Plant-Based Progress Towards a Perfection-Based Meal

How Plant-Based Meats are Grown, Treated, and Optimized to Perfection

As the world shifts towards sustainable and ethical eating, plant-based meats are rapidly gaining popularity. They offer a way to reduce our carbon footprint, improve animal welfare, and promote better health. For example, plant-based meat generally contains more nutrients and less saturated fat compared to real meat. Because plant-based meat is gradually becoming the future of the world’s primary sustainable source of protein, it is crucial, more than ever, to understand the complex process behind producing these meat alternatives and their properties that affect our health, and, of course, the enjoyability of our meals.

While many plant-based meat companies have been able to successfully make products that taste even better than real meat, others are still on the quest to replicate the taste, texture, and nutritional profile of meat using plant-based ingredients. If you have tried comparing a variety of plant-based meat products to their original analogs, you have most likely thought to yourself, “Hmm, this still doesn’t compare to the original. I wonder if another brand can make it better?”?

In this article, we’ll explore the steps and science that go into producing these “meats,” and why some varieties are tastier and more realistic than others.

What even is plant-based meat? Is it really made out of plants?

Yes, plant-based meat is exactly what it sounds like. It all starts with plants before turning into the hearty, juicy piece of meat-like deliciousness in your burger or stir-fry dish. In fact, plants contain many of the same natural components that meat does: water,? protein, fat, minerals, and vitamins. Plant-based meat leverages these similarities. At the initial stage, plants are grown, then specifically treated and processed before being cooked into local dishes and ready-to-eat meals. Let’s take a deep dive into the steps that take it from farm to dinner table.

1. Grow Crops & Extract Proteins

Some of the most commonly used plants in plant-based meats include soy, wheat, pea, and potato. Other plant proteins may also be used to add certain structural or nutritional benefits. The type of plant is selected based on certain textural or health-related advantages they can provide. The proteins are then extracted from these crops and prepared in various ways based on their properties. Soy protein concentrate, for example, is prepared by aqueous alcohol washing. Wheat gluten is most often used to give the product a chewiness similar to meat. Other proteins that can be added to enhance texture include potato, mung bean, and rice proteins. The ultimate goal is to combine plant proteins that can bind together in networks that trap water, which is later released during chewing to obtain a juicy texture.

Various methods can be employed to extract proteins, the most vital ingredient, from the plant raw materials.

2. Optimize Ingredients

This step involves addressing the differences between animal and plant proteins. Some crops require post-harvest ingredient processing, where the product is refined to yield a higher concentration of proteins. Others contain proteins that must be further processed to select for specific sets of desirable functional attributes, which can involve fractionation and reconstitution of the various plant components to ensure that proteins with certain ideal attributes (such as texture or water retention) are added to products that need those attributes the most.

3. Establish Formulation

This is where the magic happens. Manufacturers mix together the formula components, maintaining the correct balance of fats, carbohydrates, and fibres in the formula.?

Among these, oils and fats stand out as prominent factors in altering the product’s texture. They are responsible for delivering a mouth feel that mimics animal fat. Specific combinations of oils are selected such that there is a balanced blend of liquid and solid oils to ensure quality, both nutritional and taste-wise.

Although choosing the best combination of proteins, oils, and fats is crucial in achieving desired consistencies, additional additives are also required to ensure that this ideal texture is able to withstand all subsequent processing steps as well as throughout the product’s shelf-life after shipping and purchase. In this step, functional ingredients such as emulsifiers, binders, and gelling agents are added. These begin to shape the biochemical properties of the plant-based meat to yield textures similar to real meat.

4. Process & Manufacture

In addition to choosing the correct ingredients, specific factory processing equipment also works the meat alternative to finalize its texture. Certain methods include stretching, kneading, shear-cell processing, press forming, folding, layering, 3D printing, and extrusion. In most cases, extrusion is the most used method.

Extrusion uses high temperature and high pressure to shape the meat, producing desired textures and forms. Additionally, this method also kills bacteria, as heat is able to break down microbial life systems. This is crucial because plant-based meat products’ high protein and moisture content render them prone to microbial growth. This time- and temperature-dependent treatment is essential in ensuring the shelf life and safety of the meat alternative.

5. Add Additional Ingredients

The following steps are similar to most other food manufacturing processes. Like any other food product, manufacturers season the plant-based meat, adding coloring, flavoring, and aroma agents.

6. Treat Microbial Contamination

While extrusion is able to kill off most of the microbial load, certain products could still be subject to post-processing contamination or contain certain bacteria that are resistant to the extrusion process. As a result, some plant-based meats undergo additional treatments and refrigeration to ensure the safety and shelf life of the products.

