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Effects of Formulation and Process P...

Gao, Yiran,

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Effects of Formulation and Process Parameters on Extrusion Manufacturing of Soy Protein Products /

Record Type:	Electronic resources : Monograph/item
Title/Author:	Effects of Formulation and Process Parameters on Extrusion Manufacturing of Soy Protein Products // Yiran Gao.
Author:	Gao, Yiran,
Description:	1 electronic resource (61 pages)
Notes:	Source: Masters Abstracts International, Volume: 86-11.
Contained By:	Masters Abstracts International86-11.
Subject:	Chemical engineering. -
Online resource:	https://pqdd.sinica.edu.tw/twdaoapp/servlet/advanced?query=31998435
ISBN:	9798314864432

Effects of Formulation and Process Parameters on Extrusion Manufacturing of Soy Protein Products /
Gao, Yiran,

Effects of Formulation and Process Parameters on Extrusion Manufacturing of Soy Protein Products /Yiran Gao. - 1 electronic resource (61 pages)

Source: Masters Abstracts International, Volume: 86-11.

The increasing demand for sustainable and ethical protein sources has driven significant interest in plant-based meat alternatives. The evolution of plant-based proteins from ancient agricultural techniques to modern extrusion-based "textured vegetable protein" (TVP) processing has led to products with increasingly sharp approximations of animal-derived meats in taste, texture, and appearance.Today, extrusion processing is the primary industrial-scale strategy for producing structured plant-based meat analogs. The two main techniques are high moisture extrusion (HME) and low moisture extrusion (LME). HME produces ready-to-eat products with more controlled microstructure quality, but is less scalable due to reliance on highly refined products in feed sourcing, heat transport limitations in extrusion, and shelf stability in distribution. In contrast, LME uses minimally processed feed and yields shelf-stable products with lower production costs, a more sustainable supply chain, and is more environmentally friendly. Both methods transform plant proteins under high temperature and shear, causing protein denaturation and realignment to create fibrous structures that resemble muscle tissue.In this thesis, we aim to replicate existing LME TVP products using a commercially available benchtop twin screw extruder and mixture of corn meal and soy flour. We varied extrusion parameters such as temperature, feeder rates, screw speed, and moisture content. This research analyzes the impact of processing conditions on product texture, rehydration properties, and overall quality of the product. To solve the challenges with material feeding, we performed granulation pre-treatments for soy flour and corn masa to improve their flowability. Eleven formulations of different percentages of soy flour and corn masa mixtures were tested. The findings contribute to a deeper understanding of protein texturization in small-scale extrusion processing.In these experiments, we explored different protein parameters to achieve high protein content, expansion, and desirable texture in extruded products. Starting with pure defatted soy flour, we got a rubbery, minimally textured product with no expansion. To improve expansion and texturization, we blended soy flour with corn masa, resulting in products that show improved expansion and smoother surfaces. For the range of process parameters explored, best results were obtained for a formulation basis of 60g soy flour, 20g corn masa, and 20g water, a peak extrusion temperature of 140°C, a feeder speed of 60 RPM, and water pump speed of 12RPM.Our extruder allowed for independent control of the temperature across eight separate zones along the barrel of the extruder. We found that adjusting the temperature ramp along the first 5 zones of the extruder did not significantly change the products' appearance and structure. For the last three zones, we tested at 140 °C and 160 °C. We found that an increase in temperature generally led to less expansion and a more curly appearance in the products. The importance of water cooling was also identified, as it helped maintain moisture for expansion and prevent overheating. Lastly, we tested the rehydration resilience of extruded products. The results indicated that the products lost shape and became mushy when rehydrated, so further research is required to fully replicate existing commercial products manufactured at industrial scales. Future steps may include changes to the feed materials and changes to the extruder die design. We also did an acid treatment on the water and found that a lower pH would not create more expansion.

