The development of meat analogues focuses on sustainable production and requires attention to their nutritional, physicochemical, and sensory values. Anchovy protein isolate (API) is a novel and potential binding agent in the development of meat analogues. This study aimed to produce API and evaluate the physical, proximate, and sensory qualities of patty meat analogue (PMA) with the addition of API. The preparation method for API uses pH-shifting. The ratios of API added to the meat analogues were 0 % (F0), 4 % (F1), 8 % (F2), and 12 % (F3) per textured vegetable protein (TVP) weight. Furthermore, PMA was analysed for physical, proximate, and sensory properties. API had 87.23 % dry basis (db) protein content. The amino acid composition of API generally complied with the nutritional requirements of adults and children. The addition of API significantly affected the physical properties, proximate composition, and sensory (taste) qualities of PMA (p < 0.05). The protein content of PMA met Indonesian national standards (SNI) and was similar to both McDonald's and ground beef patty based on United States Department of Agriculture (USDA) standards. F3 was found to be the best based on its physical, proximate, and sensory properties.

Comparison of the specific mechanical energy, specific thermal energy, and functional properties of cold and hot extruded pea protein isolate

Pea protein is a popular source of plant-based protein, though its application in meat and dairy analog products is still lacking. This is particularly true in the development of products with fatty and creamy textures. Cold denaturation may be a way to induce these types of textures in food since this is a universal phenomenon in protein that occurs due to a weakening of hydrophobic interactions at cold temperatures. This work utilizes a single screw extruder to systematically study the impacts of moisture content (50-65 %) and pH (2,4.5,8) on the outlet temperatures, specific mechanical energy, specific thermal energy, and texture of cold-extruded pea protein. It was found that at pH 2 and moistures of 60 % and greater, the temperature of the product exiting the extruder is <5.5 °C, and also produced 13.7 %-36.5 % more specific thermal energy, indicating the occurrence of cold denaturation in these products. Based on these findings, a comparison of hot and cold extrusion was conducted as a function of pH and oil content. It was found that cold extrusion imparts 43.0 %-56.2 % more mechanical energy into the protein than hot extrusion, and the cold extruded protein had higher values of Young's modulus and breaking stress. The protein extruded at low temperatures was also able to bind 32.93 % more oil than hot extruded proteins when extruded with 10 % added oil, which may aid in the formation of protein-based fat memetics for the food industry.

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.

Effects of Haematococcus pluvialis Addition on the Sensory Properties of Plant-Based Meat Analogues

Due to the increase in population and the deficiency of land resources, the cost of raising livestock is gradually increasing. Plant-based meat analogues (PBMAs) are considered excellent substitutes for animal meat. Our research investigated the effect of Haematococcus pluvialis (HP) on gluten-based soybean and wheat PBMA with contents of 1%, 3%, 5%, and 7%. Compared with the control group, HP significantly improved the color of the extrudates, showed visual characteristics similar to red meat, and achieved a soft texture and apparent rheological properties. The 7% HP had negative effects on the organizational degree and viscosity. In addition, the E-nose indicated that the different contents of HP changed the flavor of the extrudates. The extrudates with 3% and 5% HP were most similar to each other among all of the extrudates for volatile compounds, and the extrudates with 1% HP and 7% HP had significantly different flavors compared to the control group. Furthermore, 20 different volatile compounds were compared according to their retention indices and retention areas. The results showed that the proportions of alcohol, ester, terpenes, acid, and furan were increased. When the threshold was referenced, HP was considered to provide PBMAs with grassy and healing grain flavor properties. Therefore, the results proved that the addition of HP can improve PBMAs sensory properties.

