Comparison of the Rheological Properties of Plant Proteins from Various Sources for Extrusion Applications.

Plant proteins in foods are becoming increasingly popular with consumers. However, their application in extruded products remains a major challenge, as the various protein-rich raw materials (e.g., from different plant origins) exhibit very different material properties. In particular, the rheological properties of these raw materials have a distinct influence on the extrusion process and must be known in order to be able to control the process and adjust the product properties. In this study, process-relevant rheological properties of 11 plant-based protein-rich raw materials (differing in plant origin, protein content, and manufacturer) are determined and compared. The results demonstrate distinct differences in the rheological properties, even when plant origin and protein content are identical. Time sweeps reveal not only large differences in development of viscosity over time, but also in magnitude of viscosity (up to 15-fold difference). All materials exhibit gel behaviour and strain thinning behaviour in the strain sweeps, whereas their behaviour in the non-linear viscoelastic range differs greatly. Typical relaxation behaviour of viscoelastic materials could be observed in the stress relaxation tests for all materials. Comparison of the maximum achieved shear stress, which correlates with the elastic properties, reveals an up to 53-fold difference. The results of this study could serve as a starting point for adapting raw material selection and composition to process and product design requirements and help to meet the challenge of applying plant-based proteins in food extrusion.

Morphology Development and Flow Characteristics during High Moisture Extrusion of a Plant-Based Meat Analogue.

Plant-based meat analogues that mimic the characteristic structure and texture of meat are becoming increasingly popular. They can be produced by means of high moisture extrusion (HME), in which protein-rich raw materials are subjected to thermomechanical stresses in the extruder at high water content (>40%) and then forced through a cooling die. The cooling die, or generally the die section, is known to have a large influence on the products' anisotropic structures, which are determined by the morphology of the underlying multi-phase system. However, the morphology development in the process and its relationship with the flow characteristics are not yet well understood and, therefore, investigated in this work. The results show that the underlying multi-phase system is already present in the screw section of the extruder. The morphology development mainly takes place in the tapered transition zone and the non-cooled zone, while the cooled zone only has a minor influence. The cross-sectional contraction and the cooling generate elongational flows and tensile stresses in the die section, whereas the highest tensile stresses are generated in the transition zone and are assumed to be the main factor for structure formation. Cooling also has an influence on the velocity gradients and, therefore, the shear stresses; the highest shear stresses are generated towards the die exit. The results further show that morphology development in the die section is mainly governed by deformation and orientation, while the breakup of phases appears to play a minor role. The size of the dispersed phase, i.e., size of individual particles, is presumably determined in the screw section and then stays the same over the die length. Overall, this study reveals that morphology development and flow characteristics need to be understood and controlled for a successful product design in HME, which, in turn, could be achieved by a targeted design of the extruders die section.

Blending Proteins in High Moisture Extrusion to Design Meat Analogues: Rheological Properties, Morphology Development and Product Properties.

High moisture extrusion (HME) of meat analogues is often performed with raw materials containing multiple components, e.g., blends of different protein-rich raw materials. For instance, blends of soy protein isolate (SPI) and another component, such as wheat gluten, are used particularly frequently. The positive effect of blending on product texture is well known but not yet well understood. Therefore, this work targets investigating the influence of blending in HME at a mechanistic level. For this, SPI and a model protein, whey protein concentrate (WPC), were blended at three different ratios (100:0, 85:15, 70:30) and extruded at typical HME conditions (55% water content, 115/125/133 °C material temperature). Process conditions, rheological properties, morphology development, product structure and product texture were analysed. With increasing WPC percentage, the anisotropic structures became more pronounced and the anisotropy index (AI) higher. The achieved AI from the extrudates with a ratio of 70:30 (SPI:WPC) were considerably higher than comparable extrudates reported in other studies. In all extrudates, a multiphase system was visible whose morphology had changed due to the WPC addition. The WPC led to the formation of a much smaller dispersed phase compared to the overlying multiphase structure, the size of which depends on the thermomechanical stresses. These findings demonstrate that targeted mixing of protein-rich raw materials could be a promising method to tailor the texture of extruded meat analogues.

Extrusion Processing of Rapeseed Press Cake-Starch Blends: Effect of Starch Type and Treatment Temperature on Protein, Fiber and Starch Solubility.

