Mechanical stretching technology for plant-based meat analogs with enhanced texture utilizing wheat gluten and pea protein isolate

The high-moisture extrusion process is widely used in the plant-based meat industry to produce meat analogs. However, new technologies are still being developed to mimic the diverse structural characteristics of meat. Therefore, in this study, we explored the potential of mechanical stretching combined with vacuum-autoclaving for the production of wheat gluten (WG)-pea protein isolate (PPI)-based meat analogs. Doughs were prepared using varying WG-PPI ratios and the effects of stretching and vacuum-autoclaving on their textural and microstructural properties were examined. The WG content significantly influenced the levels of hardness, cohesiveness, and springiness of the meat analogs. A higher WG content enhanced gluten network formation but resulted in a decreased hardness and texturization index due to increased structural disorder. Microstructural analysis revealed that vacuum-autoclaving enhanced protein bonding, resulting in more distinct fibrous structures. Varying the WG-PPI ratio generated a range of microstructures, further influencing the textural characteristics of the meat analogs. These findings suggest that mechanical stretching and vacuum-autoclaving can be effective in producing plant-based meat analogs with desirable textural qualities and fibrous structures. • A novel process using mechanical stretching and vacuum-autoclave was proposed. • Mechanical stretching increased protein alignment and texturization index. • Vacuum-autoclaving promoted protein aggregation and fibrous structures. • Higher wheat gluten enhanced springiness but reduced hardness and texturization. • Varying WG-PPI ratios changed pore size and protein network density in meat analogs.