Top plant-based processing technologies food companies need to know

The plant-based food industry is rapidly evolving, driven by innovative processing technologies that significantly enhance the texture, flavor, and nutritional value of plant-based proteins. At Steakholder, we are at the forefront of this transformation, dedicated to utilizing these advanced technologies to create high-quality, sustainable products that meet and exceed consumer expectations.

Discover the top plant-based processing technologies that are revolutionizing the food industry. From advanced extrusion techniques that perfect the texture of meat alternatives to innovative fermentation processes that enrich flavor and nutrition, we cover the essential methods that every food company should know.

1. Advanced extrusion technologies

How extrusion technology enhances the texture and structure of plant-based proteins

Extrusion technology is a cornerstone of plant-based protein processing, transforming the way we create meat alternatives. This sophisticated method involves forcing a mixture of plant proteins and other ingredients through a high-pressure, high-temperature chamber. The intense conditions cause the proteins to denature and realign into fibrous structures, resulting in a product with a texture that closely resembles traditional meat.

Extrusion technology not only replicates the texture of meat but also enhances the nutritional profile of plant-based products. By carefully selecting and combining different plant proteins, food scientists can ensure that extruded products are rich in essential amino acids, vitamins, and minerals. This makes plant-based meats not only appealing in terms of texture but also for overall health.

Benefits and applications in creating meat alternatives

Extrusion technology offers numerous benefits for producing plant-based meat alternatives. One primary advantage is the ability to customize textures to meet specific consumer preferences. The process can be adjusted to create varying degrees of chewiness and firmness, closely mimicking the textures of different types of meat, from tender beef steaks like our SH™-Marbled Beef Steak to flaky fish filets like our SH™-White Fish. This versatility is crucial for developing a wide range of products, such as steak, chicken filet, and seafood alternatives.

The controlled expansion and texturization during extrusion result in products that are juicy and satisfying, closely replicating the sensory attributes of animal meat. This is particularly important for attracting flexitarians and meat-eaters looking for plant-based options that do not compromise on taste and texture.

The structural integrity provided by extrusion ensures that plant-based meat products can withstand further processing and cooking without falling apart. This is essential for creating products that can be grilled, fried, or baked, offering consumers the versatility they expect from traditional meat. At Steakholder, extrusion is at the core of our technology for meat, enabling us to produce plant-based meats that deliver on flavor, texture, and cooking performance, setting new standards in the industry.

Examples of successful products made using extrusion

Many successful plant-based products on the market today are made using advanced extrusion technology. Here, we have leveraged this technology to develop our SH™-Marbled Beef Steak, a standout product known for its juicy, meat-like texture.

The SH™-Marbled Beef Steak combines a mix of plant proteins and other ingredients that, when extruded, create a product that satisfies even the most discerning palates. This product has set a new benchmark for plant-based meat alternatives, demonstrating that it is possible to create delicious, nutritious, and sustainable food that appeals to a broad audience.

By utilizing advanced extrusion techniques, we ensure that our SH™-Marbled Beef Steak delivers an authentic meat-like experience, both in taste and texture, without compromising on nutritional value or sustainability. This commitment to innovation and quality is what makes Steakholder a leader in the plant-based food industry, setting the standard for what plant-based meat products can achieve.

2. High-moisture processing techniques

Overview of high-moisture extrusion cooking (HMEC)

High-moisture extrusion cooking (HMEC) is a specialized extrusion technique that uses higher moisture content to produce plant-based proteins with a fibrous, meat-like texture. This method involves the introduction of water or steam during the extrusion process, which allows the plant proteins to align in a way that mimics the structure of animal muscle fibers. The higher moisture content not only aids in creating a meat-like texture but also helps in binding the ingredients together more effectively, resulting in a cohesive final product.

Advantages of HMEC in producing juicy, meat-like textures

HMEC offers several advantages over traditional extrusion methods, particularly in its ability to produce plant-based meats with superior textural properties. The increased moisture content in HMEC results in products that are juicier and have a more satisfying bite. This enhanced juiciness is crucial for replicating the sensory experience of eating meat, as it prevents the plant-based product from being dry or crumbly.

Case studies of companies utilizing high-moisture processing

Several companies have successfully utilized HMEC to produce high-quality plant-based meats, showcasing the effectiveness of this technology. At Steakholder, we have integrated HMEC into our production process to develop products that meet the highest standards of taste and texture.

