“Creating a great product requires a 360°view of customer expectations and a deep understanding of how the product is processed,” said Gilles Maller introducing Galaxy Texturization Technology, Clextral’s groundbreaking patented technology for Vegetable Protein Texturization.

Redefining alternative protein textures

Galaxy Technology sets a new standard by creating softer, more flexible textures and producing large whole cut pieces. The products obtained are equivalent to that of meat or fish.

“This innovative equipment is a game-changer for the market, delivering unmatched product performance.”

Transforming protein texture with innovative technologies

Totally new, this technology combines the principle of a shearcell fibration process and the continuous extrusion process.

The protein material is cooked in the extruder which continuously feeds the dynamic die. The structure and orientation of the fibers are different – in particular, the final structure of the product is due to the shearing and cooling of the dynamic die.

The Galaxy Texturing Technology enables a throughput up to 400kg per hour.

Exploring the universe of possibilities of extruded alternative protein

Continuous technology developed on the extrusion platforms opens up infinite possibilities for parameterization and modularity (temperatures, cooking, cooling, pressure, shear rate, screw profile and speed, residence time, etc.). Mastering this flexibility is key to product innovation and creation of new texture.

Pioneering innovation and elevating the standard of alternative protein products

Clextral is the pioneer and expert, since the 80’s, in the texturization and fibration of vegetable proteins by extrusion. With more than 35 years of experience in plant-based proteins, it offers its customers a flexible technology to create ever more realistic and tasty products while maintaining the highest nutritional profile. Its process team has developed proven recipes using soy and peas, and continues to explore the texturization of protein-rich raw materials, including a wide variety of pulses and even insect proteins.

Meet the Clextral USA team at the Food tech Summit Mexico, October 2 & 3, 2024, Booth 3516, so that, together, we can grow your business and be at the forefront of tomorrow’s food challenges.

Don’t hesitate to contact us for more information about your future Clextral equipment!

Clextral Alternative protein sample textured with Galaxy

Clextral Galaxy Texturization Technology

Clextral Large piece of product with Galaxy Technology

The demand for dairy alternatives has been steadily growing in popularity with consumers. The last three years have brought a rapid increase in new product offerings and an evolution of products available in the market. Today’s consumers are looking for additional dairy-free offerings beyond milk, seeking out plant-based cheese, sour cream, ice cream and more. They desire a variety of plant-based products and reward brands with repeat purchases when successful formulations are brought to market.

While consumers seek new alternatives to replace traditional dairy products, taste remains king. Recent Mintel research indicates 52% of consumers think that “taste” is the most important quality when deciding which plant-based products to purchase, with 39% of respondents indicating “health.” 

Enzymes play an important role in successfully formulating and processing many of the foods consumed every day. They also play a vital role in ensuring dairy alternative formulations have the taste and texture that will keep consumers coming back for more. “At Amano Enzyme, we are dedicated to helping food and beverage manufacturers create dairy alternatives that deliver healthy and delicious plant-based foods sure to satisfy consumers,” said Viet Ha, Technical Sales Manager, Amano Enzyme USA. “Our specialty enzymes help brands overcome many of the challenges associated with plant-based products, so that consumers don’t have to sacrifice flavor or texture to enjoy the nutritional benefits of plant-based foods.”

Deliver next-level taste and texture with Amano Enzyme solutions 

Amano Enzyme has developed an array of enzyme solutions that help formulators enhance the nutritional content, sensory aspects and functional properties of non-dairy products while helping processors overcome typical formulation challenges. With more than 75 years of experience producing specialty enzymes for food manufacturing and processing, Amano Enzyme offers a portfolio of innovative solutions for a wide range of plant-based food applications, including:

• Protein Glutaminase “Amano” 500 (PG500) provides anti-curdling and separation technologies for plant-based milk alternatives. This solution helps deliver creamy, foamy, frothy plant-based dairy products consumers are sure to love.
• AMTN 1.2L to control the sugar profile in plant-based milks.
• CheeseMax™ PB helps manufactures deliver a perfect, melty, stretchy high protein plant-based cheese.
• Lipase RH “Amano” an ideal solution for buttery-tasting plant-based oils.

From flavor to functionality, Amano Enzyme can help bring your next plant-based dairy vision to life. Take the next step and find out more about Amano Enzyme or request a sample here.

