Replicating the complex bite and texture of meat remains a major challenge for plant-based meat analogues, as these depend on a multiscale structure and often differ in their fracture behaviour. In this study, we applied a multiscale structural–textural approach that integrates (i) molecular interactions, (ii) meso-scale architecture, and (iii) macroscopic fracture behaviour to compare meat with three plant-based analogues produced by extrusion, 3D printing, and a newly developed dry spinning method.

Dry spinning represents a promising bottom-up strategy to replicate the hierarchical organization of meat fibers, offering finer structural control and fiber alignment than conventional methods such as extrusion or 3D printing, while maintaining potential for scalability. To evaluate these approaches, we combined mechanical testing with microstructural characterization. In this way, we linked the different processing methods directly to variations in structural hierarchy and fracture behaviour.

At the macro scale, texture profile analysis and dynamic mechanical analysis in compression revealed that meat analogues were generally more anisotropic and viscoelastic than meat. Fiber orientation and interfiber connection played a decisive role for anisotropy and in fracture behaviour. Scanning electron microscopy imaging supported the mechanical data and identified sample-specific fracture patterns. Among the analogues, the dry-spun sample showed the lowest anisotropy and a more homogeneous deformation, indicating stronger and more uniform interfiber connections that resisted localized fracture.

At the meso scale, large amplitude oscillatory shear characterized the storage, and loss moduli, dissipation ratio, and strain-stiffening behavior. Meat showed a short linear viscoelastic region, low dissipation, and gradual stiffening, reflecting a stable, hierarchically organized network. Meat analogues displayed extended linear viscoelastic region ranges, higher dissipation, and earlier onset of plastic deformation, with differences strongly linked to processing technique. The dry-spun analogue exhibited the shortest linear viscoelastic region but maintained an almost isotropic response, like meat. At the micro scale, temperature-dependent small amplitude oscillatory shear confirmed that meat underwent classical thermally induced gelation. In contrast, most analogues were thermally pre-set and showed lower responsiveness to temperature changes. Protein solubility tests in selective solvents showed that meat networks involved a combination of hydrophobic, electrostatic, and disulfide interactions, while the meat analogues were mainly stabilized by hydrophobic interactions.

This multiscale analysis reveals how processing-driven differences at the molecular and meso scale define the macroscopic failure modes of meat analogues. The results provide a mechanistic framework for engineering plant-based products with improved bite and texture, narrowing the texture gap between meat and its analogues.

This poster qualifies for consideration for the Elsevier Best Poster Competition (graduate student research).