English

ISBN: 9798314864432Subjects--Topical Terms:

560457
Chemical engineering.
Subjects--Index Terms:

Process parameters

Effects of Formulation and Process Parameters on Extrusion Manufacturing of Soy Protein Products /
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245 1 0 $a Effects of Formulation and Process Parameters on Extrusion Manufacturing of Soy Protein Products / $c Yiran Gao.
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500 $a Source: Masters Abstracts International, Volume: 86-11.
500 $a Advisors: Peterson, Joseph Daniel Committee members: Srivastava, Samanvaya; Wright, Thaiesha Andrea.
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520 $a The increasing demand for sustainable and ethical protein sources has driven significant interest in plant-based meat alternatives. The evolution of plant-based proteins from ancient agricultural techniques to modern extrusion-based "textured vegetable protein" (TVP) processing has led to products with increasingly sharp approximations of animal-derived meats in taste, texture, and appearance.Today, extrusion processing is the primary industrial-scale strategy for producing structured plant-based meat analogs. The two main techniques are high moisture extrusion (HME) and low moisture extrusion (LME). HME produces ready-to-eat products with more controlled microstructure quality, but is less scalable due to reliance on highly refined products in feed sourcing, heat transport limitations in extrusion, and shelf stability in distribution. In contrast, LME uses minimally processed feed and yields shelf-stable products with lower production costs, a more sustainable supply chain, and is more environmentally friendly. Both methods transform plant proteins under high temperature and shear, causing protein denaturation and realignment to create fibrous structures that resemble muscle tissue.In this thesis, we aim to replicate existing LME TVP products using a commercially available benchtop twin screw extruder and mixture of corn meal and soy flour. We varied extrusion parameters such as temperature, feeder rates, screw speed, and moisture content. This research analyzes the impact of processing conditions on product texture, rehydration properties, and overall quality of the product. To solve the challenges with material feeding, we performed granulation pre-treatments for soy flour and corn masa to improve their flowability. Eleven formulations of different percentages of soy flour and corn masa mixtures were tested. The findings contribute to a deeper understanding of protein texturization in small-scale extrusion processing.In these experiments, we explored different protein parameters to achieve high protein content, expansion, and desirable texture in extruded products. Starting with pure defatted soy flour, we got a rubbery, minimally textured product with no expansion. To improve expansion and texturization, we blended soy flour with corn masa, resulting in products that show improved expansion and smoother surfaces. For the range of process parameters explored, best results were obtained for a formulation basis of 60g soy flour, 20g corn masa, and 20g water, a peak extrusion temperature of 140°C, a feeder speed of 60 RPM, and water pump speed of 12RPM.Our extruder allowed for independent control of the temperature across eight separate zones along the barrel of the extruder. We found that adjusting the temperature ramp along the first 5 zones of the extruder did not significantly change the products' appearance and structure. For the last three zones, we tested at 140 °C and 160 °C. We found that an increase in temperature generally led to less expansion and a more curly appearance in the products. The importance of water cooling was also identified, as it helped maintain moisture for expansion and prevent overheating. Lastly, we tested the rehydration resilience of extruded products. The results indicated that the products lost shape and became mushy when rehydrated, so further research is required to fully replicate existing commercial products manufactured at industrial scales. Future steps may include changes to the feed materials and changes to the extruder die design. We also did an acid treatment on the water and found that a lower pH would not create more expansion.
546 $a English
590 $a School code: 0031
650 4 $a Chemical engineering. $3 560457
650 4 $a Food science. $3 3173303
650 4 $a Nutrition. $3 517777
653 $a Process parameters
653 $a High moisture extrusion
653 $a Textured vegetable protein
653 $a Low moisture extrusion
653 $a Soy protein products
690 $a 0542
690 $a 0359
690 $a 0570
710 2 $a University of California, Los Angeles. $b Chemical Engineering 0294. $e degree granting institution. $3 3822425
720 1 $a Peterson, Joseph Daniel $e degree supervisor.
773 0 $t Masters Abstracts International $g 86-11.
790 $a 0031
791 $a M.S.C.
792 $a 2025
856 4 0 $u https://pqdd.sinica.edu.tw/twdaoapp/servlet/advanced?query=31998435