For the valorization of oilseed press cakes into food products, extrusion can be used. A common way of applying the protein- and fiber-rich press cakes in directly expanded products is the combination thereof with starch, since starch gives a favourable texture, which correlates directly to expansion. To control product properties like expansion of protein and fiber-rich extruded products, the underlying physicochemical changes of proteins, fibers and starch due to thermomechanical input need to be comprehensively described. In this study, rapeseed press cake (RPC) was extruded and treated under defined thermomechanical conditions in a closed-cavity rheometer, pure and in combination with four starches. The impact of starch type (potato PS, waxy potato WPS, maize MS, high-amylose maize HAMS) and temperature (20/25, 80, 100, 120, 140 °C) on protein solubility, starch gelatinization (Dgel), starch hydrolysis (SH) and fiber solubility of the blends was evaluated. The extrusion process conditions were significantly affected by the starch type. In the extruded blends, the starch type had a significant impact on the protein solubility which decreased with increasing barrel temperature. Increasing barrel temperatures significantly increased the amount of soluble fiber fractions in the blends. At defined thermomechanical conditions, the starch type showed no significant impact on the protein solubility of the blends. Therefore, the observed effects of starch type on the protein solubility of extruded blends could be attributed to the indistinct process conditions due to differences in the rheological properties of the starches rather than to molecular interactions of the starches with the rapeseed proteins in the blends.

Effect of Oil Content and Oil Addition Point on the Extrusion Processing of Wheat Gluten-Based Meat Analogues.

High-moisture extrusion is a common process to impart an anisotropic, meat-like structure to plant proteins, such as wheat gluten. The addition of oil during the process promises to enhance the sensory properties of the meat analogs. In this study, the influence of oil on extrusion-relevant parameters as well as the structure-related characteristics of extruded wheat gluten was investigated. Oil was added directly to the extruder at different contents (0, 2, 4, 6%) and addition points (front/end of the extruder barrel). Process conditions, complex viscosity, Young's modulus and oil phase morphology were determined as a function of oil content and oil addition point. With increasing oil content, material temperature, die pressure, and complex viscosity decreased. The addition of oil at the end of the extruder barrel reduced this effect compared to the addition of oil in the front part of the extruder. It was observed that the extrudate's tensile strength is a function of material temperature, resulting in an increase in tensile strength with increasing material temperature. The oil was dispersed in the gluten matrix as small droplets with irregular shape. As the oil content increased, the size of the oil droplets increased, while the addition of oil at the end of the extruder resulted in a decrease in droplet size.

Impact of Rapeseed Press Cake on the Rheological Properties and Expansion Dynamics of Extruded Maize Starch.

Rapeseed press cake (RPC), an oil pressing side product rich in protein and fiber, can be combined with starch and valorized into directly expanded products using extrusion technology. The mechanism of starch expansion has been studied in detail, but the impact of RPC on expansion behavior is poorly understood. However, it can be linked to rheological and physicochemical properties and is a key product quality parameter. Blends with different amounts of RPC (0, 10, 40 g/100 g) were extruded at different barrel temperatures (100, 120, 140 °C) and moisture contents (24 or 29 g/100 g). The initial, intermediate and final sectional, longitudinal and volumetric expansion indices (SEI, LEI, VEI) were monitored directly, 10 s and 24 h after die exit to measure extrudate growth and shrinkage. The viscous and elastic properties of the extruded blends were investigated in a closed cavity rheometer. Starch and blends with 10 g/100 g RPC achieved a high initial SEI followed by significant short-term shrinkage. Blends containing 40 g/100 g RPC did not show any initial expansion. With increasing RPC content, the intermediate SEI decreased, but all samples reached a similar final SEI due to time-dependent swelling of the RPC blends. With increasing RPC content, the elasticity of the starch-based extruded samples significantly increased. Our study shows that comprehensive control and understanding of expansion mechanisms can be achieved only by investigating all stages of extrudate growth and shrinkage. We also found that the closed cavity rheometer is a powerful tool to correlate the rheological properties and expansion mechanisms of biopolymers.

Extrusion Processing of Pure Chokeberry (Aronia melanocarpa) Pomace: Impact on Dietary Fiber Profile and Bioactive Compounds.