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Reference:
Mintel, “Taste is the top reason US consumers eat plant-based proteins,”
https://www.mintel.com/press-centre/taste-is-the-top-reason-us-consumers-eat-plant-based-proteins/. 

As consumers increasingly seek diets that are both healthier and more sustainable, the fortified food and beverage sector is experiencing significant growth in order to deliver well-balanced diets. Functional foods, enriched with a range of active ingredients such as botanicals, vitamins, and probiotics, are becoming more prevalent.

Among these, Vitamin D fortification is a strong trend in the market, driven by the fact that deficiency is a significant concern, affecting 37 percent of the global population. Given that only a few foods naturally contain substantial amounts of Vitamin D, many brands are fortifying their products with this essential nutrient. However, the fortification process faces challenges, as essential nutrients degrade over time with the impact of UV light, low pH and high temperatures. With these stability challenges, many FMCG manufacturers opt for overage of active ingredients, which can be costly and wasteful.

Nutrient microencapsulation offers a promising solution, as explored by brands such as Britvic. Xampla’s nutrient microencapsulation protects vitamins against external factors, preserving their efficacy. Leveraging its breakthrough natural plant protein technology, Xampla can prolong the shelf life of essential nutrients and minimise costly overages. This ensures that products deliver their promised nutritional claims by the time they reach consumers with superior nutrient protection, as well as optimised delivery.

For more information, visit https://xampla.com/nutrient-microencapsulation/

The future of plant-based food is not merely a fleeting trend but a transformative movement, reshaping our global food system. At Aromatech, we are at the forefront of this evolution, enhancing the sensory experience of plant-based foods and helping drive the industry’s growth.

The Rise of Plant-Based Diets
The rise of plant-based diets is fueled by growing awareness of the environmental impact of meat and dairy production, animal welfare concerns, and the pursuit of health and wellness. Consumers are increasingly demanding alternatives that offer the same taste and texture as traditional animal products, without the ethical and ecological costs.
The global plant-based food market is expanding rapidly, with innovations in plant-based milks, vegan cheese alternatives like feta, and plant-based proteins, as well as advancements in fermentation technologies and cellular agriculture, paving the way for more realistic and nutritious options.

Aromatech’s Role in Enhancing Sensory Experiences
Aromatech’s contribution lies in our expertise in flavor and aroma development. We understand that one of the key challenges for plant-based foods is replicating the sensory experience of meat, dairy, and other animal products. Through advanced technologies, we create natural and organic flavors, as well as aroma compounds, that mimic the taste and smell of these products, enhancing the overall appeal of plant-based foods.

Customization for Diverse Consumer Preferences
Our work allows for the customization of flavors and aromas to cater to diverse consumer preferences, ensuring that plant-based foods are not only sustainable but also enjoyable. This is crucial as the industry continues to grow, driven by technological advancements, increased investment, and rising consumer awareness.

A Flavorful and Sustainable Future
As we look to the future, Aromatech is committed to playing a pivotal role in this movement. By continuing to innovate and collaborate with food scientists, technologists, and manufacturers, we aim to make plant-based foods an integral part of the global food system, offering delicious, nutritious, and sustainable alternatives for a healthier planet and a more compassionate world.

Join Us at the Plant-Based World Expo 2024
Experience firsthand the future of plant-based foods by joining us at the Plant-Based World Expo 2024. Visit our booth (#309) to discover our innovative products, sample our plant-based offerings, and discuss how we can help you achieve your plant-based goals.

Subscribe to our weekly newsletter:
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For inquiries, contact us at [email protected] or explore our flavoring solutions on our website: www.aromatechus.com

Concepta Ingredients presents the Arboreto Premium Protein range, highlighting a plant-based protein active ingredient that helps combat climate change

The ingredient supplied by the Brazilian company is ideal for the plant-based market and promotes the socio-environmental development of the communities involved in its extraction and in actions to combat global warming.

Concepta Ingredients – a business unit of the Sabará Group that specializes in providing natural solutions for the food and beverage industry – has just launched the Arboreto Premium Protein range. The highlight is the plant-based protein active PRO 1000G, which is derived from the extraction process of sesame oil, a plant native to tropical Africa and Asia, introduced to Brazil by the Portuguese in the 16th century. The product has characteristics that make it an excellent nutritional profile, as it is rich in protein, fiber, calcium and a source of essential amino acids. 

