Hybrid plant-based meat alternatives structured via co-extrusion: A review

Abstract

Background

Hybrid foods, which combine plant-based proteins with conventional animal sources and/or future-forward alternatives, have emerged as a promising strategy to gradually bridge the gap between current animal-based diets and sustainable alternatives. Extrusion technology has also proven its potential in structuring diverse proteins into fibrous, meat-like textures.

Scope and approach

This review explores the co-extrusion of plant-based proteins with meat, fish and/or emerging alternative sources, including insects, algae, mycoproteins, and cell-cultured meat, as an innovative approach to the development of hybrid meat alternatives. We have discussed how the co-extrusion of plant-based proteins with conventional and/or alternative sources can complement them in mimicking conventional meats’ fibrous structure or achieve appealing textural, taste, color, and nutritional features. Challenges such as phase separation, off-flavors, and thermal instability or incompatibility are discussed, along with potential solutions through processing innovations, enzymatic modifications, and technological advancements.

Key findings and conclusions

Overall, precise optimization of extrusion parameters and mixing ratios for every two sources are critical to maintaining protein structuring and essential nutrients during co-extrusion. A shift toward utilizing co-extrusion to develop hybrid products that transcend fibrous texture—integrating enhanced nutritional value, color, flavor, cost and health benefits through the complementary and unique potentials of diverse sources and reactions during co-extrusion—should define the future direction. By leveraging extrusion and hybrid formulation advancements, the food industry can develop scalable, nutritionally rich, and environmentally sustainable alternatives that align with evolving dietary preferences and global food security goals.