Our use of HMEC technology ensures that our plant-based meats are nutritious and incredibly satisfying to eat.

3. Fermentation innovations

Role of fermentation in improving flavor and nutritional value

Fermentation is a time-honored technique that has been employed for centuries to preserve and enhance the flavor of foods. Today, it is being adapted and refined to improve the flavor and nutritional profile of plant-based proteins. Fermentation involves the use of beneficial microbes, such as bacteria, yeast, and fungi, to break down complex molecules in food. This process not only increases the digestibility of plant proteins but also enhances their nutritional value by producing vitamins, amino acids, and other beneficial compounds.

The flavor profile of plant-based foods can be significantly improved through fermentation. Traditional plant-based ingredients often lack the depth and complexity of flavors found in animal products. Fermentation introduces a variety of desirable flavors, such as umami, tanginess, and savory notes, which can transform the taste of plant-based proteins.

Emerging fermentation technologies in plant-based food production

Emerging fermentation technologies are at the forefront of innovation in plant-based food production, pushing the boundaries of what is possible. These technologies involve advanced microbial strains and precision fermentation techniques that allow for greater control over the fermentation process. 

One of the most exciting developments in this field is the use of mixed-culture fermentation, where multiple microbial strains are used in a single fermentation process. This approach can produce more complex and layered flavors, as different microbes contribute different metabolites and enzymes.

Examples of innovative plant-based products using fermentation

Innovative companies are leveraging fermentation to create a new generation of plant-based foods that stand out in the market. We have harnessed the power of fermentation to enhance the flavor of plant-based meats. By fermenting plant proteins, we can create products with a more savory flavor, which enhances their overall taste and appeal.

This process also improves the digestibility of the proteins, making our plant-based meats more beneficial for consumers' health. Our fermented plant-based products are designed to deliver a rich and satisfying taste experience, ensuring that they meet the high expectations of modern consumers.

4. Precision fermentation and cellular agriculture

Introduction to precision fermentation and its impact on plant-based foods

Precision fermentation is an advanced biotechnological process that utilizes genetically engineered microorganisms to produce specific proteins, enzymes, and other functional ingredients. Unlike traditional fermentation, which relies on naturally occurring microbes, precision fermentation involves modifying the genetic makeup of microorganisms to optimize the production of target compounds. This technology allows for the creation of highly customized plant-based products with precise nutritional profiles and flavor characteristics.

The impact of precision fermentation on plant-based foods is profound. It enables the production of ingredients that were previously difficult or impossible to obtain from plants alone. This means that plant-based products can now achieve higher levels of quality, authenticity, and nutritional value.

How cellular agriculture is shaping the future of protein production

Cellular agriculture is revolutionizing the future of protein production. By cultivating animal cells in controlled environments, such as bioreactors, it can produce meat, seafood, and other animal-derived products without the need for traditional animal farming. By growing cells directly from animal tissues, cellular agriculture can produce real meat that is indistinguishable from conventionally farmed meat in terms of taste, texture, and nutritional content.

The sustainability benefits of cellular agriculture are significant. Traditional animal farming is associated with numerous environmental challenges, including high greenhouse gas emissions, extensive land and water use, and biodiversity loss. Cellular agriculture, on the other hand, requires fewer natural resources and generates less pollution. It also eliminates many of the ethical concerns related to animal welfare, as it does not involve raising and slaughtering animals.

In addition to its environmental and ethical advantages, cellular agriculture offers the potential to meet the growing global demand for protein. As the world's population continues to increase, so does the need for sustainable and scalable protein sources. Cellular agriculture can produce large quantities of high-quality protein in a relatively short amount of time, making it a viable solution for addressing food security challenges.

Successful applications and products in the market

There are already successful applications of precision fermentation and cellular agriculture in the market, demonstrating the potential of these technologies to transform the food industry. At Steakholder, we are pioneering the development of cell-cultivated meat products. Our cutting-edge technology allows us to grow animal cells into structured meat products, such as steaks and chicken fillets, that offer the same sensory attributes as conventionally farmed meat. These cell-cultivated meats are produced without the environmental and ethical drawbacks of traditional animal agriculture, providing consumers with a sustainable and humane alternative.

Our approach to cellular agriculture ensures that we can deliver high-quality, nutritious meat products while significantly reducing the impact on the environment. By cultivating meat directly from animal cells, we bypass many of the issues associated with conventional farming, such as excessive land and water use, greenhouse gas emissions, and animal welfare concerns.

