An integrated approach to structure, texture and nutritional quality in high-moisture extruded meat analogues from faba protein concentrate and single-cell proteins

This study evaluated meat analogues using high-moisture extrusion (HME) using faba protein concentrate (FPC) alone (Control) and blends with single-cell proteins (SCPs): microalgae Chlorella vulgaris (SCP1) and bacteria Xanthobacter spp. (SCP2). Three blends were formulated via linear programming based on the beneficial nutrients content in meat (beef, pork and chicken): Blend1 (60% FPC + 40% SCP1), Blend2 (22.5% FPC + 77.5% SCP2), and Blend3 (13.5% FPC + 11% SCP1 + 75.5% SCP2). Composition, texture, phytic acid and in vitro digestibility analyses assessed protein quality and mineral bioaccessibility. Samples were oven cooked before assays to simulate typical consumption. Cooking caused minor structural changes, without significantly affecting protein denaturation or phytic acid levels, as extrusion was the dominant thermal process. Protein digestibility was high (close to 100%) across all samples and generally unaffected by cooking. SCP inclusion significantly improved amino acid profiles, with Blend1 and Blend2 classified as excellent sources and Control and Blend3 as good sources of essential amino acids. Minerals such as manganese and potassium showed enhanced bioaccessibility linked to reduced phytic acid levels due to SCP incorporation and extrusion. Compared to average meat and dietary reference values, extruded blends demonstrated promising nutritional equivalency, supporting their potential as sustainable, nutrient-dense meat analogues. This study highlights the benefit of combining alternative protein blends with high-impact extrusion to enhance meat substitute nutritional quality.