Plant-Based Foods

A major advantage of the technology lies in its flexibility and efficiency. Extrusion is a continuous process in which raw materials are automatically and precisely dosed into the process. "The right technology for research, development and production of plant-based foods is decisive for high-quality products and innovative ideas," explains Dr Patrick Wittek, process engineer at Coperion.

Coperion offers a complete system from a single source: From raw material feeding, dosing and mixing to extrusion. The gravimetric dosing systems from Coperion K-Tron enable a consistent supply of raw materials to the ZSK twin-screw extruder. In the production of TVP (a dry, directly expanded product), the solid mass is pressed through a perforated plate and granulated. For HMMA (a product with a high water content), a special cooling nozzle is used to give the vegetable proteins a fibrous, meat-like structure. The extruder achieves throughputs of up to 500 kg per hour and, thanks to the modularity of the processing section, offers a high degree of flexibility when changing products.

The flexibility of the ZSK twin-screw extruder allows manufacturers to quickly switch between the TVP and HMMA processes without having to make major adjustments. This hybrid solution allows for the efficient production of TVP and HMMA on the same machine.

Coperion has continuously developed extrusion technology in recent years to meet the growing demands for plant-based food production. The trend is moving away from mere imitation of meat towards new, independent plant-based products. The MEGAtex S7 cooling nozzle was developed specifically for the production of HMMA and offers manufacturers greater flexibility for quickly adapting recipes and configurations.

The modular design of the ZSK food extruder makes it easy to change recipes and make adjustments. This flexibility is particularly advantageous for research and development and for smaller production quantities. "Our customers benefit from the ability to test different products on the same machine and to achieve consistent results every time," reported Dr Wittek.

The choice of plant-based raw materials has a significant influence on the texture, flavour and colour of the final products. Soya, pea and wheat proteins are among the most commonly used raw materials. At the same time, research is being conducted into new protein sources such as field beans, lupins and algae in order to develop further possibilities.

The extrusion technology contributes to sustainability, as plant-based proteins have a smaller carbon footprint than animal-based proteins. In addition, extrusion makes it possible to process proteins into tasty and easily digestible foods, which increases the acceptance of plant-based alternatives. Thanks to its efficiency, extrusion also helps to reduce production costs and increase profitability.

The availability of high-quality plant-based raw materials continues to be a challenge. In particular, the quality and sufficient quantities of raw materials must be ensured in the long term. Coperion is constantly working on the further development of its extrusion technology to be able to efficiently use raw materials with a lower degree of processing. Overall, extrusion technology offers a flexible, sustainable solution for the production of plant-based meat alternatives. Continuous research and adaptation to industry needs makes Coperion a key player in the plant-based food production sector.