This innovative method not only addresses the growing demand for meat but also aligns with our commitment to sustainability and ethical production practices. Here at  Steakholder, we are dedicated to leading the way in creating a more sustainable and responsible food system through the development of advanced cell-cultivated meat products.

5. 3D printing for customized food production

How 3D printing technology is revolutionizing plant-based food production

3D printing technology enables the production of highly customized and intricate food products. This cutting-edge approach allows for the precise deposition of plant-based ingredients, layer by layer, to create complex structures that closely mimic the texture and mouthfeel of traditional meats.

By utilizing computer-aided design software, food scientists can design detailed 3D models of food items, specifying the exact placement and composition of each ingredient. This level of control over the food production process ensures that the final product can replicate the fibrous, juicy, and tender qualities of animal-based meats.

3D printing technology is particularly advantageous for producing plant-based meats because it can accurately simulate the muscle fibers and connective tissues found in animal products. This capability is achieved through the use of plant proteins, fats, and binders that are extruded through a printer nozzle and deposited in precise patterns.

The result is a plant-based meat product that not only looks like traditional meat but also delivers a similar sensory experience, making it more appealing to a broader range of consumers, including flexitarians and meat-eaters.

2 types of 3D printing technology

Drop on Demand (DoD) technology - DLS™ for seafood textures

Drop on Demand (DoD) technology, which we refer to as DLS ™(Drops Location in Space), is revolutionizing the creation of seafood textures in plant-based products.

This advanced 3D printing method precisely deposits droplets of plant-based ingredients layer by layer, replicating the intricate and delicate textures found in seafood. DLS™ allows us to mimic the unique flakiness and mouthfeel of fish and other seafood, offering a highly realistic and satisfying alternative for consumers seeking sustainable and delicious seafood options.

Extrusion technology - FPL™ for meat textures

Our FPL™ (Fused Paste Layering) technology utilizes advanced extrusion methods to create plant-based meat textures that closely mimic the fibrous structure of traditional meat.

By carefully aligning plant proteins and other ingredients, FPL™ builds layers that replicate the chewiness and juiciness of meat. This innovative 3D printing technique ensures that our plant-based meat products offer a highly realistic and satisfying eating experience, appealing to both flexitarians and meat-lovers looking for sustainable alternatives.

Benefits of using 3D printers for texture, flavor, and customization

The benefits of 3D printing in food production are numerous and far-reaching. One of the primary advantages is the ability to tailor textures to meet specific consumer preferences. By adjusting the composition and arrangement of ingredients, food producers can create plant-based meats with varying degrees of tenderness, chewiness, and juiciness. 

3D printing also offers unparalleled flexibility and efficiency in the production process. It allows for rapid prototyping and testing of new product formulations, enabling food companies to innovate quickly and respond to changing consumer trends.

The ability to produce small batches of customized products reduces waste and supports sustainable manufacturing practices. Moreover, the precision of 3D printing ensures consistent quality and reduces the risk of human error during production.

Examples of companies leveraging 3D printing for innovative plant-based products

We are pioneers in the use of 3D printing technology for plant-based food production. Our innovative approach allows us to create plant-based meats that closely mimic the taste, texture, and appearance of traditional meat products. By utilizing advanced 3D printing techniques, we can control the deposition of plant-based proteins, fats, and other ingredients with exceptional precision, resulting in products that offer an authentic meat-like experience.

For example, our SH™- Marbled Beef Steak is a testament to the capabilities of 3D printing. This product is designed to replicate the intricate structure of a beef steak, with layers of plant-based proteins and fats arranged to provide a juicy, flavorful, and satisfying bite. The use of 3D printing technology ensures that each steak is consistent in quality and delivers the same exceptional taste and texture in every bite.

Our commitment to leveraging 3D printing technology sets a new standard in the plant-based food industry, demonstrating that it is possible to create delicious, nutritious, and sustainable meat alternatives. Through continuous innovation, Steakholder is redefining what plant-based foods can achieve, providing consumers with high-quality options that do not compromise on taste or experience.

Final thoughts

The integration of advanced processing technologies is transforming the plant-based food industry, making it possible to create products that are not only sustainable and nutritious but also delicious and satisfying. At Steakholder, we are committed to leveraging these cutting-edge technologies to develop high-quality plant-based proteins that meet the evolving needs of consumers. By staying at the forefront of innovation, we are helping to shape a more sustainable and health-conscious future for the food industry.