Frontline Food Consultants and Engineers possess extensive experience and knowledge for aiding your development of superior legume-based protein foods. The proteins comprising legume-based are obtained from such foods as peas, lentils, chickpeas, and beans. These have also been popular for their ability to produce high protein, enhanced nutritional value, and functionality in many food items. This means that, when dealing with legume-based protein products, we offer complete food processing solutions and food industry service, helping to guarantee the best flavor, texture, quality and nutritional profile on the market. We do full-process turnkey solutions to the whole process. 

Our New Product Development services help you formulate legume-based proteins with application in protein powders, meat substitutes, or snacks. We provide Technological Support with the aim of introducing techniques for further extraction and processing of grain legumes, primarily wet milling and protein isolation, which are necessary to achieve the highest possible protein content and functional properties of legume grains. Our Process Improvement specialty Areas major in Drying, Milling, and Texturizing services. 

We also offer Regulatory Compliance & Documentation services which will give you an assurance that your legume-based protein products meet respective safety and quality requirements. This comprises those related to allergen control as well as nutritional information provision. Our Audits & Training are a means by which we guarantee the appropriate compliance of your production units as well as the quality of all batches of legume-based protein produced.

What do Legume-Based Proteins Mean?

Soya-based proteins come from soya beans while those based on grains come from grains like peas, lentils, chickpeas, and beans. These plant proteins get great importance due to their rich contents of proteins, fiber and essential amino acids They are used effectively in the manufacturing of meat substitutes vegetarian products, protein supplements, and many nutraceutical products and functional foods. Most of the legume-based proteins are plant-based products thus catering for the increasing consumption rates of plant products across the globe.

They include the following activities establishing a center for the production of protein products from legumes. First, the legumes are sorted and washed: they are then milled in order to obtain a fine grind of the legume. Sophisticated techniques such as wet milling in soy and protein isolating in peas. They are used to sediment the protein, and these sedimentation steps help to rid the protein of unwanted such as starch and fiber. This process produces a high-quality protein isolate or concentrate, as previously described. The two can then be additionally converted into several forms such as powder form, texturized protein or even RTE products.

Appropriate drying and milling utensils can go a long way in getting the right particle size and texture while deploying our texturizing machines. This in turn aids in the development a to make a product that resembles the mouthfeel and texture arising from the use of meat-based proteins. Further, we need convenient packaging solutions that keep food tasty and nutrient-rich for its tendency to improve shelf life as expected by the customers. 

Type of leguminous proteins

Lentil Protein

  • Profile: This protein comes from lentils and has high nutritional value, with essential amino acids, fiber and minerals.
  • Applications: This flavor is consumed in protein powders, nutritional bars, and meatless products. Lentil protein is tasteless with a slight nutty flavor and its texture is comparable with sheet gelatin to give it functional application.

Chickpea Protein

  • Profile: A protein that comes from chickpeas, chickpea protein contains a higher level of protein and fiber coupled with a slightly healthy nutty flavor.
  • Applications: It can be used in almost anything, from hummus to protein powders and even processed meats and vegetarian products. Protein from chickpeas gives foods a more appealing mouthfeel and provides nutritional value.

Pea Protein

  • Profile: Extricated from yellow peas, pea protein enjoys popularity due to the fact that it is rich in protein and contains all essential amino acids.
  • Applications: It is used in flavoring in protein products, meat substitutes and other plant-based products, and dairy products. Pea protein is tasteless, and it can be easily applied to different products.

Bean Protein

  • Profile: The bean protein is mainly derived from different types of beans such as black beans and from kidney beans are protein and dietary fiber.
  • Applications: Most commonly applied to meat substitutes, protein bars or even soup. The protein derived from beans has a stronger taste and texture which will prove useful in a variety of product uses.

Soy Protein

  • Profile: However, some of the most commonly discussed legume-based proteins do include soy protein in he list since it is popular and widely used in many products.
  • Applications: Present in tofu, tempeh, soy milk, and meat substitutes including burgers. Soy protein contains all the essential amino acids and it is incorporated in many plant foods.

Production Process of Legume-based Proteins

Ingredients selection 

  • Objective: Make sure to use quality legumes and the rest of the ingredients used.
  • Process: Choosing a legume with high protein content and a low proportion of undesirable substances. Getting supplies at the right sources to maintain the quality of food and work against foodborne illness.

