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Maker - Product Challenge

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Changemakers

TVP milling Equipment

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Vegan meat alternatives and plant-based foods have rapidly grown in popularity over the last decade. Many people are switching to meat substitute food products. Your body does not discriminate between proteins and calories coming from meats and those coming from plants. From a nutritional point of view, they all have the same value. But chewing on a portion of veggie pumpkin protein does not feel the same as a cut of meat - the texture is completely different.

Textured Vegetable Protein

What does a $300,000 burger taste like? Meat. The first lab-grown burger took two years and 20,000 strands of muscle tissue to produce. But with rapid advances in cultivated meat processing technology, non-animal meat alternative products can now take a lot shorter to prepare. And cost much less.

Cultivated meat

Making.com is a new online platform that helps makers find production technology quicker by grouping it around the products they make.

With the protein transition, both more sustainable plant- and animal-based solutions are advancing. We excitingly met Tobias Gaiser and John Sheehy from <a href="https://www.coperion.com/en/home">Coperion</a> who have <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr">key technology and know-how for the protein transition. We had a very insightful talk at</span> <a href="https://anugafoodtec.com">Anuga FoodTec</a> about the future of protein.



Among other processes, Coperion specializes in industrial extruders with their expertise in making texturized vegetable proteins (TVP) and high-moisture meat analogs (HMMA). They also have know-how in <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr">precision fermentation and other key processes for making cultivated meat</span>.

John, who is the Global Key Account Manager for Alternative Proteins, took the time to detail all the varieties and making processes of <span class="ui-provider a b c d e f g h i j k l m n o p q r s t u v w x y z ab ac ae af ag ah ai aj ak" dir="ltr"> plant-based and insect protein in addition to cultivated meat. He </span>explained that cultivated meat can not always compete with real meat in terms of texture and flavor. Therefore it is now being mixed with TVP, which has a special very meat-like texture. "The extrusion process creates these specific fibers within the TVP," adds John. These products should reach the market within a few months.

Tobias explained that TVP can be made from soy, pea, or wheat protein, but the list of alternatives is growing over time. Therefore the possibilities are endless. He emphasized that being plant-based is not just a statement, but many of their employees actually follow that course.

We're grateful for this talk with Coperion and are enthusiastic to see what innovations are coming our way in the protein revolution!

#Changemaker: how about a cultivated TVP fish or meat burger?

Food

Protein

With consumerism comes great responsibility. More and more are switching their diet towards vegan and vegetarian alternatives, varying from dairy to meat. As more plant-based meat technologies are being invented, the production is rising in popularity. Ever wondered which challenges come with that?

Plant-based meat

I’m high in fiber, proteins, and minerals. What are your superpowers?

Lentils are one of the oldest crops ever, and you’ll be surprised how versatile this humble legume can be. They are higher in proteins than beef and have other essential nutrients. That’s why they are the new "old" superhero or, more accurately, superfood.



Martin Jager and Cassandra Winter know it well. Martin and Cassandra are the founder of <a href="https://www.easyvegan.at/en/easyvegan-is-loved-by-everyone/" target="_blank" rel="noopener">EasyVegan</a>, ready-made frozen products relying on the power of lentils.

The Making.com team met them at Free From Amsterdam 2022 where Cassandra shared how everything started. Cassandra is a <em>burger lover</em> but wanted to create something tastier than the tofu and veggie burgers already on the market. So after many experiments in the kitchen with lentils, she found the right combination for a burger that - we assure you - is a wonderful explosion of flavors. So she bought a sales trailer and traveled through Austria and Bavaria, selling her vegan products at city festivals, culinary events, sporting events and concerts. EasyVegan was then founded in April 2017 with the life partner Martin to make the lentil products accessible to a broad mass.

EasyVegan products such as lentil sliders, lentil sticks, lentil balls, and lentil patties are sustainable, purely natural, lactose-free, gluten-free, GMO-free, preservative-free, and palm oil-free products. Moreover, they are SUPER tasty!

