Use of Pea Proteins in High-Moisture Meat Analogs: Physicochemical Properties of Raw Formulations and Their Texturization Using Extrusion.

A new form of plant-based meat, known as 'high-moisture meat analogs' (HMMAs), is captivating the market because of its ability to mimic fresh, animal muscle meat. Utilizing pea protein in the formulation of HMMAs provides unique labeling opportunities, as peas are both "non-GMO" and low allergen. However, many of the commercial pea protein isolate (PPI) types differ in functionality, causing variation in product quality. Additionally, PPI inclusion has a major impact on final product texture. To understand the collective impact of these variables, two studies were completed. The first study compared four PPI types while the second study assessed differences in PPI inclusion amount (30-60%). Both studies were performed on a Wenger TX-52 extruder, equipped with a long-barrel cooling die. Rapid-visco analysis (RVA) and sodium dodecyl sulphate-polyacrylamide gel electrophoresis (SDS-PAGE) indicated differences in protein solubility among the different PPI types. In general, lower protein solubility led to better product quality, based on visual evaluation. Cutting strength and texture profile analysis showed increasing PPI inclusion from 30-60% led to significantly higher product hardness (14,160-16,885 g) and toughness (36,690-46,195 g. s). PPI4 led to lower product toughness (26,110 and 33,725 g. s), compared to the other PPIs (44,620-60,965 g. s). Heat gelling capacity of PPI4 was also highest among PPI types, by way of least gelation concentration (LGC) and RVA. When compared against animal meat, using more PPI (50-60%) better mimicked the overall texture and firmness of beef steak and pork chops, while less PPI better represented a softer product like chicken breast. In summary, protein content and also functionality such as cold water solubility and heat gelation dictated texturization and final product quality. High cold water solubility and poor heat gelation properties led to excessive protein cross linking and thicker yet less laminated shell or surface layer. This led to lower cutting firmness and toughness, and less than desirable product texture as compared to animal meat benchmarks. On the other hand, pea proteins with less cold water solubility and higher propensity for heat gelation led to products with more laminated surface layer, and higher cutting test and texture profile analysis response. These relationships will be useful for plant-based meat manufacturers to better tailor their products and choice of ingredients.

Role of chickpea flour in texturization of extruded pea protein.

A growing demand for alternative sources of texturized vegetable protein (TVP) has resulted from various factors including plant allergies, perceived health risks associated with genetically modified organisms (GMO), animal welfare beliefs, and lifestyle choices. Soy and wheat have been the primary ingredients in TVP over the past few decades, but desires for clean label ingredients (especially non-GMO and nonallergenic) have led to demand for alternative plant protein ingredients such as pea protein. To understand the capabilities of pea protein to create meat-like texture with additions of another protein source that also contributes starch, this study focused on extruding pea protein with increasing amounts of chickpea flour (CPF). Six treatments, with inclusions of CPF ranging from 0 to 50%, were processed on a twin-screw extruder to determine the optimal ratio of pea protein isolate to CPF. Bulk density was the greatest with 20% CPF (272 g/L) and resulted in the lowest water holding capacity (55.5%). Texture profile analysis (TPA) hardness, springiness, and chewiness showed optimum results for the 10 and 20% CPF (674 to 1024 g, 72.1 to 80.7%, 400 to 439, respectively). With no CPF addition, protein interactions created a strong network exhibiting extreme springiness (91.3%). Addition of CPF greater than 20% resulted in a detrimental decrease in hardness by 38 to 84% and chewiness by 73 to 92%. Phase transition analysis and specific mechanical energy data provided a greater understanding of the degree of texturization during extrusion. Inclusion of CPF between 10 and 20% led to the optimum protein to starch ratio, allowing adequate protein texturization and creating product characteristics that could potentially mimic meat. PRACTICAL APPLICATION: Pea protein was mixed with increasing levels of chickpea flour to produce a textured plant protein product using extrusion technology. The ratio of protein to starch can be optimized to target specific textural attributes of textured pea protein to closely mimic different meat products like fish, chicken, or beef. The 10 and 20% chickpea flour treatments produced the highest quality products according to textural attributes.

Salmonella Inactivation During Extrusion of an Oat Flour Model Food.

