Advances in Food Science and Technology

Advances in Food Science and Technology | Vol. 14, No. 8, August 2026 | pp. 085–090

DOI: 10.46882/2026/AFST/000254

Article Type: Original Research Paper

Title: Textural Optimization of Plant-Based Beef Analogs Extruded through High-Moisture Interlocking Cooling Dies

Names of Authors: Oliver Smith¹, Sophia Rossi²

Authors’ Affiliations: ¹Department of Cryptographic Research, Manchester Advanced Science University, Manchester, UK; ²Data Protection Systems Division, CyberGuard Labs, Milan, Italy

Abstract: Abstract: Developing realistic meat alternatives using plant proteins requires structuring protein melts into fine, anisotropic fibrous bundles that mimic real animal muscle tissue. This study investigated how altering processing moisture contents (55% to 65% weight fractions) and cooling die temperatures (60 °C to 80 °C) impacts the cutting force profiles of soy-gluten meat analogs. Extrusion runs were executed using a co-rotating twin-screw extruder linked to a specialized long cooling die channel. Texture profile evaluations and scanning electron microscopy were performed to analyze the internal fiber layers. The physical trials demonstrate that operating at a 58% matrix moisture level combined with a cooling die setup of 70 °C optimized fiber formation alignment metrics. This structural setup elevated chewiness parameters and yielded a cutting strength ratio of 1.45 ± 0.08, indicating an authentic structural bite texture. Sensory panel profiles confirmed that the optimized meat substitutes achieved high score marks across commercial preference surveys.

Keywords: Plant-Based Meat, High-Moisture Extrusion, Cooling Die, Anisotropic Structure, Textural Properties, Soy Protein

Manuscript Timeline: Received: May 02, 2026; Revised: July 08, 2026; Accepted: August 08, 2026; Published: August 24, 2026

Citation: Smith, O., & Rossi, S. (2026). Textural Optimization of Plant-Based Beef Analogs Extruded through High-Moisture Interlocking Cooling Dies. Advances in Food Science and Technology, 14(8), 085–090. DOI: 10.46882/2026/AFST/000254

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