Mechanical properties and breakage pattern of plant-based burger analogues and their relationships with sensory perception

• Mechanical tests revealed strong texture variability among burgers. • In-vitro mastication showed different fragmentation patterns. • Crust resistance increased with fat and decreased with protein and sugar. • Fat content was positively related to adhesiveness and mouthfeel. • Tenderness, crispiness and meat-like texture drove liking; strange texture did not. The rising demand for plant-based meat alternatives (PBMAs) is driven by increasing environmental, ethical, and health concerns. Among these products, plant-based burgers have emerged as one of the most widely consumed meat substitutes. However, consumer acceptance of PBMAs is strongly influenced by their textural properties, which are often perceived as less appealing than traditional meat. This study evaluated the mechanical and sensory textural characteristics of 20 commercial PBMA burgers designed to mimic red meat, using a multidisciplinary approach combining instrumental texture tests (compression, penetration, and cutting), in-vitro oral processing to simulate mastication, and a consumer sensory evaluation. Instrumental measurements revealed substantial differences in mechanical parameters such as hardness, cohesiveness, adhesiveness, and crust formation. In-vitro mastication highlighted variation in particle breakdown patterns, although no direct correlation was found with mechanical attributes. Nutritional components, particularly fat and protein content, were significantly correlated with texture, suggesting that fat structuring and thermal behaviour during cooking modulate mechanical resistance. A sensory study using a check-all-that-apply (CATA) method with 100 consumers showed that attributes such as “meat-like texture,” “tender,” and “juicy” were strongly linked to consumer liking, while “strange texture”, “floury” or “pasty” textures negatively impacted acceptance. Additionally, some of these different measurements were interlinked, revealing underlying relationships between instrumental, nutritional, and sensory attributes. These findings provide valuable insights for enhancing the formulation and sensory experience of PBMA burgers. By combining mechanical, nutritional, and sensory data, this research supports the development of PBMA that are both more appealing and more aligned with consumer preferences