Meat Alternatives

Co-extrusion makes it possible to efficiently process various plant-based raw materials while simultaneously creating complex textures and layers that closely resemble real meat. The basic principle of co-extrusion is that two or more materials are simultaneously pressed through a nozzle to create a multi-layer or multi-component product (see Table 1). Albert Handtmann Maschinenfabrik GmbH & Co. KG, based in Biberach/Riss, Germany, has established itself with its co-extrusion technology in the production of plant-based meat alternatives. Particularly worthy of mention is the new FME 570 forming and marbling unit, which makes it possible to produce whole pieces of meat with lifelike fat marbling and a high production output (see Figure 1). "With the Handtmann FME 570, it is now possible to produce products such as steaks or bacon on an industrial scale, at an hourly rate of 1,000 kilograms per hour and more," emphasises Winfried Hartwig, Division Manager for Alternative Proteins at Handtmann.

When producing plant-based meat alternatives, the quality of the raw materials is crucial. "What's more important than the origin of the raw material is its quality," explains Winfried Hartwig. High-quality extrudates and texturates often have fewer off-flavours (unwanted tastes or odours), which improves the taste of the end product. Combining different textures can create more meat-like structures and a more complex mouth feel. This flexibility makes it possible to tailor the finished product to the specific needs of consumers.

Co-extrusion technology enables the economical production of complex meat alternatives, for example with the FME 570 forming and marbling unit. In order to realise such products, it is necessary to combine a meat substitute and a fat substitute mass with specific properties, as a single mass could not meet these requirements. A system that moulds the initial masses into an end product that meets customer expectations both visually and haptically is therefore crucial. Such innovations contribute significantly to the increasing acceptance of meat alternatives. In addition, this technology promotes sustainability by being able to process various plant proteins and by-products that would otherwise go to waste. This contributes to the reduction of food waste and enables a more efficient use of resources.

The market for meat alternatives is dynamic and strongly driven by innovation. The challenge is to develop systems that are efficient, flexible and easy to use. The FME 570 moulding and marbling unit from Handtmann is an example of such a system. Thanks to its modular design, it not only enables the efficient production of plant-based steaks, but can also be quickly converted for the production of other products such as plant-based cold cuts or vegan mince. Thanks to this flexibility, Handtmann offers its customers a sustainable and economical solution for the diverse requirements of plant-based food production. Another challenge for co-extrusion technology is the constant availability and quality of plant-based raw materials. To ensure this in the long term, the development of new protein sources and improvements in cultivation and processing methods are essential.