Plant-based meat substitutes

RESEARCH PROJECT

Demand


   

  • Large demand for vegan and vegetarian food products

  • Demand for plant-based meat substitutes with a fibrous texture

  • Simple processing

Result

 

 

  • Meat-like texture due to the use of special extrusion technology

  • High protein content without chemical additives

  • Raw materials: peas, lupines, wheat, beans

Benefits


 

  • Foundation of a new company:
    Amidori Food Company GmbH & Co.KG

  • Range of products: z. B. schnitzel, nuggets, burger-patties, gyros

  • Product introduction: Scandinavia 2016, Germany 2017

Why are we developing plant-based meat surrogates?

Over recently years growing awareness of health and environmental matters has led to a considerable increase in the demand for vegetarian alternatives to meat in Europe. In Asia foods such as tofu, tempeh, and saitan have provided people with protein for centuries. In addition to these traditional Asian products, foods containing textured proteins that much better mimic the typical meat structure have also appeared in the European marketplace. These products are mostly manufactured via the cooking extrusion of deoiled soy flour, soy protein concentrates, or wheat gluten. This process gives the proteins an oriented, fibrous structure.

To increase consumer acceptance of these plant-based meat surrogates we are researching how to optimize their sensory quality, namely their taste, juiciness, and firmness of bite. Simultaneously we are striving to maximize the nutritional value of the products.

Vegan burger-patties are a special challenge

Whilst wet-extruded textured proteins have a structure akin to muscle fiber, dry extrudates have a more porous and harder structure. On rehydration they become like minced meat and are very suitable for making meat-free burger-patties. The quality of a vegan burger is generally appraised by the extent to which its taste compares to a traditional minced meat burger. Although vegan burgers naturally contain no meat, consumers demand that they appear and taste like meat burgers. On being fried the vegan patties must retain their structure and not fall apart. Also, during the cooking the color must change from red to brown. Ready-to-eat vegan patties must be juicy and have firmness of bite.

Our in-depth experience has given us a detailed understanding of the properties of different plant-based proteins. A customized combination of raw materials and specific control of the extrusion process enables us to tailor the taste, texture, and biological quality of the end products. Key parameters during the extrusion process are, for example, the screw configuration, nozzle geometry, speed, throughput, and temperature profile.

What factors influence the taste and texture of plant-based meat surrogates?

Besides soy and gluten, other protein sources are now used for manufacturing vegetarian alternatives to meat. In particular, the combination of different plant-based materials improves the structure, better imitating the fibrous and juicy texture of lean meat. It is important here to understand the behavior of the various protein fractions during the manufacturing process and interactions between the recipe components. This enables recipes to be optimized and customized for respective consumer preferences and demands.

Commercialization of our tasty meat surrogate products

Our research passes to our spin-off company, Amidori Food Company GmbH & Co.KG, and leads to the production of market-ready meat surrogate products. Products have already been successfully introduced in Germany and Scandinavia with the brand name M¡dori®.

Product examples of vegetable meat alternatives

Vegan burger patties

  • processable like raw minced meat
  • juicy through the use of dry-textured proteins
  • nutritionally high-quality through the combination of different protein sources
  • sustainable due to regional raw materials

Vegetarian Schnitzel

  • muscle-meat-like fibre texture through wet extrusion process
  • meat-typical bite through targeted temperature control during extrusion
  • sensorically optimized by our sensor panel

Vegan Gyros

  • flexible recipe design and variation of the taste profile through raw material selection
  • Variation of the fibre structure by adapting the nozzle geometry during extrusion