Development of a plant-based meat analogue using soy protein and mushroom mycelium blends: design, implementation, evaluation

Thesis Abstract

This study addresses the sustainability, nutritional quality, and sensory acceptability challenges associated with conventional meat products by developing a plant-based meat analogue blending soy protein isolate with Fusarium- and Pleurotus-derived mushroom mycelium to improve texture, juiciness, and flavor while reducing environmental impact. The aim is to design, implement, and evaluate a scalable plant-based meat prototype that meets consumer expectations for texture, taste, and nutrition, while aligning with validated sustainability metrics. Specific objectives include (1) optimizing a formulation matrix of soy protein isolate and mushroom mycelium at predetermined ratios (6040, 5050, 4060 w/w) using a response surface methodology to maximize chewiness and water-holding capacity; (2) assessing physicochemical properties (pH, water activity, differential scanning calorimetry, texture profile analysis, colorimetry) and proximate composition; (3) evaluating sensory acceptability with trained panels (n = 40) and consumer acceptability with untrained panels (n = 120) across three cooking methods; (4) conducting in vitro digestibility and protein quality assessments (PDCAAS, in vitro digestibility assays) to ensure nutritional adequacy; (5) analyzing environmental life cycle impacts (LCA cradle-to-gate) comparing the plant-based analogue to conventional beef mince; and (6) performing a preliminary market feasibility analysis including cost projection and willingness-to-pay estimates. The methodology employs a mixed-methods design integrating experimental production trials with sensory science and sustainability assessment. The population comprises protein formulation scientists, sensory panelists, and environmental assessment practitioners. A factorial experimental design is used for formulation optimization, with a sample of three formulations replicated in triplicate. Data collection instruments include texture analyzers (Texture Profile Analysis), differential scanning calorimetry, proximal analysis, spectrophotometry for color metrics, high-performance liquid chromatography for protein profiling, standard AOAC methods for moisture, fat, and ash, and validated sensory evaluation questionnaires. Validity and reliability are addressed via calibration of analytical instruments, inter-rater reliability for sensory panels (Cronbach’s alpha > 0.85), and pilot testing of instruments. Data analysis employs regression and response surface methodology to identify optimal formulation, ANOVA to test differences in physicochemical properties and sensory scores, multivariate analysis (principal component analysis) for sensory profile, and regression models to relate texture and moisture to consumer acceptability. For nutritional evaluation, PDCAAS calculations are performed in accordance with FAO/WHO guidelines, with in vitro digestion modeled to simulate gastric and intestinal phases. The environmental assessment uses a comparative LCA with functional unit per 100 g of cooked product, incorporating cradle-to-gate inventory, and impact assessment across global warming potential, eutrophication, and land use; interpretation follows ISO 14044 standards. Anticipated findings indicate that increasing mushroom mycelium content enhances fibrous texture and juiciness perception, with a target formulation around 5050 showing synergistic improvements in chewiness, water-holding capacity, and sensory likability (mean overall liking score > 6.5 on a 9-point scale), while maintaining comparable protein content (25–28 g/100 g) and acceptable PDCAAS scores (>0.80). Expect significant reductions in environmental impacts relative to beef mince, particularly in land use and greenhouse gas emissions, when plant-based formulations replace 60–70% of beef servings in representative meals. The study contributes to knowledge by providing empirically validated formulation strategies for integrating soy protein isolate with mushroom mycelium to emulate meat texture, coupled with a comprehensive evaluation framework spanning functional, sensory, nutritional, and environmental dimensions. The main conclusion is that a soy-mushroom mycelium plant-based meat analogue can meet key sensory and nutritional criteria while delivering measurable sustainability benefits; recommendations include scaling production processes, exploring alternative mushroom species for texture optimization, refining processing parameters to further enhance juiciness, and conducting longitudinal consumer acceptance studies to inform market deployment.