High-moisture extruded protein fiber formation toward plant-based meat substitutes applications: Science, technology, and prospect

• Published in: Trends in food science & technology Vol. 128; pp. 202 - 216
• Main Authors: Zhang, Jinchuang, Chen, Qiongling, Kaplan, David L., Wang, Qiang
• Format: Journal Article
• Language: English
• Published: Elsevier Ltd 01.10.2022
• Subjects: animals; cooling; crosslinking; environmental sustainability; extrusion; food science; fungi; High-moisture extrusion; meat; oilseeds; Plant-based meat substitutes; Process and equipment; Protein sources; Quality evaluation; separation; texture; texturization; Theoretical basis; Process and equipment; High-moisture extrusion; Plant-based meat substitutes; Protein sources; Quality evaluation; Theoretical basis
• ISSN: 0924-2244; 1879-3053
• DOI: 10.1016/j.tifs.2022.08.008

Recently, plant-based meat substitutes have generated considerable interest for their benefits in terms of environmental sustainability and personal health. High-moisture (above 40%) extrusion is an important technology for preparing whole-cut plant-based meat substitutes with meat-like fibrous structure and texture. However, it remains challenging on a more fundamental level to understand the interactions during extrusion processing related to the transition of the protein molecules or phase into fibrous structures, which is considered as a “black box” with scarce information inside. Here, protein sources that can be texturized by high-moisture extrusion are summarized. Next, high-moisture extruded protein texturization theories are explained from three interdisciplinary subjects. Furthermore, technical points including extrusion conditions, screw configuration, and cooling die design are analyzed. Lastly, a comprehensive evaluation of high-moisture extruded plant-based meat substitutes is outlined. A wide range of protein sources from legumes, oilseeds, cereals, miscellaneous beans, vegetables, algae, fungus, and insects are available for high-moisture extrusion. There is increasing consensus that the dynamics of protein aggregation and phase separation determine the formation of fibrous structures during high-moisture extrusion. Protein fibrous structure formation mainly occurs from the die to the cooling zone through a “sub-layer transformation” cross-linking. A combination of simulation work with actual experiment requires additional focus and insight for the regulation and control of high-moisture extrusion processes. Comprehensive evaluation methods are necessary to compare plant-based meat substitutes with different animal meats. High-moisture extruded protein fiber formation toward plant-based meat substitute applications. [Display omitted] •Various alternative protein sources are available for high-moisture extrusion.•Protein aggregation and phase separation together determine the formation of fibrous structure.•Technical points for process parameters and extruder characteristics are analyzed.•Comprehensive evaluation is necessary for plant-based meat substitutes.