Novel rotating die coupled to a twin-screw extruder as a new route to produce meat analogues with soy, pea and gluten. (October 2022)

• Record Type: Journal Article
• Authors: Snel, Silvia J.E.; Bellwald, Yasmin; van der Goot, Atze Jan; Beyrer, Michael
• Is Part Of: Innovative food science & emerging technologies. Volume 81(2022)
• Publication Date: 2022-10
• Subjects: Extrusion -- Meat analogues -- Cooling die -- Shear -- Plant protein; Food -- Biotechnology -- Periodicals; Food industry and trade -- Technological innovations -- Periodicals; Aliments -- Biotechnologie -- Périodiques; Food -- Biotechnology; Periodicals; Electronic journals; 664.005
• DOI: 10.1016/j.ifset.2022.103152
• Languages: English
• ISSNs: 1466-8564

Abstract

Highlights: A novel extrusion cooling die was developed with a rotating inner cylinder. Micro- and macro-texture changed when rotational speed was altered. Angle of the fibers in the sample differed for the different rotational speeds. The tested ingredients and blends reacted differently to the applied shear. Anisotropy index increased when gluten content increased. Abstract: Modern plant-based meat analogues should have a pronounced fibrous structure as an important characteristic. In this study, we demonstrate that the combination of high moisture extrusion cooking (HMEC) with well-defined shear during cooling is a new process to make fibrous products using common meat analogue ingredients. The shear was applied via a cooling die attached to the extruder that was specially designed for that purpose. The in–house developed cooling die consists of two sequential rotating inner cylinders with a separate drive-unit in an outer cylinder that can be thermo-regulated. Three rotational speeds of the inner cylinder, 45, 75 and 105 min −1, were tested for pea protein isolate, soy protein concentrate, vital wheat gluten and blends of pea or soy with gluten. A large effect on macro- and micro-texture and anisotropy index was found when the concentration of gluten was increased. The different ingredients and blends had different optimal conditions and reacted differently to the applied shear. Interestingly, the angle of the fibers observed in the samples differed at the different rotational speeds. This was attributed to the shear thinning behavior of the plant proteins and the velocity gradient in the rotating die, arising from the temperature and viscosity gradient. The ability to change the shear rate as an independent parameter in the rotating cooling die is unique and allows texture adjustments during processing. This is an important improvement for industrial HMEC and opens new product design possibilities.