Development of plant-based products from the optimization of the milling and air sorting process of carioca beans using thermoplastic extrusion.
Sustainable foods; plant-based products; plant-based meat analogues; functionality; functional ingredients; biodigestibility.
Carioca beans (Phaseolus vulgaris L.) are the most consumed legume in Brazil and one of the main sources of protein, carbohydrates, and minerals in the national diet, although they are still underutilized in the processed ingredients industry. Given the growing global demand for sustainable plant-based alternatives, this project proposes the use of dry fractionation (grinding and air sorting) as a more efficient technological route than wet isolation, which is excessively water- and energy-intensive. Air sorting allows the grain to be separated into a Protein-Rich Fraction (PRF) and a Starch-Rich Fraction (SRF), preserving the native functionality of the proteins and reducing the environmental impact of processing.
This project focuses on the complete valorization of these fractions through thermoplastic extrusion for the development of two types of high value-added products. The FRP (Fragrance-Reduced Protein) will be applied in the production of plant-based meat analogs via high-moisture extrusion (HMEC), a process that uses water content above 50% to create fibrous and anisotropic structures that mimic the texture of animal muscle. The FRA (Fragrance-Reduced Protein) will be used to manufacture expanded extrudates (snacks) through low-moisture extrusion, aiming to maximize the radial expansion index and crispness, offering a nutritionally superior alternative to traditional cereal snacks.
One of the cornerstones of this work is the reduction of antinutritional factors, such as phytates, tannins, and oligosaccharides that cause flatulence, using the combined effect of fractionation and heat treatment during extrusion to improve protein digestibility. In addition to in-depth biochemical, rheological, and structural characterization (including electron and confocal microscopy), the project includes sensory evaluation and consumer purchase intention assessments, seeking to ensure that the new products based on carioca beans are competitive with commercial benchmarks of soy and peas.