Extrusion-Induced Gelation and Network Formation in Meat Analogs Produced from Mung Bean Protein

Extrusion processing can induce gel-like network formation in plant proteins, enabling the advancement of structured meat alternatives with tailored textural properties. In this study, extrusion-induced gelation behavior of isolated mung bean protein (IMBP) was systematically investigated during the manufacture of low-moisture meat analogs (LMMA). The effects of key processing variables, rotational speed of the screw, moisture level, and processing temperature on gel network development, hydration behavior, and textural responses were evaluated using response surface methodology as an analytical framework. Increasing moisture content promoted protein hydration and facilitated the formation of continuous gel-like interactions, resulting in enhanced pore development and water-holding capacity. Variations in screw speed and processing temperature further modulated the extent of protein denaturation and network consolidation, influencing nitrogen solubility and mechanical properties. While the integrity index remained relatively insensitive to processing conditions, structural and functional responses exhibited clear dependencies on extrusion-induced gelation dynamics. The extrusion conditions of 39% moisture, 216 rpm, and 159 °C promoted the development of a well-defined protein network, leading to improved functional properties. These findings provide mechanistic insight into extrusion-driven gelation of IMBP and highlight its potential as a protein matrix for gel-based meat analog applications.