These cutting-edge solutions aim to enhance the quality and flavor profile of meat substitutes while simultaneously improving production efficiency.
With a continuously expanding market for plant-based meat substitutes, Coperion recognizes the increasing diversity of meat alternatives and the end products that can be generated from plant-based ingredients. Utilizing the ZSK twin screw extruder, high-precision Coperion K-Tron feeders, and dependable conveying solutions, Coperion presents cost-effective system solutions that minimize interfaces, ensuring that all processing steps and technologies function harmoniously.
The extrusion process, powered by Coperion ZSK twin screw extruders, has consistently demonstrated its effectiveness in both research and the commercial manufacturing of plant-based alternative products. These versatile food extruders not only offer flexibility but also excel in reliability and product quality. Specifically designed to optimize the unique properties of plant-based raw materials, they enable the creation of products that stand out in taste and nutritional value.
Coperion’s food extruders achieve maximum rotation speeds of up to 1,800 min-1. This increased energy input facilitates the breakdown of proteins during the process, allowing for greater flexibility in product design. The closely intermeshing screws, with a diameter ratio of Da/Di of 1.8, create a substantial free volume, significantly improving the intake of protein powders that can be challenging to process. Moreover, the modular construction of the process section allows for swift recipe adjustments and modifications by simply changing screw elements and process configurations, thereby supporting a wide variety of products made from diverse raw materials.
At IFFA, Coperion will unveil the MEGAtex S7 cooling die, designed specifically for manufacturing high moisture meat analogues (HMMA). After the ZSK food extruder discharges the plant protein mass, this texturizing unit imparts a dense, fibrous structure that closely mimics animal flesh. The MEGAtex S7 allows for variable width, strength, and texture options for meat substitutes. Coperion has equipped this cooling die with features that facilitate handling and enable quick recipe and configuration changes with minimal effort.
A vital part of Coperion‘s systems includes feeding solutions from Coperion K-Tron, which will display a representative model of the K3 vibratory feeder line at IFFA. These feeders cater to the gentle handling of various materials, particularly brittle and sensitive ingredients. The innovative K3 vibratory feeders are equipped with a patented drive system and an advanced control unit, achieving a level of accuracy that is on average 35% higher than conventional models. This enhanced precision reduces waste, thus increasing overall process efficiency. Additionally, shorter retooling and downtime further bolster productivity. These new vibratory feeders offer feed rates ranging from 1 dm3/hr to 8,500 dm3/hr.
“Our technologies allow manufacturers to optimize the texture and taste of meat alternatives while maximizing nutritional content at the same time,” explained Stefan Gebhardt, director of EMEA technical sales at Coperion. “By using innovative technologies, and thanks to our many years of process expertise, we can design our systems precisely to the needs of manufacturers. Moreover, at our comprehensive Test Centers worldwide, we can carry out all-encompassing trials with a variety of raw materials.”