The company is also introducing Arboreto Premium Protein PRO 1000GB, which innovatively combines the benefits of sesame, derived from the upcycling process of oil extraction, and babaçu, an ingredient of Amazonian origin and part of Concepta Ingredients’ Bio Abundance program, which aims to promote the sustainable use of natural resources and the development of the communities involved. The new product is ideal for use in pasta, bakery items, snacks, cereals and hot drinks.

“Consumer interest in alternative flours is growing, driven by nutritional benefits such as the fact that proteins contribute to satiety and muscle mass gain,” says André Sabará, commercial director at Concepta Ingredients.

The executive points out that the company is always looking to innovate in order to surprise customers in the plant-based market and this time it is launching Arboreto Premium Protein PRO 1000GB, a protein active that stands out not only for its culinary versatility, but also for its positive socio-environmental impact. “To give you an idea, for every 20 tons of flour sold, we generate an income of R$5,333.33 per family. In the Cerrado alone, there are 60 families impacted on 700 hectares,” he adds.

PRO 1000G offers more than 40g of protein per 100g of product, which provides a prolonged feeling of satiety. It is also rich in magnesium, calcium and potassium in significant quantities. As it is gluten-free, it is an option for intolerant individuals looking for a healthy diet rich in fiber.

Bio Abundance Program

Concepta Ingredients launched the Bio Abundance Program in 2022, responsible for contributing to the indirect maintenance of more than 580,000 hectares of native vegetation, spread across the Amazon Rainforest, Cerrado, Caatinga and Atlantic Forest biomes. The initiative is based on five pillars: connecting people in a virtuous value chain between the wealth of the forest and the market; conserving the standing forest; respecting the peoples and communities that inhabit it; encouraging the use of ingredients from Brazilian biomes; and promoting socio-economic inclusion and reducing social inequality. 

The Program recently gained a platform (www.bioabundancia.com), where customers and partners can find out more about Bio Abundance and stay up to date on the species and impact figures involved in the initiative.

Visit Concepta Ingredients at Plant Based World Expo North America on September 11-12, 2024 in New York City.

Handtmann develops and produces modular system technology for food production such as alternative protein products from the sectors of vegan meat, fish and milk substitutes and more. The modular process solutions are flexibly suitable for mixing, fine-grinding, inline-grinding, portioning, linking and hanging, forming, co-extrusion and depositing of a wide range of products and consistencies of alternative proteins. 

The variety of vegan meat substitutes is vast and can be roughly categorised into vegan sausages, vegan bacon, vegan cold cuts and vegan spreads. Apart from the typical meat substitute products such as vegan fried sausage, liver sausage or salami cold cuts, there is also an increasing demand for new products that explicitly do not have a look and feel of meat, such as sausage products based on mushrooms, vegetables, tofu, mycoprotein or seitan, plant-based protein concentrates, isolates and texturates or other hydrocolloids. Furthermore, Handtmann automatic and universal processing units can be used for simultaneous heating, mixing, grinding and emulsifying of hot and cold milk alternatives. The entire range of pasty and liquid milk substitutes such as plant-based milk alternatives are processed in a compact, closed complete system. Chunky raw material is pre-ground in the processing tank and mixed with dry materials and liquids. Cheese alternatives can also flexibly be produced in a great variety. Production of vegan fish products in various shapes and individual product appearance with fish flavour, texture and optics like the original is also possible including multiple variations such as “salmon” type or “tuna” type. 

The brand new IFTA gold awarded Handtmann ConProSachet system offers a new process for packaging fluid or pasty food products and food supplements in small sachets, pods or pockets. The system uses seaweed-based material instead of plastic films. The most significant advantage is that the sachets are edible and can simply be ingested, or disposed of in organic waste after use, because they biodegrade within a few weeks. The strong trend towards take-away and snacking as well as convenience and ready meals renders this particularly relevant in gastronomy and food service, e. g. sauces, dips, dressings, jams and other comparable products. The system also offers potential for product innovation in other industry sectors thanks to the new edible sachet form, e.g. for sausage and cheese products. The system was developed in cooperation with Notpla, a UK-based company committed to the development of all-natural packaging solutions and winner of the Earthshot Prize.

Find out more in the Handtmann whitepapers or trend report providing market information and information on optimal process technology. Valuable information, both for the experienced producer of vegan products and for start-ups or food producers who wish to add such products to their portfolio.

