Influence of extrusion processing conditions on fibrous structure, texture, and digestibility of plant-based meat analogues incorporating faba bean protein and brewers’ spent grain

High-moisture extrusion is the most cost-effective method for producing meat analogues with desired microstructure and textural characteristics, owing to its combined unit operations and customisable process conditions. An appropriate combination of extrusion conditions is crucial for obtaining high-moisture meat analogue (HMMA) products with the desired characteristics. In this study, we systematically investigated the effects of varying extrusion conditions, specifically temperature (130-160 °C) and screw speed (100-300 rpm), on the formation of fibrous structure of faba bean protein-based HMMA in the presence of brewers’ spent grain. Our findings indicate that higher screw speeds and temperatures significantly enhanced the phase separation, physical cross-linking, and fibrous structure formation, which improved textural attributes and increased water retention capacity. Importantly, the fibrous structure achieved through adjusting extrusion conditions did not adversely affect the digestibility of faba bean protein-based HMMA. By reporting the efficacy of the extrusion conditions in structuring fibrous meat analogous similar to chicken meat, this study demonstrates that a high-quality meat alternative product can be efficiently produced using two sustainable ingredients (faba bean protein and brewers’ spent grain) without any external modifiers. • This study presents use of sustainable materials as a strategy for meat analogues • Higher extrusion temperatures and screw speeds enhanced structure and texture • A fibrous structure resembling chicken breast meat was successfully replicated • Extrusion optimization for fibrillation preserved digestibility without compromise • Digestibility and amino acid profiles comparable to animal meat were achieved