As the global population grows steadily towards a projected ten billion by the year 2050, the necessity for a resilient and sustainable food system becomes increasingly apparent. The current trajectory, largely hinged on meat-based diets, poses significant challenges to both environmental sustainability and public health. With meat production being a considerable factor in climate change, accounting for a marked 25% of greenhouse gas emissions, biodiversity loss, and freshwater depletion, the urgency for a shift towards alternative protein sources is clear and pressing.
The surging populations and expanding middle classes in developing regions are intensifying the demand for protein, and thus, heightening the stress on our planet’s resources. To address these concerns, it is important not only to diversify the range of protein sources but also to ensure that these alternatives are sufficiently appealing to consumers, thereby facilitating a global dietary transformation.
Recognizing the crucial role of innovation, texturization of plant proteins through extrusion technology continues to gain attention as a promising solution. This process has the potential to replicate the texture and taste of meat, allowing plant-based protein products to stand as viable and desirable options. Extrusion technology splits into two main methodologies: high moisture extrusion (HME) and low moisture extrusion (LME), each offering unique benefits and serving different aspects of the plant-based food sector.
High moisture extrusion
High moisture extrusion (HME) is a sophisticated process designed to produce plant-based textures closely resembling those found in meat. This technology operates at elevated levels of moisture—usually greater than 50%—which are key to creating the fibrous and tender consistency characteristic of animal muscle. Through the application of heat and shear forces within the extruder barrel and the later alignment of protein fibers in the cooling die, HME transforms protein-rich ingredients into a “meat-like” matrix that can be further processed into a variety of shapes and forms, mirroring meat products.
Bühler, as a global leader in food processing technologies, offers a comprehensive portfolio of solutions to support the development and manufacturing of plant-based proteins using high moisture extrusion. Addressing both research and development efforts as well as large-scale production, Bühler’s portfolio includes an array of cooling dies designed to meet the diverse needs of producers. For instance, for R&D purposes and pilot-scale production, Bühler provides specialized equipment with lower throughput capacities in the range of 10-50 kg/h (PolyCool 50). This scale allows for experimentation and optimization of product formulations and processes without the commitment to large-scale volumes.
Moving beyond the pilot phase, the modular PolyCool 200 with a gap width of 15mm as well as the modular annular PolyCool 350 are available before stepping up to workhorses, such as the PolyCool 500 and PolyCool 1000. These robust, high-capacity machines are engineered to satisfy the demands of large-scale production, having the ability to produce 500 – 1000 kg/h of textured protein. This high-throughput capability ensures that manufacturers can not only scale up their operations efficiently but also maintain the critical quality and consistency required for commercial success. If higher capacities are required solutions are in place and ready to be implemented in the production process.
The flexibility in Bühler’s equipment range empowers producers to scale their production seamlessly from the initial stages of product development to full market deployment, facilitating a more agile response to the rapidly growing demand for sustainable, plant-based protein alternatives. With the PolyCool 500 and PolyCool 1000 at the heart of HME production, Bühler clients are equipped to make significant strides towards a sustainable and secure food future.
The ability to control texture is vital in the HME process, especially when the goal is to emulate the sensory appeal. Bühler’s PolyCool leverages innovative breaker plates to refine the texture of plant-based proteins. These perforated plates alter the flow dynamics, enabling the formation of complex, macroscopic textures. By tailoring the breaker plates to customer`s demand they are enabled to closely mimic the fibrous nature of meats like beef, chicken, or fish in their products.
Moreover, Bühler’s pioneering Protein Aeration Technology, currently pending patent, complements the texturization capabilities by incorporating gas directly into the extrudate. This innovation results in a lighter, more tender product with improved mouthfeel and a more natural appearance suitable for marination. With these textural control mechanisms, the PolyCool portfolio allows for a high degree of customization in plant-based meat alternatives, offering producers the tools to create a variety of textures, from tender and juicy to firm and flaky, directly from the cooling die. These texturization advancements are transformative, greatly enhancing the consumer appeal of meat analogs and marking a significant step towards more sustainable and appealing protein options.
Low moisture extrusion
Low moisture extrusion (LME) is another pivotal technology in the growing field of plant-based protein production. Unlike high moisture extrusion, which focuses on creating a meat-like texture with high water content, LME operates at much lower moisture levels, typically around 15-30%. This process is particularly advantageous for producing a wide range of textured vegetable proteins (TVP) and fibrous structures suitable for dry applications such as cereal bars, snacks, and of course meat analogs.
Bühler’s approach to LME prioritizes versatility and efficiency. With a deep understanding of the complexities involved in low moisture extrusion, processes that can handle the intense mechanical shear and reduced water content required to achieve the desired expansion and texturization of plant proteins are necessary. The applied systems must ensure consistent cooking, optimal texturization, and precise shaping, ultimately resulting in a high-quality consumer product with a long shelf-life due to the low moisture content achieved by our drying solutions.
Through the utilization of specific die designs and screw profiles, Bühler’s LME equipment sharpens producers’ ability to fine-tune texture and shape, ensuring that the resulting TVP has the correct density and chewiness to meet consumer preferences. From granules and chunks to flakes and shreds, the flexibility of Bühler’s low moisture extrusion technology enables producers to diversify their product offerings and expand into new market segments, all while addressing the demand for protein-rich, and sustainable food options.
Bühler’s commitment to advancing LME technology not only underscores leadership in plant-based protein processing but also reflects a dedication to providing scalable solutions. This commitment ensures that as the demand for sustainable and diverse protein products grows, producers can confidently rely on Bühler to facilitate their entry and expansion in this dynamic and expanding market space.
Enhancing this strategic landscape, Bühler has introduced the DryTex Chunks and Chips die to its LME portfolio, setting a new process option in dry or semi-moist textured protein. This innovative die design allows producers to create long, meaty pieces of plant-based proteins with a fibrous texture ideal for various applications. The development of the DryTex die allows us to address the latest market trends while meeting the growing desire for more authentic and diverse plant-based food experiences. With such technological innovations, Bühler continues to empower customers to not only meet but drive consumer demand in a forward-thinking industry.
Outlook
The alternative protein market will further evolve in the upcoming years requesting more efficient and precise process technologies to create complex meat alternatives. The presented process solutions are a snapshot of Bühler’s R&D pipeline, however, Bühler is constantly working on innovation to support the large-scale shift to sustainable, alternative protein sources. We serve as a strong technology partner and collaborate and co-develop the future of proteins together with our customers. Hence, we are proud that our individual process solutions allow our customers to actively tailor their meat alternative products with regards to texture, but also efficient processing and thus, to proceed in the alternative protein market.
For more information please visit: https://www.buhlergroup.com/global/en/industries/Extrusion-solutions/Alternative-Proteins.html
