Data-driven extrusion technology for plant-based food innovation

Overview

This research program advances extrusion as a versatile, continuous processing technology for plant-based foods, addressing the growing shift from animal and dairy proteins to sustainable plant-based alternatives. The work focuses on improving the nutritional and functional quality of plant raw materials, including low-value side-streams such as brewers spent grain. By integrating pre-processing steps such as mechanical and enzymatic fractionation and fermentation with extrusion, the program aims to enhance protein utilization and controlled bioavailability. A central innovation is the use of measurement-based, data-driven product design and process control, which is essential for managing the variability and complexity of plant-based materials and ensuring long-term sustainable, profitable operations.

Technical specifications

Core approach:

• Systematic comparison of raw and pre-processed samples across multiple plant protein sources
• Dry and wet extrusion techniques applied to model samples of pure proteins and protein-carbohydrate blends
• Pre-processing treatments including mechanical fractionation, enzymatic fractionation, and fermentation to improve nutritional and functional properties
• Foodomics-based characterization combining targeted and untargeted quantification with high-throughput analytical platforms
• Multivariate data analysis to correlate biological characteristics, processing modifications, and nutritional needs
• Predictive model development integrating data from raw materials, process samples, and final products, including chemical-functional analyses, proteomics, and in-vitro studies

Key applications:

• Plant-based protein ingredients and finished food products
• Valorization of food industry side-streams into high-value ingredients
• Scalable, continuous manufacturing of sustainable protein foods

Technology readiness level

The research builds on prior departmental work demonstrating the feasibility of Foodomics approaches for correlating biological characteristics with processing modifications and nutritional needs. The program is structured around four work packages progressing from sample library establishment (WP1) through pre-processing optimization (WP2), extrusion-based product design (WP3), and predictive model development (WP4). Current readiness is at the applied research stage, with validation ongoing through systematic experimental work. The technology is positioned for advancement toward industrial-scale application through continued interdisciplinary collaboration and data-driven optimization.