Design, Implementation and Evaluation of Fermented Plant-Based Meat Analogues

Thesis Abstract

Fermented plant-based meat analogues (FPBMA) offer a promising route to sustainable protein with enhanced flavor, texture, and nutritional profiles, yet practical challenges remain in scalability, sensory acceptance, and microbial safety. This study addresses the gap by designing, implementing, and evaluating FPBMA prototypes that balance consumer acceptability with industrial feasibility. The aim is to develop FPBMA formulations employing controlled fermentation to improve organoleptic properties and nutritional quality while ensuring safety and shelf-life stability. Specific objectives are (1) to identify fermentative microbial consortia and enzyme systems that optimize texture, juiciness, and umami flavor in plant-based matrices; (2) to engineer fermentation protocols (substrate preparation, inoculum ratios, fermentation temperature, and duration) that preserve or enhance protein digestibility and micronutrient bioavailability; (3) to evaluate sensory performance and consumer acceptance across multiple demographic cohorts; (4) to assess microbiological safety, shelf-life, and physicochemical stability under retail conditions; and (5) to develop a scalable production framework and a cost–benefit model for industrial adoption. A mixed-methods approach combines experimental design with sensory science and economic feasibility. The experimental component uses a factorial design (3x3x2) to test three plant protein bases (soy, pea, and lentil isolates), three fermentation inocula combinations (Lactobacillus plantarum, Propionibacterium freudenreichii, and a defined starter culture blend), and two processing temperatures (30°C and 37°C) across four fermentation durations (12, 24, 48, and 72 hours). N=360 FPBMA samples are produced and subjected to proximate analysis, amino acid profiling, mineral bioavailability (in vitro dialysis), texture profile analysis (hardness, cohesiveness, springiness), water-holding capacity, and lipid oxidation measurements. Sensory evaluation employs a consumer panel of N=200 adults (balanced by age, gender, and region) using a 9-point hedonic scale and Just-About-Right (JAR) scaling for saltiness and umami, complemented by a trained-panel descriptive analysis (n=12) to map flavor and texture attributes. Microbiological safety assessment includes total viable counts, lactic acid bacteria enumeration, pathogen screening (Salmonella, Listeria, Staphylococcus aureus) following ISO standards, and challenge tests with common spoilage organisms. Shelf-life studies monitor FPBMA samples at 4°C and 25°C for up to 28 days, tracking microbial growth, lipid oxidation (TBARS), colorimetric changes, and volatile profiles via GC-MS. Data analysis utilizes multivariate statistics and modeling to identify drivers of quality and acceptability. ANOVA and ANCOVA test the main effects and interactions of protein base, inoculum, and fermentation temperature on physicochemical and sensory outcomes, with post hoc Tukey tests for pairwise comparisons. Regression analyses quantify relationships between fermentation parameters and textural attributes, while structural equation modeling elucidates pathways linking fermentation-induced biochemical changes to consumer acceptance. Theoretical grounding draws on the Food Technology Innovation Adoption Theory and the Dual-Process Flavor Perception Model to interpret sensory outcomes, supplemented by the Theory of Planned Behavior to explain consumer willingness to purchase FPBMA. A risk assessment framework based on HACCP principles ensures microbial safety compliance, and a techno-economic model estimates production costs, capital expenditure, and break-even timelines for scaling. Expected findings indicate that FPBMA produced with pea and lentil bases combined with Lactobacillus plantarum–propionibacteria blends at 30°C for 24–48 hours yield superior texture (higher cohesiveness and springiness), enhanced umami taste, and improved protein digestibility relative to control plant-protein analogues. Sensory results are anticipated to show broad acceptability across age and regional segments, with preferred products achieving consumer “Just-Right” levels of saltiness and umami. Safety analyses are expected to confirm absence of pathogens and stable shelf-life under refrigerated conditions, with TBARS within acceptable limits up to 21 days. The study contributes to knowledge by integrating fermentation science with plant-protein technology to deliver FPBMA that meet sensory, nutritional, and safety criteria while offering a viable pathway for scalable production and market adoption. Practical recommendations include optimizing fermentation parameters for different plant matrices, advising on inoculum selection for industrial reactors, and providing a cost-effective production roadmap aligned with regulatory requirements. The research advances understanding of how targeted fermentation modulates texture, flavor, and nutritional quality in FPBMA, informing future product development and policy discussions on sustainable protein systems.