Location: Food Processing and Sensory Quality Research
2025 Annual Report
Objectives
Objective 1: Resolve the underlying biochemical mechanisms involved in effective texturization of plant proteins to enable increased commercial use of bean-based ingredients.
Objective 2: Develop innovative methods for texturization of plant-based proteins and assess the effects of these technologies on food product quality and sensory characteristics to enable the development of new products.
Approach
In recent times, there has been a rising demand from consumers for high protein foods. As a result, global protein markets are expected to expand with increasing consumer health consciousness and growing demand for plant-based food. Along with these current trends, there is a looming food deficit on the horizon. By 2050, global food production will need to increase by 70% to feed the rapidly growing world population. To accomplish this, roughly 33% of dietary protein will need to come from protein isolates derived from alternative sources. US agricultural commodities like pulse crops, oil seeds, cereals, hemp, and others can be utilized to fill these protein deficits. To support utilization of these commodities, research is needed to identify components linked to functional, nutritional, and organoleptic quality of protein isolates and texturized vegetable protein, and high moisture meat analogs made from them. Because this is an emerging area of study, there is a lack of scientific literature and understanding related to the biochemical and processing factors that influence quality of these products. Identifying the mechanisms behind product variability will provide avenues to reduce it. The goals of this research are to decrease global food shortages and increase value of US agricultural commodities by advancing strategies to incorporate alternative proteins into the human diet. This research will enhance the functionality of alternative protein isolates, texturized vegetable proteins, and high moisture meat analogs through optimization of processing and biochemical modifications while maintaining or improving their sensory quality. Technologies such as extrusion will be used to yield texturized proteins and meat analogues, and analytical and affective sensory analysis methods will be used to assess end-use quality. The central hypothesis of this project is that alternative protein functionality and quality is dependent on the synergistic effects of processing techniques as well as the biochemistry of the starting material.
Progress Report
This project was initiated after the deadline for ad hoc review (April 2022). Therefore, there is no 5-year plan and no milestones.
Over the past three years, researchers made substantial progress in understanding and improving the biochemical and processing factors that influence the quality of plant-based protein ingredients. This work supports National Program 306 (Product Quality and New Uses) and directly addresses the urgent need for expanded sources of sustainable, nutritious proteins to meet global food demand.
ARS researchers at New Orleans,Louisiana developed and applied new methods to characterize the protein composition of pulse crops and other emerging plant protein sources. These crops exhibit more biochemical variability than traditional protein sources like soy. By screening and comparing protein profiles in raw materials and protein isolates, researchers identified sources of inconsistency that affect texture and processing. This knowledge is being shared with breeders and geneticists to guide the development of more consistent, high-functioning crop varieties. These improvements will help farmers deliver value-added commodities and provide processors with more reliable ingredients for protein-rich foods.
To support these goals, ARS modernized research infrastructure by acquiring new extrusion and filtration equipment and expanding protein isolation capabilities. This enabled more controlled processing experiments and allowed researchers to develop and test scalable methods for improving protein structure and functionality. In collaboration with Washington State University, ARS researchers evaluated how different processing conditions, including feed moisture, screw speed, and mechanical energy, affect the formation of fibrous protein structures. These studies revealed how raw material chemistry and processing conditions interact to influence quality and laid a foundation for improving large-scale production of protein-based foods.
In peer-reviewed research published in 2024 and 2025, scientists discovered that certain processing aids, including cysteine and sodium metabisulfite, enhanced protein interactions by enabling the formation of disulfide-linked networks. These structural changes resulted in stronger and more coherent fibrous protein matrices, which are important for texture and mouthfeel. Another study showed that even when total disulfide bond content remained unchanged, structural properties improved through molecular reorganization during processing. These findings provide industry with targeted strategies to improve texture and reliability in plant-based protein products.
To better align processing outcomes with consumer expectations, ARS researchers conducted a consumer sensory study of plant- and mushroom-based jerky-style products with 152 participants. Consumer feedback was correlated with instrumental texture measurements to identify key drivers of acceptance and areas for improvement. This work helps guide product development to meet both sensory and nutritional goals.
In FY2025, ARS researchers developed and validated a new method for evaluating “visual fibrousness,” or the appearance of fibrous or thread-like structures in food. Using standardized reference images and a 15-point scale, a trained sensory panel of eight participants confirmed the method’s reliability. This technique provides an objective, repeatable tool to assess the visual appearance of texture. It supports quality assurance and enables clearer communication among developers, manufacturers, and consumers about expectations for protein-rich food products.
