Electrostatic spray drying for color reduction in plant proteins

Overview

Electrostatic spray drying (ESD) is a cutting-edge technology designed to address color reduction in plant-protein ingredients used for high moisture extrusion (HME) in meat analogs. This innovative approach involves refining a dark protein slurry to remove colored fractions, then drying it under nitrogen to form fine, free-flowing particles with a light-colored, clean-label carrier matrix. The resulting powder is lighter in color, dispersible, and retains its functional properties, enabling it to be blended directly into extrusion feeds. The process avoids synthetic whiteners while maintaining texture, nutrition, and processability.

Technical specifications

The ESD process operates at low temperatures, minimizing thermal browning and oxidation. Key features include:

• Refinement and drying: Initial refinement of protein slurry to remove brown pigments, followed by nitrogen-based electrostatic spray drying.
• Carrier matrix: Utilizes light-colored, clean-label carriers like maltodextrin or soluble fiber to visually mask residual pigments.
• Glassy shell formation: Rapid immobilization of protein in a protective shell limits oxidation and minimizes Maillard reaction darkening.
• Compatibility: The dry, free-flowing powder integrates seamlessly into existing extrusion processes without major redesign.

Technology readiness level

This technology is currently at TRL 4, indicating it has been validated in a laboratory environment and is ready for further development and optimization. Future validation phases will focus on refining the process parameters and testing in operational settings.