Process optimization of saturated steam-assisted texturized plant protein for mimicking cooked chicken breast characteristics

This study addresses the global demand for sustainable protein alternatives by optimizing the texturization of plant-based proteins using saturated steam technology. The optimization of this process was done using a Central Composite Rotatable Design for key process parameters (e.g., dough processing time, thermal exposure time & temperature) that influence the quality of TPPs. Saturated steam-assisted texturization significantly impacted the acceptability attributes such as texture, color, and sensory preferences of TPPs. Thermal exposure time and temperature were critical in optimizing hardness, chewiness, and overall acceptability. Increased exposure (beyond 30 min and 115 °C) caused protein denaturation, texture softening, and increased browning. The results indicated that moderate thermal exposure time (30 min) and temperature (118 °C) yielded the most desirable texture, color, and sensory acceptance. Finally, TPPs demonstrated superior protein content (39.41%), lower fat (0.50%), and equivalent in-vitro protein quality (0.86) compared to boneless chicken breast, positioning them as a viable, nutritious alternative to traditional meat products.