Processing technology for plant-based food by Handtmann, e. g. ConPro Sachet products or whole cuts

Clextral, a pioneer in extruded plant proteins, offers cutting-edge technologies to meet tomorrow’s food challenges. With over 35 years’ experience, our company stands out for its technological innovations dedicated to the production of alternative proteins, offering tasty, realistic, 100% plant-based products.

Advanced extrusion technologies

Our twin-screw extrusion technology enables us to produce HME (High Moisture Extrusion) and TVP (Texturized Vegetable Proteins) with unmatched efficiency. Thanks to our expertise and our complete production lines, it is possible to create ultra-realistic and tasty meat and fish analogues, meeting consumers’ growing needs for sustainable and healthy alternatives to meat products. Clextral has placed innovation at the heart of its strategy for many years, to best satisfy this large market.

Innovation for performance: HCD Technology

Innovation, the keystone of our approach, is represented by our High Capacity Die technology (HCD): this efficient advance enables us to produce up to 2,500 lbs. of alternative proteins per hour, meeting the high-productivity requirements of the meat and fish analog market. The HCD technology, with its double parallel output, doubles production capacity while maintaining consistent quality. This technology ensures that both product belts exit at the same speed, in a continuous flow, guaranteeing identical stretching, hardness and fibration characteristics.

Clextral commitments: durability, productivity, adaptability

Clextral is committed to providing sustainable food solutions for the future. Our flexible technology enables us to create even more realistic and tasty products, while optimizing production costs. HCD not only increases productivity, but also reduces energy costs and initial investments thanks to the optimized size of the extruders.

Inspired by global trends, our R&D team has created recipes adapted to a wide variety of raw materials. Our process flexibility fosters innovation and the use of differentiating ingredients, allowing us to meet consumer expectations in terms of taste and texture.

Meet the Clextral USA team at Plant Based World Expo North America, at the Javits Center in New-York (NY) from September 11 to 12, 2024, so that, together, we can grow your business and be at the forefront of tomorrow’s food challenges. Don’t hesitate to contact us for more information about your future Clextral equipment!

The plant-based food industry is rapidly evolving, and at Aromatech, we are proud to be at the forefront of this exciting transformation alongside our partner, Van Hees.

As leaders in flavor innovation and ingredient solutions, we are committed to delivering high-quality, natural, and organic products that meet the growing demand for plant-based alternatives.

At the Plant-Based World Expo 2024, we will showcase our extensive range of plant-based flavors designed to enhance the taste and appeal of various food products. From savory dishes to sweet treats, our flavors are crafted to bring out the best in plant-based ingredients, ensuring that consumers enjoy delicious and satisfying meals.

Our partner, Van Hees, renowned for its expertise in texture and functional ingredients, will present their latest innovations that provide the perfect mouthfeel and consistency for plant-based products. Together, we offer a comprehensive solution for manufacturers looking to create exceptional plant-based foods.

For more information, visit our websites:
https://www.aromatechus.com
https://www.van-hees.com 

Don’t miss out on the plant-based revolution – see you at Plant-Based World Expo 2024!

By Scott Grimes, Technical Business Development Manager at Donaldson

Consumer demand for healthier food options has compelled manufacturers to develop innovative ways to retain their place on the plate. Plant-based proteins and meat alternatives are growing in popularity, and companies are rapidly creating their own versions of both food items.

The increased competition is having an impact on the ingredient supply chain, so manufacturers are exploring new formulations and engineering new processes to develop equivalent products. Those processes are becoming increasingly complex and effective filtration management is a critical step in moving from research and development to successful commercial production.

$7.4 Billion USD plant-based protein sales in 2021*

Market Demand for Plant-Based Proteins

According to a 2021 study conducted by the Plant Based Foods Association* and The Good Food Institute, retail sales of plant-based foods increased by 6.2% from 2020 to 2021, bringing the market value to an all-time high of $7.4 billion USD. Whether in the center of the plate, as a dairy substitute, or as an ingredient in an energy drink, protein alternatives have reached the mainstream across the food and beverage spectrum.

Emerging Protein Alternatives

Current plant-based proteins have evolved well beyond just traditional bean and seed combinations. The growth and availability of potential alternatives has also inspired consumer discretion as they begin to seek more refined flavor profiles, textures, and taste characteristics. To meet those needs, manufacturers are expanding their options and using soybean roots, mushroom stems, fungal spores, and other plant-based sources. New ingredients like these often require new production processes and the addition of fermentation. Proper filtration plays a critical role in the micro-biological processing of those materials to achieve the desired characteristics.

