Developing new technology for commercial production of meat substitutes
- Product Development
Typical examples include breadcrumbs, croutons, gluten-free bread products, modified and pre-gelatinised flours, rusk for sausage fillings, and ice cream inclusions.
Compared with traditional processes, extrusion can bring significant savings in space, equipment, energy and labour; the process is also extremely flexible, enabling quick and easy switching between different recipes.
Extrusion is hygienic and energy efficient - all the action is in the short barrel: ingredients in, product out seconds later.
If it is possible to make a product with an extruder, it is almost certainly the cheapest, most efficient and most compact method for making it. Conventional processing typically involves a great deal more equipment, time and cost.
Breadcrumb is a typical example. The traditional process involves mixing, forming and baking bread before discarding the crusts and grinding. The same product can be made with no waste using only a twin-screw extruder and dryer.
Similarly for croutons; a bread-like texture can be developed in the extruder and the pieces cut to size at the die or a post-extrusion cutter. Croutons for the ingredients market (such as soups and salads) or a crunchier variant for the snacks market can both be produced by this method with rapid changes between them.
Extrusion is also an excellent way of addressing the market for gluten-free bread products as it can handle with ease the various alternative flours and starches used to make the dough. Screw profiles can be adjusted to achieve the desired characteristics much more readily than conventional processes, and it also overcomes the problems caused by stickiness of the dough.
Extruders also bring a lot of advantages to modified and pre-gelatinised flours used in products such as instant soups, ready meals, bakery pre-mixes and infant nutrition. The wide range of conditions that can be created in an extruder enable characteristics such as rapid and/or cold-water thickening, increased protein or fibre content, improved dispersibility and enhanced texture to be readily developed.
Other examples include soy-based high-protein crispies used in breakfast cereals, chocolate bars and snack/trail mix to add texture and volume, and low-protein versions based on wheat or corn; rusk for sausage fillings; and ice cream inclusions – generally cookie or biscuit based.
As well as the enormous savings in space, equipment, energy and labour the process is also much more flexible, enabling quick and easy switching between different recipes. Extrusion systems can be expanded as a business grows or markets change to move from ingredients into production of foods such as snacks and cereals,
Extrusion is perhaps the most versatile process available to the food industry. It is capable of producing a wide range of end products from a variety of different ingredients and rapidly switching between them. It can replicate products made using other, less flexible, methods and the breadth of process options offers product developers plenty of scope for innovation.
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