Little research exists on Salmonella inactivation during extrusion processing, yet many outbreaks associated with low water activity foods since 2006 were linked to extruded foods. The aim of this research was to study Salmonella inactivation during extrusion of a model cereal product. Oat flour was inoculated with Salmonella enterica serovar Agona, an outbreak strain isolated from puffed cereals, and processed using a single-screw extruder at a feed rate of 75 kg/h and a screw speed of 500 rpm. Extrudate samples were collected from the barrel outlet in sterile bags and immediately cooled in an ice-water bath. Populations were determined using standard plate count methods or a modified most probable number when populations were low. Reductions in population were determined and analyzed using a general linear model. The regression model obtained for the response surface tested was Log (NR /NO ) = 20.50 + 0.82T - 141.16aw - 0.0039T2 + 87.91aw2 (R2 = 0.69). The model showed significant (p < 0.05) linear and quadratic effects of aw and temperature and enabled an assessment of critical control parameters. Reductions of 0.67 ± 0.14 to 7.34 ± 0.02 log CFU/g were observed over ranges of aw (0.72 to 0.96) and temperature (65 to 100 °C) tested. Processing conditions above 82 °C and 0.89 aw achieved on average greater than a 5-log reduction of Salmonella. Results indicate that extrusion is an effective means for reducing Salmonella as most processes commonly employed to produce cereals and other low water activity foods exceed these parameters. Thus, contamination of an extruded food product would most likely occur postprocessing as a result of environmental contamination or through the addition of coatings and flavorings.

Use of Enterococcus faecium as a surrogate for Salmonella enterica during extrusion of a balanced carbohydrate-protein meal.

Multiple outbreaks of salmonellosis have been associated with the consumption of low-moisture products, including extruded products. Therefore, there is a need for a nonpathogenic, surrogate microorganism that can be used to validate extrusion processes for Salmonella. The objective of this research was to determine if Enterococcus faecium NRRL B-2354 is an adequate surrogate organism for Salmonella during extrusion. Extrusions at different temperatures were done in material contaminated with both organisms. Results indicated that the minimum temperature needed to achieve a 5-log reduction of E. faecium was 73.7°C. Above 80.3°C, the enumeration of E. faecium showed counts below the detectable levels (<10 CFU g(- 1)). Salmonella was reduced by 5 log at 60.6°C, and above 68.0°C the levels of this organism in the product were below the detection limit of the method. The data show that E. faecium is inactivated at higher temperatures than Salmonella, indicating that its use as a surrogate would provide an appropriate margin of error in extrusion processes designed to eliminate this pathogen. Attempting to minimize risk, the industry could validate different formulations, in combination with thermal treatments, using E. faecium as a safer alternative for those validation studies.

Validation of extrusion as a killing step for Enterococcus faecium in a balanced carbohydrate-protein meal by using a response surface design.

Outbreaks of salmonellosis and recalls of low-moisture foods including extruded products highlight the need for the food and feed industries to validate their extrusion processes to ensure the destruction of pathogenic microorganisms. Response surface methodology was employed to study the effect of moisture and temperature on inactivation by extrusion of Enterococcus faecium NRRL B-2354 in a carbohydrate-protein mix. A balanced carbohydrate-protein mix was formulated to different combinations of moisture contents, ranging from 24.9 to 31.1%, and each was inoculated with a pure culture of E. faecium to a final level of 5 log CFU/g. Each mix of various moistures was then extruded in a pilot scale extruder at different temperatures (ranging from 67.5 to 85°C). After the extruder was allowed to equilibrate for 10 min, samples were collected in sterile bags, cooled in dry ice, and stored at 4°C prior to analysis. E. faecium was enumerated with tryptic soy agar and membrane Enterococcus media, followed by incubation at 35°C for 48 h. Each extrusion was repeated twice, with the central point of the design being repeated four times. From each extrusion, three subsamples were collected for microbial counts and moisture determination. Based on the results, the response surface model was y = 185.04 - 3.11X(1) - 4.23X(2) + 0.02X(1)(2) - 0.004X(1)X(2) + 0.08X(2)(2), with a good fit (R(2) = 0.92), which demonstrated the effects of moisture and temperature on the inactivation of E. faecium during extrusion. According to the response surface analysis, the greatest reduction of E. faecium for the inoculation levels studied here (about 5 log) in a carbohydrate-protein meal would occur at the temperature of 81.1°C and moisture content of 28.1%. Other temperature and moisture combinations needed to achieve specific log reductions were plotted in a three-dimensional response surface graph.