In the spin process, the starting material (protein
content > 90%, e.g., soya protein isolate) is sus-
pended in water and dissolved by the addition of
alkali. The 20% solution is then aged at pH 11
through constant stirring. The viscosity increases
during this step as the protein unfolds. The solution
is then pressed through the orifices of a nozzle
(5000–15 000 orifices, each with a diameter of
0.01–0.08 mm) into a coagulating bath of pH 2–3.
The bath contains an acid (citric, acetic, phosphoric,
lactic, or hydrochloric) and, usually, 10% sodium
chloride. Spinning solutions of protein–acidic poly-
saccharide mixtures also contain earth alkali salts.
The resulting protein filaments are extended further
(to about two to four times the original length) in a
‘winding up‘ step, and are bundled into thicker fibers
with diameters of 10–20 mm. The molecular inter-
actions are enhanced during stretching of the fibers,
thus increasing the mechanical strength of the fiber
bundles.
0043 The adherent coagulation solvent is then removed
by pressing the fibers between rollers, followed by
passing a neutralizing bath (sodium bicarbonate plus
sodium chloride) of pH 5.5–6 and, occasionally, also
a hardening bath (concentrated sodium chloride).
The fiber bundles may be combined into thicker
cords with diameters of 7–10 cm. Additional treat-
ment involves passage of the bundles through a bath
containing a binder (a protein that coagulates when
heated, such as egg protein) and other additives
such as modified starch or other polysaccharides,
aroma compounds or lipids. This treatment produces
bundles with improved thermal stability and aroma.
A typical bath for fibers that are processed to produce
a meat analog might consist of 51% water, 15%
ovalbumin, 10% wheat gluten, 8% soya flour, 7%
onion powder, 2% protein hydrolysate, 1% sodium
chloride, 0.15% monosodium glutamate, and 0.5%
pigments. Finally, the soaked fiber bundles are heated
and chopped.
0044 In the extrusion process, the moisture content
of the starting material (protein content about 50%,
e.g., soya concentrate) is adjusted to 30–40%,
and additives (sodium chloride, buffers, aroma com-
pounds, pigments) are incorporated. Aroma com-
pounds are added in fat as a carrier, when necessary,
after the extrusion step to compensate for aroma
losses. The protein mixture is fed into the extruder
(a thermostatically controlled cylinder or conical
body that contains a polished, rotating screw with
a gradually decreasing pitch) that is heated to
120–180
C and develops a pressure of 3–4 10
6
Pa.
Under these conditions, the mixture is transformed
into a plastic, viscous state in which solids are dis-
persed in the molten protein. Hydration of the protein
takes place after partial unfolding of the globular
molecules and stretching and rearrangement of the
protein strands along the direction of mass transfer.
The process is affected by the rotation rate and shape
of the screw, and by the heat transfer and viscosity of
the extruded material and its residence time in the
extruder. As the molten material exits from the extru-
der through a die of 4 mm diameter, the water vapor-
izes, leaving behind vacuoles in the ramified protein
strands.
0045The extrusion process is more economical than the
spin process. However, it yields fiber-like particles
rather than well-defined fibers. A great number and
variety of extruders are now in operation. As with
other food processes, there is a trend toward develop-
ing and utilizing high-temperature/short-time (HTST)
extrusion cooking.
See also: Aerated Foods; Casein and Caseinates: Uses
in the Food Industry; Colloids and Emulsions;
Emulsifiers: Organic Emulsifiers; Enzymes: Uses in
Food Processing; Functional Foods; Protein: Chemistry;
Quality; Sources of Food-grade Protein; Rheological
Properties of Food Materials; Single-cell Protein:
Yeasts and Bacteria; Soy (Soya) Beans: Processing for
the Food Industry; Soy (Soya) Cheeses; Stabilizers:
Types and Function; Wheat: Grain Structure of Wheat and
Wheat-based Products
Further Reading
Damodaran S and Paraf A (eds) (1997) Food Proteins and
their Applications. New York: Marcel Dekker.
Froning GW (1988) Nutritional and functional properties
of egg proteins. In: Hudson BJF (ed.) Developments
in Food Proteins, vol. 6, pp. 1–34. London: Elsevier
Applied Science.
Hettiarachchy NS and Ziegler GR (eds) (1994) Protein
Functionality in Food Systems. New York: Marcel
Dekker.
Kinsella JE (1978) Texturized proteins: fabrication,
flavoring, and nutrition. Critical Reviews in Food
Science and Nutrition 10: 147–207.
Kinsella JE and Shetty KJ (1978) Yeast proteins: recovery,
nutritional and functional properties. Advances in
Experimental Medicine and Biology 105: 797–825.
Kinsella JE and Srinivasan D (1981) Nutritional, chemical
and physical criteria affecting the use and acceptability
of proteins in foods. In: Solms J and Hall RL (eds)
Criteria of Food Acceptance, pp. 296–332. Zurich:
Forster Verlag.
Mitchell JR (1986) Foaming and emulsifying properties of
proteins. In: Hudson BJF (ed.) Developments in Food
Proteins, vol. 4, pp. 291–338. London: Elsevier Applied
Science.
Morrissey PA, Mulvihill DM and O’Neil EM (1987) Func-
tional properties of muscle proteins. In: Hudson BJF
4840 PROTEIN/Functional Properties