The partial substitution of starch with dietary fiber (DF) in extruded ready-to-eat texturized (RTE) cereals has been suggested as a strategy to reduce the high glycemic index of these food products. Here, we study the impact of extrusion processing on pure chokeberry (Aronia melanocarpa) pomace powder (CPP) rich in DF and polyphenols (PP) focusing on the content and profile of the DF fractions, stability of PP, and techno-functional properties of the extrudates. Using a co-rotating twin-screw extruder, different screw speeds were applied to CPP with different water contents (cw), which resulted in specific mechanical energies (SME) in the range of 145-222 Whkg-1 and material temperatures (TM) in the range of 123-155 °C. High molecular weight soluble DF contents slightly increase with increasing thermomechanical stress up to 16.1 ± 0.8 g/100 g dm as compared to CPP (11.5 ± 1.2 g/100 g dm), but total DF (TDF) contents (58.6 ± 0.8 g/100 g dm) did not change. DF structural analysis revealed extrusion-based changes in the portions of pectic polysaccharides (type I rhamnogalacturonan) in the soluble and insoluble DF fractions. Contents of thermolabile anthocyanins decrease linearly with SME and temperature from 1.80 ± 0.09 g/100 g dm in CPP to 0.24 ± 0.06 g/100 g dm (222 Whkg-1, 155 °C), but phenolic acids and flavonoids appear to be largely unaffected. Resulting techno-functional (water absorption and water solubility) and physical properties related to the sensory characteristics (expansion, hardness, and color) of pure CPP extrudates support the expectation that granulated CPP extrudates may be a suitable food ingredient rich in DF and PP.

Functionalization of Enzymatically Treated Apple Pomace from Juice Production by Extrusion Processing.

Food by-products can be used as natural and sustainable food ingredients. However, a modification is needed to improve the technofunctional properties according to the specific needs of designated applications. A lab-scale twin-screw extruder was used to process enzymatically treated apple pomace from commercial fruit juice production. To vary the range of the thermomechanical treatment, various screw speeds (200, 600, 1000 min-1), and screw configurations were applied to the raw material. Detailed chemical and functional analyses were performed to develop a comprehensive understanding of the impact of the extrusion processing on apple pomace composition and technofunctional properties as well as structures of individual polymers. Extrusion at moderate thermomechanical conditions increased the water absorption, swelling, and viscosity of the material. An increase in thermomechanical stress resulted in a higher water solubility index, but negatively affected the water absorption index, viscosity, and swelling. Scanning electron microscopy showed an extrusion-processing-related disruption of the cell wall. Dietary fiber analysis revealed an increase of soluble dietary fiber from 12.6 to 17.2 g/100 g dry matter at maximum thermo-mechanical treatment. Dietary fiber polysaccharide analysis demonstrated compositional changes, mainly in the insoluble dietary fiber fraction. In short, pectin polysaccharides seem to be susceptible to thermo-mechanical stress, especially arabinans as neutral side chains of rhamnogalacturonan I.

Linking Expansion Behaviour of Extruded Potato Starch/Rapeseed Press Cake Blends to Rheological and Technofunctional Properties.

In order to valorise food by-products into healthy and sustainable products, extrusion technology can be used. Thereby, a high expansion rate is often a targeted product property. Rapeseed press cake (RPC) is a protein- and fibre-rich side product of oil pressing. Although there is detailed knowledge about the expansion mechanism of starch, only a few studies describe the influence of press cake addition on the expansion and the physical quality of the extruded products. This study assessed the effect of RPC inclusion on the physical and technofunctional properties of starch-containing directly expanded products. The effect of starch type (native and waxy), RPC level (10, 40, 70 g/100 g), extrusion moisture content (24, 29 g/100 g) and barrel temperature (20-140 °C) on expansion, hardness, water absorption, and solubility of the extrudates and extruder response was evaluated. At temperatures above 120 °C, 70 g/100 g of RPC increased the sectional and volumetric expansion of extrudates, irrespective of starch type. Since expansion correlates with the rheological properties of the melt, RPC and RPC/starch blends were investigated pre- and postextrusion in a closed cavity rheometer at extrusion-like conditions. It was shown that with increasing RPC level the complex viscosity |ƞ*| of extruded starch/RPC blends increased, which could be linked to expansion behaviour.

High Moisture Extrusion of Soy Protein: Investigations on the Formation of Anisotropic Product Structure.

