Accurate dosing of meat substitutes
What can the food industry learn from the production of successful meat alternatives?

The global population is growing rapidly, and the demand for sustainable, protein-rich food is increasing accordingly. Meat alternatives, based on plant-based proteins, offer a promising response to this development.

However, behind every successful plant-based “meat” product lies a complex production process, in which accurate ingredient dosing plays a crucial role. Within this field, technology providers such as Clextral (extrusion technology) and Kubota Brabender Technologie (dosing systems) work closely together. SPS | Solids Process Solutions represents Kubota in the Benelux and supports producers in translating this technology into a stable and reproducible process.

Flexitarians and the rise of meat alternatives
The growth of the global population and increasing awareness of sustainability have led to a clear trend: a conscious reduction in meat consumption.

Flexitarians are increasingly choosing plant-based alternatives that closely resemble meat in terms of taste, texture, and appearance. These products are made from protein-rich raw materials such as wheat gluten, soy, peas, lentils, chickpeas, and lupins.

For producers, the challenge lies not only in developing the right formulation, but above all in consistently reproducing the desired product characteristics under industrial conditions.

From raw material to end product: precision is key
In practice, the success of meat alternatives strongly depends on the accuracy with which raw materials are dosed. As is also observed in test facilities, even small deviations in ingredient feeding have a direct impact on both the process and the final product.

This can result in:

• variations in texture and fibre structure
• deviations in taste perception
• reduced product consistency

A deviation at the beginning of the process propagates throughout the entire production chain.

Two extrusion processes, one critical factor
The production of meat alternatives is mainly based on two extrusion processes:

• Dry process (TVP – Textured Vegetable Protein)
• Wet process (HMEC – High Moisture Extrusion Cooking)

In the dry process, a sponge-like, fibrous structure is created at relatively low moisture levels. The wet process operates at higher moisture contents and temperatures, resulting in a more meat-like structure. Despite these differences, both processes have one key requirement in common: they rely on highly accurate and stable ingredient dosing.

The role of dosing technology
To achieve this level of precision, gravimetric feeding systems are widely used in practice. These systems enable accurate feeding of a wide range of materials — including challenging bulk solids such as protein powders, fibres, and additives. In test environments, different feeder configurations are applied to determine the optimal setup for each product and formulation. This allows producers to quickly adapt to different raw materials and process conditions.

Practical applications in the market
Global demand for products such as TVP is growing rapidly. In Europe, Asia, and the Americas, extrusion lines are used for applications such as plant-based minced meat and chicken alternatives. In High Moisture Extrusion Cooking (HMEC), structures are created that closely resemble products such as pulled pork or chicken fillet. In these processes, parameters such as moisture content, temperature, and cooling are critical — but without accurate dosing, consistent product quality cannot be achieved.

Hygiene and flexibility in food processing
In addition to accuracy, food safety is an essential requirement. Dosing systems must meet strict hygienic standards and be easy to clean. Flexibility is equally important: producers need to switch quickly between different products and raw materials. Modern dosing systems address these requirements through:

• hygienic design
• ease of cleaning
• broad applicability

Looking ahead
The food industry is evolving rapidly. In addition to the growth of meat alternatives, we see a broader shift towards new raw materials and product categories, such as plant-based proteins, hybrid products, and functional ingredients. At the same time, market demands are increasing. Consumers expect not only consistent quality and taste, but also transparency, sustainability, and a higher level of product consistency. For producers, this means that processes must become more flexible while remaining highly controllable. Variability in raw materials, shorter product life cycles, and frequent product changeovers require systems that can adapt quickly without compromising accuracy. As a result, the focus in food processing is increasingly shifting towards process control and reproducibility. In this context, the importance of stable and accurate dosing continues to grow.

Conclusion
The increasing variability in raw materials, higher product requirements, and the need for flexibility mean that food producers must make critical decisions at an earlier stage in the process. It is precisely in these early phases — from product development to scale-up — that the foundation for a stable and reproducible production process is established.

At SPS | Solids Process Solutions, we support producers in this process in close collaboration with partners such as Kubota Brabender Technologie. By contributing at an early stage with expertise in dosing technology and process design, we help prevent later optimisation issues and process disturbances.

Do you have questions about dosing food ingredients or setting up your process for maximum stability from the start?
Feel free to contact us. We are happy to support you with a solution tailored to your application.