Manufacturing Protein Alternatives

One of the plant-based protein segment’s most popular end-products – the burger patty – comes in an array of flavors, textures, and colors to appeal to as many consumers as possible. For all its variety, the category staple is still based on two primary elements: protein ingredients and structural ingredients – both of which require significant process filtration in their development.

Protein ingredients, such as fungal spores, go through a bioreaction process that requires the use of sterile filtered gases along with nutrients to support desired growth inside of the bioreactor. This process helps create unique product qualities with defining characteristics, such as texture.

Similarly, the manufacturing of key structural ingredients, like food starches, also requires strict process controls to help ensure maximum product quality. Sterile-grade gas and liquid filtration are often part of the process. Manufacturers use process-gas filtration to aid in evenly dispersing, or sparging filtered gases in the fermentation process, including during the anaerobic phase, which brings another set of sophisticated requirements.

Donaldson’s family of LifeTec™ filter elements are designed for applications that require sterile compressed air and gases that help optimize the processing of food and beverages, including plant-based products. The portfolio also includes versions for liquid applications including beer and wine, non-alcoholic beverages, and food ingredients.

Partnering with Purveyors of Plant-Based Proteins

While the processes involved in plant-based protein manufacturing have become increasingly complex, they are required to meet food production safety regulations and standards. A strategically engineered solution helps food producers to meet most requirements using filtered air and liquids. Without a filtration solution, manufacturers would not be able to meet their production goals while staying in compliance. Donaldson, along with its subsidiary, Solaris Biotechnology, are currently working with several innovative plant-based protein producers. From helping engineer initial lab-based product development feasibility studies to the creation of full-scale industrial systems, together we provide intuitive, scalable filtration solutions for plant-based food manufacturers.

You May Like…

Webinar: Filtration for Fermentation of Plant-Based Protein

Learn about the proper filtration techniques for air, gas and liquid used in the fermentation process and how they can support against contaminations.

 

Resources

Brochure

 

Plant-based meat, seafood, and dairy have enjoyed significant growth in recent times, but now momentum is stalling.

There are various reasons for this. One is that, in a sector driven by health-conscious consumers, the rise in media stories around ultra-processing have had an impact. A 2021 survey of vegans, vegetarians, flexitarians, and omnivores found that meat-reducer and meat-avoider consumers pay more attention to clean labels than omnivores.(1) A 2022 study on plant-based burgers, meanwhile, found that the use of simple and familiar ingredients helps to increase product authenticity and consumer acceptance.(2)

At the same time, many shoppers – and especially those who also consume animal products – expect plant-based alternatives to replicate the sensorial experience of the real thing. Taste, texture, and aroma are all vital, but color is the first thing consumers see and sets expectations on product quality. If a plant-based patty doesn’t look like a meat burger, they won’t believe it tastes like one either.

Concentrates made from fruits, vegetables, and plants can provide a highly effective solution for all types of plant-based food and drink. These colors can deliver shades from across the rainbow with minimal impact on flavor. They also offer perfect synergy with the plant-based category, enabling manufacturers to deliver visually appealing products with clean and clear labels.

EXBERRY® color concentrates are made from non-GMO fruits, vegetables, and plants and can be used in plant-based meat, fish, yogurt, ice cream, and beyond. Due to the way they are created, they support simple label declarations such as “fruit and vegetable juice for color,” “carrot juice for color” or “paprika (color).” They also pass the strictest ‘do-not-use’ ingredient lists of brands who choose the most natural, transparent ingredients for their products.

We offer complete customer support, working closely with our customers through every step of the product development process. Our services include concept innovation, color selection and matching, stability testing, upscaling, and regulatory matters.

No matter your requirements, EXBERRY® colors can provide the perfect solution for plant-based products – allowing you to deliver appetizing color shades while helping to maximize consumer acceptance. For more information visit, exberry.com.

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(1)Noguerol, A.T. et al. ‘Green or clean? Perception of clean label plant-based products by omnivorous, vegan, vegetarian and flexitarian consumers’ Food Research International (2021)
(2) Birke Rune, C.J. ‘Consumer perception of plant-based burger recipes studied by projective mapping’ Future Foods (2022)