<a href="https://making-tst.imgix.net/2022/11/WhatsApp-Image-2022-11-23-at-10.55.28-3.jpeg"><img class=" wp-image-60450 aligncenter" src="https://making-tst.imgix.net/2022/11/WhatsApp-Image-2022-11-23-at-10.55.28-3-225x300.jpeg" alt="" width="366" height="488" /></a>

&nbsp;

#Changemaker: The plant-based burger made of lentils you didn't know you needed!

Our food chain starts in the soil, growing crops and livestock. But between the fields and the stores, there is a line of industrial food processing equipment. Processes may be as minimalistic as cleaning fruit and as complex as homogenizing milk alternatives made from pressed legumes. In each case, processing technology is an important link in the food production chain.

<span style="font-weight: 400;">Shaped and filled extruded products are extremely popular with consumers, but can be complex and inefficient to manufacture on a large scale whilst maintaining high consistency and quality. A dedicated extrusion solution designed from the ground up for high level production provides consistency while delivering reduced costs.</span>


<h2>Twin screw extruder with enhanced quality and production flexibility</h2>
<span style="font-weight: 400;">The SBX Master Extruder by Baker Perkins has been designed specifically to enable the production of a range of high quality extruded snacks. Its integrated design allows for the easy addition of flavouring and colours, and the SBX Master is capable of producing complex multi-ingredient premium product, as well as more standard designs such as expanded corn balls, multigrain rings and shaped designs.</span>

<span style="font-weight: 400;">The SBX Master is built for flexibility. A modular barrel design allows the perfect length to be chosen to exactly suit the product required, maximising quality, and advanced features are available such as super-cooling to allow the production of fine extruded flakes.</span>

<span style="font-weight: 400;">Set up, recipe selection and full condition monitoring are available through an easy-to-use HMI with graphical representation. The open frame design means all areas of the machine are easily accessible for cleaning and maintenance, and AC motors are used throughout which are maintenance free and consume less power than DC equivalents.</span>

<span style="font-weight: 400;">Another key aspect in reducing costs is the SBX Master’s capability for rapid product changeover. Face-cutter blades are able to be changed quickly, without the need for the extruder to be brought to a complete stop, and fully automatic start-up and shutdown cycles have been designed to minimise waste between production runs.</span>

Extruder for large-scale production of TVP

Baker Perkins supplies technology for the bakery, biscuit, confectionery, supplements, snack and breakfast cereal sectors, The company's production machines are based on over 100 years of experience in the field.

Soya, peas, beans or cereals are low in fat, high in fibre and protein content, and therefore a nutritious and healthy base for new meat analogues. The global shift away from meat leads to an increased demand for these TVP textured vegetable proteins (TVP) that can be often purchased in the form of dry chunks or flakes.


<h2>Higher moisture content for a meaty result</h2>
How is TVP made? Vegetable protein isolate from for example beans or peas is passed through an extruder. In this <a href="https://making.com/plant-based-meat">plant-based meat process</a> it is steamed, heated and – still hot – squeezed out of the machine nozzle. As soon as the substance cools, it changes into the desired form.

To achieve fibrous, chewy and meat-like TVP for veggie burgers it needs to be extruded at far higher moisture content of 50-70% . For sausages and for example nuggets only 20-30% is required. The moisture level facilitates forming, enabling a fibrous structure which can look and taste like natural meat.
<h2>Extrusion equipment for meatless meat</h2>
So the extrusion process begins with making a premix from soy beans, wheat, peas, lentils, etc. This mass is then transferred into a <a href="https://www.bakerperkins.com/news/developing-new-technology-for-commercial-production-of-meat-substitutes">double screw extruder,</a> where by the means of steam heating, shear, as well as presence of water, the meat-like structure is formed. When the material exits the extruder die, the structure is ready and can be further processed with different dyes or flavours, depending on the final product. The dye shape plays a significant role here, as it determines the final product - e.g., a circular cross-section tool for sausage-like products or a square cross-section for chicken analogues. Below a video of a TVP extruder from Baker Perkins. They have a cool R&amp;D centre to help their customers fine tune new recipes with for example seaweed and algae and further improve their meat-like taste and appearance.

[embed]https://www.youtube.com/watch?v=0B5RiyxijDI[/embed]

How to produce textured vegetable protein TVP?

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TVP milling

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