Optimizing Protein Fiber Spinning to Develop Plant-Based Meat Analogs via Rheological and Physicochemical Analyses

The substitution of meat products in the human diet with plant-based analogs is growing due to environmental, ethical, and health reasons. In this study, the potential of fiber-spinning technology was explored to spin protein fiber mimicking the structural element of meat muscle for the purpose of developing plant-based meat analogs. Overall, this approach involved extruding fine fibers and then assembling them into hierarchical fibrous structures resembling those found in whole muscle meat products. Considering the nutritional facts and to help build muscle fiber, soy protein, polysaccharide (pectin, xanthan gum, or carrageenan), plasticizer (glycerol), and water were used in the formulations to spin into fibers using an extruder with circular orifice dies. Extrudability and thermal and rheological properties were assessed to characterize the properties of the spun fiber. The extrusion trials showed that the presence of the polysaccharides increased the cohesiveness of the fibers. The properties of the fibers produced also depended on the temperature used during extrusion, varying from pasty gels to elastic strands. The extrudability of the fibers was related to the rheological properties (tan δ) of the formulations. This study demonstrated that fiber-spinning technology can be used to produce fibrous materials from plant-derived ingredients. However, the formulation and operating conditions must be optimized to obtain desirable physicochemical and functional attributes in the fibers produced.

Behavior of enzymes under high pressure in food processing: mechanisms, applications, and developments

High pressure processing (HPP) offers the benefits of safety, uniformity, energy-efficient, and low waste, which is widely applied for microbial inactivation and shelf-life extension for foods. Over the past forty years, HPP has been extensively researched in the food industry, enabling the inactivation or activation of different enzymes in future food by altering their molecular structure and active site conformation. Such activation or inactivation of enzymes effectively hinders the spoilage of food and the production of beneficial substances, which is crucial for improving food quality. This paper reviews the mechanism in which high pressure affects the stability and activity of enzymes, concludes the roles of key enzymes in the future food processed using high pressure technologies. Moreover, we discuss the application of modified enzymes based on high pressure, providing insights into the future direction of enzyme evolution under complex food processing conditions (e.g. high temperature, high pressure, high shear, and multiple elements). Finally, we conclude with prospects of high pressure technology and research directions in the future. Although HPP has shown positive effects in improving the future food quality, there is still a pressing need to develop new and effective combined processing methods, upgrade processing modes, and promote sustainable lifestyles.

Developments in Plant Proteins Production for Meat and Fish Analogues

In recent years, there have been significant developments in plant proteins production for meat and fish analogues. Some of the key developments include the use of new plant protein sources such as soy, legumes, grains, potatoes, and seaweed, as well as insect proteins, leaf proteins, mushrooms, and microbial proteins. Furthermore, to improve the technological and functional properties of plant proteins, they can be subjected to traditional and unconventional treatments such as chemical (glycosylation, deamidation, phosphorylation, and acylation), physical (pulsed electric fields, ultrasound, high hydrostatic pressure, dynamic high-pressure treatment, and cold plasma), and biological (fermentation and enzymatic modification). To obtain the high quality and the desired texture of the food product, other ingredients besides proteins, such as water, fat, flavors, binders, dyes, vitamins, minerals, and antioxidants, also have to be used. The final product can be significantly influenced by the matrix composition, variety of ingredients, and water content, with the type of ingredients playing a role in either enhancing or constraining the desired texture of the food. There are several types of technologies used for meat and fish analogues production, including extrusion, shear cell technology, spinning, 3D printing, and others. Overall, the technologies used for meat and fish analogues production are constantly evolving as new innovations are developed and existing methods are improved. These developments have led to the creation of plant-based products that have a similar texture, taste, and nutritional profile to meat and fish, making them more appealing to consumers seeking alternatives to animal-based products.

Effects of Process Parameters on the Fibrous Structure and Textural Properties of Calcium Caseinate Extrudates

Textured calcium caseinate extrudates are considered promising candidates in producing fish substitutes. This study aimed to evaluate how the moisture content, extrusion temperature, screw speed, and cooling die unit temperature of the high-moisture extrusion process affect the structural and textural properties of calcium caseinate extrudates. With an increase in moisture content from 60% to 70%, there was a decrease in the cutting strength, hardness, and chewiness of the extrudate. Meanwhile, the fibrous degree increased considerably from 1.02 to 1.64. The hardness, springiness, and chewiness showed a downward trend with the rise in extrusion temperature from 50 °C to 90 °C, which contributed to the reduction in air bubbles in the extrudate. Screw speed showed a minor effect on fibrous structure and textural properties. A low temperature (30 °C) in all cooling die units led to damaged structure without mechanical anisotropy, which resulted from fast solidification. These results show that the fibrous structure and textural properties of calcium caseinate extrudates can be effectively manipulated by adjusting the moisture content, extrusion temperature, and cooling die unit temperature.

