1208From nano to bite: The role of dietary fibers in plant-based meat alternatives

Tong Guan, Patrick Rühs, Peter Fischer*,**

Institute of Food, Nutrition and Health, ETH Zurich, Schmelzbergstrasse 7, 8092 Zurich, Switzerland

Plant-based meat analogues are the rising stars of the food industry and typically obtained via high-moisture extrusion cooking. Texturization is believed to mainly take place during the solidification in a cooling die attached to the end of the extruder. However, the mechanisms behind this texturization are not fully understood yet. This work presents three parts elucidating the flow and structuring of meat analogues in bound flow conditions with superimposed gelation. In situ SANS studies of fiber evolution within a custom-designed extruder cooling die demonstrated that macroscopic fibrous structures did not emerge from unfolding, elongation and orientation on molecular level. Based on that, chain-like arrangement of protein nanoaggregates, fractures of the viscoelastic mass in the flow field and sharp temperature-dependent solidification are proposed as underlying mechanisms for macroscopic fiber formation [1]. Texturization was also studied using a high pressure shear cell to compare the rheological behavior of different raw materials highlighting the relevance of polymerization and fracturing in fibrous structure formation. Finally, we could show that the incorporation of dietary fiber into plant-based meat analogues enhances their fibrous structure. Here we employed SANS and scanning SAXS-based imaging techniques to access the nano-structure of soy- and pea-based extrudates with the addition of pea fiber, pectin, and cellulose. We discovered that the inclusion of fiber leads to the formation cellulose-rich regions at microscale, which act as nucleation sites for fractures in the extrudate, leading to a greater prevalence of fibrous structures at macroscale [2]. Our studies examine the flow structuring across multiple length scales, providing valuable insights for optimizing formulations, and particularly the first comprehensive overview on protein gel fracture in extrusion flow.

[1] T. Guan, C. Sägesser, R. Villiger, L. Zychowski, J. Kohlbrecher, J. Dumpler, A. Mathys, P. Rühs, P. Fischer, O. Matsarskaia: In situ studies of plant-based meat analog texturization, Food Hydrocolloids 155 (2024) 110215
[2] T. Guan, V. Lutz-Bueno, M. Schlangen, A. Diaz, O. Matsarskaia, P.A. Rühs, P. Fischer: From nano to bite: Dietary fibers induce fracture mechanisms during highmoisture extrusion of plant-based meat alternatives, Food Hydrocolloids 173 (2026) 112241