Development of a Plant-Based Meat Analog Fermentation System

Thesis Abstract

The rapid growth of plant-based foods has intensified the need for scalable, reproducible fermentation systems that can produce meat analog textures and flavors with commercial viability, environmental sustainability, and consumer acceptance. This study addresses the gap between bench-scale fermentation concepts and industrial-scale production of plant-based meat analogs by designing, implementing, and evaluating a dedicated fermentation system capable of integrating plant-based protein hydrolysates, microbial fermentation, and post-fermentation texturization processes. The aim is to develop a modular fermentation platform that enables controlled bioprocessing to improve texture, juiciness, and flavor profiles of plant-based meat analogs while ensuring cost-effectiveness and reproducibility across batches. Specific objectives are to (1) characterize optimal microbial consortia and enzyme pretreatment conditions for producing fibrous, fibrolamellar textures from legume-based protein matrices; (2) design and implement a pilot-scale fermentation assembly equipped with inline monitoring (pH, dissolved oxygen, metabolite sensors) and programmable processing steps for controlled texturization; (3) evaluate sensory, rheological, and physicochemical attributes of fermented products against conventional plant-based meats; (4) analyze the economic feasibility and life cycle environmental impacts of the fermentation system; and (5) establish a validated operating protocol and quality assurance framework for scalable production. A mixed-methods design was employed, combining experimental optimization with analytical evaluation. The population consisted of microbial strains from food-grade Bacillus, Lactobacillus, and Propionibacterium genera and plant protein matrices derived from soy, pea, and chickpea sources. A factorial experimental design (2-level for microbial inoculación, 3-level for hydrolysate pre-treatment, and 2-level for fermentation temperature) across 12 pilot runs yielded 96 measurement points per batch. Data collection instruments included inline near-infrared spectroscopy for real-time compositional monitoring, rheometer measurements for textural properties, gas chromatography–mass spectrometry for volatile flavor profiling, high-performance liquid chromatography for amino and organic acid quantification, sensory evaluation with a trained panel of 15 assessors, and life cycle assessment using SimaPro. Validity and reliability were ensured through calibration curves, inter-rater reliability checks for sensory data (Cohen’s kappa > 0.7), and replication across three independent fermentation runs. Data analysis employed analysis of variance (ANOVA) to determine significant effects of process variables, response surface methodology (RSM) for optimization, multivariate principal component analysis (PCA) blending flavor and texture indicators, and regression modeling to link process parameters with consumer-relevant attributes. A conceptual framework integrating the Technology Readiness Level (TRL) progression with the Food Quality Assurance model guided interpretation of results. Expected findings indicate that specific combinations of protein hydrolysates and microbial consortia under calibrated fermentation temperatures will produce fibrous networks with increased tensile strength (modulus improvement of 25–40% over control), enhanced juiciness (water-holding capacity rise by 8–15%), and favorable flavor compound profiles (reduction in grassy notes and elevation of buttery/roasted esters). Inline monitoring is anticipated to reliably predict product quality metrics (r^2 > 0.85 for texture and flavor correlations). Economic analysis is expected to show break-even feasibility at annual production volumes aligning with mid-sized athletic-nutrition brands, with preliminary life cycle assessment results indicating a 15–25% reduction in greenhouse gas emissions compared with conventional animal-derived equivalents, assuming renewable energy utilization. The study contributes to knowledge by integrating a plant-based protein fermentation module with a robust texturization strategy, providing a replicable protocol, quality assurance framework, and a decision-support model for scaling. The main conclusion posits that a carefully engineered plant-based meat analog fermentation system can deliver consistent textural and flavor improvements without excessive energy or water demands, enabling scalable production of high-quality products. Recommendations include deploying modular pilot plants in collaboration with industry partners, further exploring non-GMO microbial consortia to diversify flavor profiles, implementing continuous fermentation for improved productivity, and expanding life cycle analyses to account for regional energy mixes.