Legume Preparation

  • Objective: Cook legumes and perform the extraction of protein samples.
  • Process: Separating small stones wedging and washing legumes to reduce the foreign material and make them ready for other processes. Soaking assists in the legumes to be softened making it easy to grind them.

Protein Extraction

  • Objective: Protein fractionation and concentration from legumes.
  • Process: Rinsing and pulverizing it with other techniques including wet abrading or dry partitioning where protein from the legumes is separated from starch and fibers. The protein is then concentrated through higher-speed centrifugation and further purified.

Texturization

  • Objective: Make a fibrous structure for vegetal meat products.
  • Process: This can be best realized by use of extrusion. In a process called extrusion, the ingredient is cooked at high pressure and temperature in an extruder which makes the protein concentrate expand and become fibrous. This also increases the desirability of the texture as well as improves the functional properties of the protein. The extrudate must also be able to be formed into different forms, for instance, patty, nugget, or strip. This method is applied mainly when making vegetable protein products that mimic the texture of actual animal products in a useful manner.

Concentration and Formulation

  • Objective: Protein concentrates and products.
  • Process: Separating other liquids and solids from the protein in order to get it more concentrated. Blending with other ingredients to get the required characteristics of texture, flavor and functionality.

Quality Control and Testing

  • Objective: Guarantee safety, uniformity and standard of the end products more frequently.
  • Process: Sensory assessments, nutrient profiling and microbiological examination. Controlling of key characteristics like protein content, texture profile and flavor profile of the end products.

Packaging and Labeling

  • Objective: The product shall be protected and information to the consumers should be Nancy.
  • Process: Sensitizing packaging of the legume-base proteins in packets that will enhance their freshness while minimizing contamination issues. Such labels consist of nutritional values, ingredients, allergens and usage instructions.

Packaging Solution for Legume-Based Proteins

Bottles and Jars as Packaging for Liquid Protein Products

  • Objective: Give suitable and secure containers for packaged liquid protein products.

Materials:

  • Plastic Bottles: Crystal-clear, very light, do not break easily, and act as barriers to most items. Usually intended for use with protein shakes and liquids.
  • Glass Jars: They are inert and recyclable, creating an excellent presence for high-end products and protein powders. Their advantage consists of a high-quality appearance and an inability to directly engage with the materials.
  • Pouches and Bags (Sab 005 D to be used for powdered protein products)
  • Objective: These categories are aimed at making powdered proteins easily storable and very convenient to use.

Materials:

  • Multi-layer Laminated Films: They should afford protection against moisture, air, and light. Reclosable bags improve the usability of the products, and at the same time Retort Pouches prolong food shelf life.
  • Stand-up Pouches: Offer stability on shelves and are developed to have low packaging material usage while at the same time protecting the product.

Vacuum Sealing (Applicable to Textured Protein Products)

  • Objective: Reduce spoilage of products and get them to last longer on shelves.
  • Materials:
  • Vacuum Sealed Packs: Different ways of preserving content from spoiling and changing its texture and taste. Mainly found with regard to the frozen or dried textured proteins.
  • Sustainability

Recyclable Materials

  • Objective: Decrease the impact on the environment and respond to current consumers’ need for environmentally friendly products.
  • Sustainable Practices: Using recycled materials like glass; PET and aluminum. Reducing packaging waste at the design stage by having optimized packaging solutions.

Reduced Packaging Weight

  • Objective: Conserve the environment as much as possible.
  • Sustainable Practices: Creating packaging that will take less material while ensuring that the product is safe from other elements. Cutting overall waste for gathering resources as well as other types of waste.

Biodegradable Options

  • Objective: Further increase sustainability to a greater extent.
  • Sustainable Practices: Investigating environmentally friendly packaging materials, for instance, biodegradable or compostable packaging.

Labeling and Branding

Label Materials and Design Considerations

  • Objective: To capture consumers’ attention and to convey details of the product.
  • Materials: High-quality durable material that can effectively last through the various storage conditions that may prevail. Nutrition facts and allergens declarative information such as the list of ingredients where the product is a component of should be provided.

Creative Design

  • Objective: Carry out differentiation of the various products in the market.
  • Design Considerations: The best way through which it is possible to ensure that products get to stand out is by having attractive and innovative labels. Some reasons include enhanced use of brightly colored containers with clear brand names and Company messages on sustainability.