The development process of plant-based meat alternatives: raw material formulations and processing strategies

With the rapid growth of the world's population, the demand for meat is gradually increasing. The emergence and development of plant-based meat alternatives (PBMs) offer a good alternative to solve the environmental problems and disease problems caused by the over-consumption of meat products. Soybean is now the primary material for the production of PBMs due to its excellent gelation properties, potential from fibrous structure, balanced nutritional value, and relatively low price. Extrusion is the most widely used process for producing PBMs, and it has a remarkable effect on simulating the fibrous structure of real meat products. However, interactions related to phase transitions in protein molecules or fibrous structures during extrusion remain a challenge. Currently, PBMs do not meet people's demand for realistic meat in terms of texture, taste, and flavor. Therefore, the objectives of this review are to explore how to improve fiber structure formation in terms of raw material formulation and processing technology. Factors to improve the taste and texture of PBMs are summarized in terms of optimizing process parameters, changing the composition of raw materials, and enriching taste and flavor. It will provide a theoretical basis for the future development of PBMs.

Scope, nutritional aspects, technology, and consumer preferences toward seafood alternatives

Sustainability, human health, and animal welfare are three broad areas that pose a greater impact on mankind. The increased consumption of animal-based foods such as fish or seafood has threatened the ecosystem due to rising greenhouse gas emissions, biodiversity loss, diseases, and consumption of toxic metals contained in fish by cause of water pollution. This has led to increased awareness among consumers to adopt seafood alternatives for a sustainable future. It is also not well known whether consumers are ready to switch from traditional seafood towards a safer and sustainable seafood alternative. This encourages the in-depth study of the scope of seafood alternatives in consumers' food choices. This study also highlights the nutritional perspectives and technologies involved in the development of seafood alternatives along with the future outlook for a greener planet.

Plant-Based Meat Analogues from Alternative Protein: A Systematic Literature Review

This study aimed to conduct a systematic literature review (SLR) of the research performed in the plant-based meat analogues area. Historical, current, and future tendencies are discussed. The paper offers a comprehensive SLR coupled with a bibliometric analysis of the publication from 1972 to January 2022. The articles were obtained using a research string and precise inclusion and exclusion criteria from two prominent databases, Scopus and Web of Science (WoS). The Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) flow technique was used to describe the data screening and selection. In total, 84 publications were selected for further analysis after a thorough literature assessment. From this study, six main themes were identified: (1) objectives of the study; (2) type of plant protein; (3) product type; (4) added ingredients; (5) texturization technique; and (6) quality assessment considered in the studies. Recent trends in publication imply that meat analogue technology is gaining prominence. This review revealed significant research on improving meat analogues via texturization. Even though extrusion is used industrially, the technique is still in its infancy and needs improvement. Future studies should focus more on fiber and protein-protein interactions, macromolecule conformation and mechanisms, diversifying or improving current methods, sensory attributes, and gastrointestinal absorption rate of each novel protein ingredient.

Consumer Perception and Acceptability of Plant-Based Alternatives to Chicken

The prevalence of plant-based alternatives (PBAs) to meat in the marketplace has been increasing in recent years due to consumer demand. One of these plant-based products has aimed to mimic chicken products, specifically chicken nuggets. However, few sensory studies have been conducted on these products. The objective of this study is to evaluate the sensory properties, acceptability, and consumer perception of these PBAs. Participants (n = 105) were asked to evaluate five PBAs and a control (chicken nugget) using hedonic scales and a check-all-that-apply question. They also answered an open-ended comment question about PBAs. The participants separated the control from the PBAs in terms of their hedonic scores and sensory properties. They separated the PBAs based on their textural properties and if they had off-flavors. Participants disliked PBAs that were associated with an aftertaste, as well as beany, fibrous, and chewy attributes. The participants believed the PBAs currently on the market did not successfully mimic a chicken nugget and that improvement is needed, but they did believe PBAs are environmentally friendly.