These efforts also advanced fundamental understanding of how to build structured protein matrices from crops like peas, lentils, and chickpeas. By identifying how proteins behave during processing and how structural transformations occur, ARS is helping the food industry unlock the full potential of U.S.-grown crops as primary sources of protein. These advances help diversify protein supply chains, reduce dependence on imported or animal-based protein, and create new economic opportunities for American farmers.
Taken together, this project contributes to national and global protein security by enabling the use of domestic crops in nutritious, stable, and appealing food products. Consumers benefit from increased access to healthy and sustainable foods made with ingredients grown and processed in the United States. Farmers gain opportunities to add value to crops that traditionally served commodity markets. This research supports long-term food resilience by expanding the range and quality of proteins available for human consumption.
Accomplishments
1. Processing aids improve texture of plant-based proteins. ARS researchers at New Orleans,Louisiana and collaborators at Washington State University discovered that adding specific compounds during extrusion, such as cysteine, sodium metabisulfite, and glutathione, improves protein structure by enabling crosslinking between proteins. These additives helped form stronger protein networks during cooking, resulting in more fibrous and cohesive texture. Even when total disulfide bond levels stayed the same, researchers found that bond reorganization during processing significantly improved texture quality. These findings provide practical options for manufacturers to enhance the structure of protein-rich foods made from crops like peas and lentils. This work strengthens domestic protein supply chains by improving processing outcomes for underutilized crops. It supports farmers by expanding market demand and helps consumers access more appealing, plant-based protein options that contribute to long-term protein security.
2. Extrusion settings and protein type affect product structure. ARS researchers at New Orleans,Louisiana,in collaboration with Washington State University, studied how processing conditions such as feed moisture, screw speed, and temperature interact with different protein sources to influence product structure. Their results showed that each factor plays a unique role in determining the fibrousness and cohesiveness of the final product. The study also found that some combinations of protein type and extrusion conditions consistently led to improved texture. This knowledge gives food companies a pathway to optimize the processing of plant-based proteins, supports the use of underutilized crops, and leads to more reliable and appealing products for consumers. By improving processing predictability, this work helps secure a stable, high-quality supply of plant-derived proteins to meet future dietary needs.
3. Mechanical energy and mixing influence protein behavior. ARS researchers at New Orleans,Louisiana explored how mechanical energy and mixing affect the structure of plant proteins during processing. Using rheological testing, they examined how different shear patterns impacted the alignment and behavior of glutenin and gliadin proteins. The results showed that changes in mixing and flow conditions can influence protein structure and ultimately product stability. These insights support better process design for structured protein products and help increase the range of crops that can be used in high-protein foods. This research enables more efficient use of available agricultural resources to produce quality protein ingredients, which is critical to ensuring long-term protein security for a growing population.
4. Consumer insights guide development of protein-rich jerky products. ARS researchers at New Orleans,Louisiana conducted a consumer study of plant- and mushroom-based jerky products to understand sensory preferences and willingness to pay. A total of 152 consumers rated texture attributes such as chewiness, toughness, and springiness. Soy jerky received the highest liking scores. Pea and faba bean jerky, when paired with protein content information, showed increased purchase intent. The study revealed that poor texture and high prices were key barriers to acceptance. These results give manufacturers clear targets for sensory improvement and pricing. This research helps farmers by increasing demand for pulse crops and benefits consumers by supporting the development of flavorful, protein-rich snacks that align with their health goals.
Review Publications
Yazar, G., Smith, B., Kokini, J. 2024. Effect of mixing and LAOS deformations on microstructural properties of gliadin and glutenin as analyzed by stop-flow frequency sweeps in SAOS. Foods. https://doi.org/10.3390/foods13203232.
Wagner, C., Smith, B., Ganjyal, G. 2025. The individual contribution of extrusion processing parameters and protein type on high moisture meat analogue texture, integrity, anisotropy, and protein chemistry. ACS Food Science and Technology. https://doi.org/10.1021/acsfoodscitech.4c01050.
Chaffee, O.R., Ardoin, R.P. 2025. Consumer perceptions of plant-based and mushroom-based jerky: A focus on texture, main ingredient and protein information, and willingness to pay. Current Research in Food Science. vol 10. https://doi.org/10.1016/j.crfs.2025.101058.
Kamboj, A., Richter, J., Bernin, J., Watanabe, P., Zhao, J., Smith, B., Ganjyal, G. 2025. Azodicarbonamide, hydrogen peroxide, and l-ascorbic acid aid in the modification of protein texture during high-moisture meat analog extrusion processing. Journal of Food Science. https://doi.org/10.1111/1750-3841.70346.