7. Package & Ship

The last step, of course, is to package the products into clean and food-safe packaging before delivering them to your local grocery stores.?

→ Why are some plant-based meats better than others?

Texture Differences

Mouthfeel is a significant factor when it comes to evaluating the quality of plant-based meat alternatives. Texture is what decides whether or not the dish has succeeded in mimicking real meat. Unsuccessful plant-based meat tends to be flaky and dry whereas a successful, realistic, and satisfying cut will have a fibrous, juicy texture reminiscent of real meat. Because plant proteins tend to be dry and crumbly, the use of binders and stabilizers is absolutely crucial in recreating the succulence of meat.

Binders and Texturisers

Binders, such as proteins and starches, help hold the plant-based ingredients together, providing structure and integrity to the product. Texturisers, like modified starches and protein isolates, enhance the mouthfeel and juiciness, making the plant-based meat more appealing and closer to the texture of real meat. By improving the cohesiveness and overall sensory experience, these ingredients ensure that plant-based meats are not only nutritionally comparable to their animal counterparts but also enjoyable to eat, thereby increasing consumer acceptance and satisfaction.

BDF Binders

Halim Biotech’s BDF Natural Binders are a game-changer in plant-based meat production. These binders provide the necessary cohesiveness and elasticity to plant proteins, creating a meat-like texture without compromising on the plant-based integrity. Their natural origin and excellent binding properties make them a top choice for producers. Moreover, they also help create structured fats, which are a popular ingredient in plant-based meat formulations as they improve texture, reduce fat content, and enhance overall nutrition.

Hydrocolloids

Hydrocolloids are essential in plant-based meat formulations due to their unique ability to modify texture and stabilise the product. These compounds, such as carrageenan, guar gum, and xanthan gum, interact with water and other ingredients to create a gel-like network that enhances moisture retention and prevents ingredient separation. This results in a consistent, desirable texture that mimics the bite and chew of animal meat. Additionally, hydrocolloids can improve the overall stability of plant-based meat, extending its shelf life and maintaining its quality during storage and cooking. By leveraging the functional properties of hydrocolloids, producers can create plant-based meats that deliver a satisfying eating experience and meet consumer expectations for texture and consistency.

Curdlan

Our curdlan is a standout stabiliser in this space. Derived from bacterial fermentation, curdlan forms a gel when heated, which helps maintain the structure and moisture of plant-based meats during cooking. This results in a juicier, more meat-like product that consumers are sure to love. Moreover, curdlan is incredibly resistant, and therefore able to prolong the shelf-life of plant-based meats. Lastly, it also boasts a neutral taste profile that will not hinder the taste of the meat alternative, allowing its natural flavor to shine.

Combining Functional Ingredients

In certain products, both additives can be combined. By integrating BDF Probind Transglutaminase (TG) Blends and curdlan into the production process, manufacturers can overcome the challenges of maintaining texture in plant-based meat products. This combination not only improves the chewiness and juiciness but also ensures these qualities are retained through the freezing and thawing cycle, resulting in a consistently high-quality product.

The next time you take a hearty bite of juicy impossible meat in a plant burger or savour the aromatic flavors of a vegan stir-fry, consider the long journey that your meat alternative went through, from planting crops all the way to combining ingredients and manufacturing. Plant-based meats are the future of protein, and so are the functional ingredients that hold them together.

Halim Biotech’s BDF Probind and curdlan have been thoroughly researched and proven to significantly improve the quality of food manufacturers’ plant-based meats! Contact us to learn more today.

References:

Earth911. How Is Plant-Based Meat Made? https://earth911.com/food-beverage/how-is-plant-based-meat-made/.

Good Food Institute. The Science of Plant-Based Meat. https://gfi-apac.org/science/the-science-of-plant-based-meat/.

How safe are plant-based meat alternatives? https://www.ift.org/news-and-publications/food-technology-magazine/issues/2021/february/columns/food-safety-and-quality-how-safe-are-plant-based-meat-alternatives.

Thermo Fisher Scientific. Plant-Based Meat Manufacturing: Reducing the Carbon Footprint of Our Food. https://www.thermofisher.com/sg/en/home/materials-science/food-development/applications/plant-based-meat-development.html#:~:text=Plant%2Dbased%20meat%20manufacturing,-Reducing%20the%20carbon&text=A%20twin%2Dscrew%20extrusion%20process,beef%2C%20chicken%2C%20and%20seafood.