The high moisture extrusion of plant proteins is well suited for the production of protein-rich products that imitate meat in their structure and texture. The desired anisotropic product structure of these meat analogues is achieved by extrusion at high moisture content (>40%) and elevated temperatures (>100 °C); a cooling die prevents expansion of the matrix and facilitates the formation of the anisotropic structure. Although there are many studies focusing on this process, the mechanisms behind the structure formation still remain largely unknown. Ongoing discussions are based on two very different hypotheses: structure formation due to alignment and stabilization of proteins at the molecular level vs. structure formation due to morphology development in multiphase systems. The aim of this paper is, therefore, to investigate the mechanism responsible for the formation of anisotropic structures during the high moisture extrusion of plant proteins. A model protein, soy protein isolate, is extruded at high moisture content and the changes in protein-protein interactions and microstructure are investigated. Anisotropic structures are achieved under the given conditions and are influenced by the material temperature (between 124 and 135 °C). Extrusion processing has a negligible effect on protein-protein interactions, suggesting that an alignment of protein molecules is not required for the structure formation. Instead, the extrudates show a distinct multiphase system. This system consists of a water-rich, dispersed phase surrounded by a water-poor, i.e., protein-rich, continuous phase. These findings could be helpful in the future process and product design of novel plant-based meat analogues.

Modification of Apple Pomace by Extrusion Processing: Studies on the Composition, Polymer Structures, and Functional Properties.

By-products of fruit and vegetable processing are an inexpensive and sustainable source of dietary fiber, potentially offering valuable functional properties such as water binding and thickening. Due to these favorable properties, they can be utilized to reformulate widely-consumed foods, e.g., bakery products or beverages. In this study, apple pomace was used as a model system to study whether extrusion technology affects food by-product functionality and thus has the potential to broaden the application of by-products in foods. The effect of the process parameters and the extent of thermo-mechanical treatment on the structural and functional properties of apple pomace were analyzed after extrusion trials using various screw speeds, water contents, and barrel temperatures. Compared to the raw material, apple pomace extruded at Tbarrel = 100 °C, n = 700 min-1 and mH2O = 17% showed an increased water solubility up to 33%. The water absorption increased from 5 to 19 Pa·s and the paste viscosity from 5 to 339 Pa·s by extrusion processing. Analyses of dietary fiber contents and fiber polysaccharide structures revealed that thermo-mechanical stress (n = 700 min-1, mH2O = 22%) increased the content of soluble dietary fiber from 12.5 to 16.7 g/100 g dry matter, and that the harshest conditions even enabled the formation of low-molecular-weight dietary fiber. Arabinans (as neutral rhamnogalacturonan I side chains) appeared to be most sensitive to thermo-mechanical stress, whereas xylans (i.e., a group of minor polysaccharides) were an example of a more stable fiber polysaccharide. Also, the degree of methylation of the pectic polysaccharides was strongly reduced from 50% to 15% when thermo-mechanical stress was applied. Imaging and pore size analysis showed that extrusion processing could disrupt the rigid cell wall macromolecular structure.

The Influence of Extrusion Processing on the Gelation Properties of Apple Pomace Dispersions: Involved Cell Wall Components and Their Gelation Kinetics.

By-products of fruits and vegetables like apple pomace can serve as techno-functional ingredients in foods. Due to their physicochemical properties, e.g., viscosity, water absorption, or oil-binding, food by-products can modify the texture and sensory perception of products like yogurts and baked goods. It is known that, by extrusion processing, the properties of by-products can be altered. For example, by thermo-mechanical treatment, the capacity of food by-products to increase viscosity is improved. However, the mechanism and involved components leading to the viscosity increase are unknown. Therefore, the complex viscosity of apple pomace dispersions and the involved fractions as pectin (a major part of the water-soluble fraction), water-soluble and water-insoluble fraction, were measured. In the investigated range, an increase in the pectin yield and water solubility was observed with increasing thermo-mechanical treatment by extrusion processing. However, pectin and water-soluble cell wall components had only a limited effect on the complex viscosity of apple pomace dispersions. The insoluble fraction (particles) were investigated regarding their swelling behavior and influence on the complex viscosity. An intensification of thermo-mechanical treatment resulted in increasing swelling behavior.

Influence of Thermomechanical Treatment and Ratio of ß-Lactoglobulin and α-Lactalbumin on the Denaturation and Aggregation of Highly Concentrated Whey Protein Systems.

The influence of thermomechanical treatment (temperature 60 °C-100 °C and shear rate 0.06 s-1-50 s-1) and mixing ratio of ß-lactoglobulin (ßLG) and α-lactalbumin (αLA) (5:2 and 1:1) on the denaturation and aggregation of whey protein model systems with a protein concentration of 60% and 70% (w/w) was investigated. An aggregation onset temperature was determined at approx. 80 °C for both systems (5:2 and 1:1 mixing ratio) with a protein concentration of 70% at a shear rate of 0.06 s-1. Increasing the shear rate up to 50 s-1 led to a decrease in the aggregation onset temperature independent of the mixing ratio. By decreasing the protein concentration to 60% in unsheared systems, the aggregation onset temperature decreased compared to that at a protein concentration of 70%. Furthermore, two significantly different onset temperatures were determined when the shear rate was increased to 25 s-1 and 50 s-1, which might result from a shear-induced phase separation. Application of combined thermal and mechanical treatment resulted in overall higher degrees of denaturation independent of the mixing ratio and protein concentration. At the conditions applied, the aggregation of the ßLG and αLA mixtures was mainly due to the formation of non-covalent bonds. Although the proportion of disulfide bond aggregation increased with treatment temperature and shear rate, it was higher at a mixing ratio of 5:2 compared to that at 1:1.

