Meat substitutes are food products developed to mimic the taste, texture, and nutritional value of traditional meat. Sobatech developed a continuous three-phased process to produce Texturized Vegetable Proteins (TVP’s) based products allowing for efficient scaling of production meeting the rising demand for meat alternatives worldwide. The process starts at the continuous dosing of the TVP’s and ends at homogenizing the final mix. It allows for consistent and uniform blending of ingredients without any manual intervention.
Sobatech’s 3-phased process for TVP’s
Efficient and consistent mixing technology are the paramount to maintaining product quality and meeting large-scale demands. Sobatech’s 3-phased process for processing TVP’s is designed to optimize the hydration, emulsification, and the final mixing of TVP’s.
Phase 1: continuous TVP hydration
The continuous hydrater provides an optimal solution for hydrating large volumes of TVP’s over time. It is available in various sizes and specifications, allowing it to accommodate substantial quantities of TVP. The hydration system operates as a closed system, where the product is continuously fed into the machine. Inside, the TVP’s are hydrated uniformly and consistently, preserving their structure ensuring a lump-free and even hydration.
Phase 2: continuous production of emulsion
During this phase, water, oil and (methylcellulose) powder are mixed by high shear. This process takes place in parallel to phase 1. Sobatech is a specialist in high shear mixing. By carefully handling the shear forces, optimum emulsion is achieved without affecting the quality of the ingredients. The fibers remain intact during the kneading process. This is of great importance because preserving the fibre structure is essential for the final texture of the product.
Phase 3: continuous production of final mix
In this phase, the product from phase 1 (hydrated TVP) and phase 2 (emulsion) are dosed together in the final kneading step. Additionally, a powdered premix is added. During this process, the quality of the product is controlled by measuring the amount of kneading energy in the mixing chamber.
Benefits of a Sobatech continuous mixing system
The Sobatech continuous mixing system offers a range of advantages for the production of meat substitutes. Its innovative system enhances efficiency and product consistency through its automated kneading systems. Below are some of the key benefits that come with using a Sobatech continous mixing system:
- Cleaning in Place (CIP) available
- Fully automated dark room operation
- Constant (quality) control of product viscosity and temperature
- Consistent product quality
- Lower energy consumption
- Computer-controlled process due to customised HMI panel
