Innovative solutions for processing alternative proteins
What are the challenges in processing alternative proteins?
The production of alternative proteins requires precise control and continuous optimisation of manufacturing processes to ensure consistently high product quality and safety. Even minor deviations in the fermentation environment or in formulations can affect the texture, flavour and nutritional value of the final products and lead to production losses or financial damage. Real-time monitoring of the production equipment and early detection of deviations are therefore crucial to ensuring the efficiency and reliability of the overall process.
Another key challenge is scaling production to industrial volumes. A stable supply of growth media, precise control of temperature, pressure, and other critical parameters, as well as the hygienic separation of different production lines must be carefully coordinated. Intelligent process control and energy-efficient technologies help reduce resource consumption and significantly improve the economic viability of alternative protein production.
Which solution does ifm offer?
Real-time maintenance
ifm sensors monitor system conditions and report deviations at an early stage, enabling users to take action before unplanned downtime impacts overall plant operation.
Energy efficiency
Process sensors measure all relevant process parameters in production, eliminating blind spots and creating full transparency across the production process.
Process optimisation
To ensure long-term process reliability across complex, multi-stage operations, ifm provides a comprehensive range of sensors, connection systems and control components.
Automation of extruders
Extruders play a central role in the production of alternative proteins, especially in the manufacture of plant-based meat and dairy alternatives. Inside an extruder, protein sources are forced through a die under high pressure and elevated temperature. Pressure and heat alter the protein structures, resulting in a meat-like texture, enabling plant-based proteins to closely mimic the taste and texture of animal products.
Automation of mixers
Mixers play a key role in the production of alternative proteins, as they ensure the uniform blending of multiple ingredients. In the production of plant-based meat alternatives, mixers homogenise proteins, starches, fats, and spices into a uniform mass. This step is crucial to ensure a uniform texture, balanced flavour and proper moisture distribution in the final product. Precise mixing helps optimise both the quality and consistency of alternative protein products.
Automation of emulsifiers
An emulsion is essential in the production of meat substitutes, as it combines water, vegetable fats and proteins to form a stable, homogeneous mass. It provides the characteristic texture, juiciness and meat-like mouthfeel that consumers expect. In addition, the emulsion ensures uniform ingredient distribution and supports binding and shape stability, particularly in plant-based burgers, sausages, and sliced products. Without a stable emulsion, the texture would be crumbly, dry and less appealing.
Automation of heaters & freezers
Products suited for reheating (and requiring only minimal preparation by the consumer) are cooked after forming and coating. Various thermal processes such as frying, baking, boiling and/or steaming are used for cooking. In addition, increasing the usable lifespan of products is a key requirement. The process used to achieve this is referred to as Extended Shelf-Life Processes (ESLP). The aim of ESLP is to protect products from microorganisms. This is achieved by cooling the products to a temperature at which microorganisms and bacteria are killed. The cooling temperature varies depending on the product and the raw materials used.
Automation of homogenisers
Fat and protein molecules are evenly distributed by a homogeniser to achieve a smooth consistency. The milk is continuously agitated to ensure thorough mixing of the different phases. Without homogenisation, fat and water would separate, resulting in an uneven consistency and phase separation. The process improves the texture, mouthfeel and shelf life of the milk. It also prevents sedimentation within the packaging, ensuring the milk remains homogeneous. As a result, the product becomes more appealing and more closely resembles conventional milk.
Automation of decanters
Decanters are used in the plant-based milk industry to precisely separate solid components such as outer shells, fibres or cell residues of raw materials like oats, soya, almonds or peas from the liquid phase. Continuous centrifugation produces a smooth, creamy plant-based milk with consistent quality and improved shelf life. Decanters also enable efficient processing of large product volumes, helping to reduce waste and optimise the use of raw materials.
Automation in the fermentation process
Automation of the fermentation process ensures consistent product quality and optimises efficiency through real-time monitoring of temperature, density and nutrient levels. It replaces manual sampling and laboratory testing, minimises quality risks and enables immediate response to deviations. In addition, precise temperature control helps reduce energy consumption.
Automation of pasteurisation systems
Pasteurisation using ultra-high temperature (UHT) systems is essential to ensure the safety and quality of plant-based milk. Such systems require robust and reliable components that can withstand extreme temperature fluctuations. During the sterilisation of liquid products, harmful bacteria are eliminated through rapid heating and cooling immediately prior to aseptic packaging. This process extends shelf life and preserves product quality until the package is opened.
Automation of CIP systems
The CIP process is particularly important to ensure that production equipment is thoroughly cleaned and rinsed before the start of a new production run. A clean system is essential for food safety and product flavour. The overall effectiveness of the cleaning-in place (CIP) process is based on four fundamental principles: time, mechanics, chemicals and temperature. This means applying the correct chemical concentration at the right temperature and flow rate for the appropriate duration. The cleaning process must also follow the correct sequence, including pre-rinsing, (alkaline) cleaning, intermediate rinsing, (acidic) cleaning and final rinsing. The use of ifm solutions for CIP systems enhances both product quality and food safety.
Automation of aseptic filling machines
Aseptic filling machines are used for sterile filling. During the packaging process, high filling rates must be achieved while maintaining product quality. Efficient operation of aseptic filling machines is critical to meeting production schedules and minimising the risk of contaminated batches that result in product losses.