Denaturation Behavior and Kinetics of Single- and Multi-Component Protein Systems at Extrusion-Like Conditions.

In this study, the influence of defined extrusion-like treatment conditions on the denaturation behavior and kinetics of single- and multi-component protein model systems at a protein concentration of 70% (w/w) was investigated. α-Lactalbumin (αLA) and ß-Lactoglobulin (ßLG), and whey protein isolate (WPI) were selected as single- and multi-component protein model systems, respectively. To apply defined extrusion-like conditions, treatment temperatures in the range of 60 and 100 °C, shear rates from 0.06 to 50 s⁻1, and treatment times up to 90 s were chosen. While an aggregation onset temperature was determined at approximately 73 °C for WPI systems at a shear rate of 0.06 s⁻1, two significantly different onset temperatures were determined when the shear rate was increased to 25 and 50 s⁻1. These two different onset temperatures could be related to the main fractions present in whey protein (ßLG and αLA), suggesting shear-induced phase separation. Application of additional mechanical treatment resulted in an increase in reaction rates for all the investigated systems. Denaturation was found to follow 2.262 and 1.865 order kinetics for αLA and WPI, respectively. The reaction order of WPI might have resulted from a combination of a lower reaction order in the unsheared system (i.e., fractional first order) and higher reaction order for sheared systems, probably due to phase separation, leading to isolated behavior of each fraction at the local level (i.e., fractional second order).

Impact of defined thermomechanical treatment on the structure and content of dietary fiber and the stability and bioaccessibility of polyphenols of chokeberry (Aronia melanocarpa) pomace.

Dietary fiber is a potential replacement for other ingredients such as starch in reformulated extruded breakfast cereals. Analysis of chokeberry pomace powder revealed a total dietary fiber content of 57.8 ± 2 g/100 g with 76% being insoluble, 20% high molecular soluble and 4% low molecular soluble dietary fiber. The fiber polysaccharide composition was analyzed in detail by using a variety of analytical approaches. Extrusion-like processing conditions were studies in a Closed Cavity Rheometer enabling the application of defined thermal (temperature range 100-160 °C) and mechanical treatments (shear rates between 0.1 s-1 and 50 s-1) to chokeberry pomace powder. Application of temperatures up to 140 °C irrespective of the mechanical treatment does not remarkably alter dietary fiber structure or content, but reduces the initial content of total polyphenols by about 40% to a final content of 3.3 ± 0.5 g/100 g including 0.63 ± 0.1 g/100 g of anthocyanins, 0.18 ± 0.02 g/100 g of phenolic acids and 0.090 ± 0.007 g/100 g of flavonols, respectively. The retained polyphenols are fully bioaccessible after in vitro digestion, and antioxidant capacity remains unchanged as compared to the untreated pomace powder. Glucose bioaccessibility remains unaffected, whereas glucose content is reduced. It is concluded that chokeberry pomace powder is a good source of dietary fiber with the potential to partially substitute starch in extruded breakfast cereals.

Influence of medium-chain triglycerides on expansion and rheological properties of extruded corn starch.

Enhancement of product properties of extruded starch based products can be achieved by incorporating health promoting oil into the matrix. In order to achieve a preferably high expansion with a homogeneous pore structure, the expansion mechanisms have to be understood. In our study, we applied a customized twin-screw extruder set up to feed medium-chain triglycerides after complete gelatinization of corn starch, minimizing its effect on the starch gelatinization. Despite the fact, that the addition of up to 3.5% oil showed no influence on the extrusion parameters, we observed a three-fold increase in sectional expansion. Longitudinal expansion was less affected by the oil content. Rheological properties of the gelatinized starch were measured using an inline slit die rheometer. In addition to shear viscosity, we presented a method to determine the Bagley pressure, which reflects the elongational properties of a fluid. We were able to observe an increase in the Bagley pressure from about 25 bar up to 35-37 bar due to the addition of oil.