Innovative approaches to the processing and packaging of alternative proteins

For several years now our nutrition has been influenced by the two megatrends of "Health" and the "Neo economy". Animal-based products in particular are greatly affected by this. A variety of different alternatives to milk, cheese and cream etc. have been available for a few years. The per capita consumption of milk and dairy products worldwide is rising very slightly, as reported by Food Outlook from the FAO (Food and Agriculture Organization of the United Nations); this was still 117.4 kilos in 2020, and the prognosis for 2024 is 120.6 kilos. According to Statista Consumer Market Insights, Germany is ranked 4th in the world for sales of dairy alternatives. Many manufacturers of dairy products, both established companies and start-ups, are not just watching these developments, but are also expanding their product range and becoming involved in this new sub-segment of the market.

These alternative products, which have arisen from this new trend, and which range from the replacement of milk itself right up to cheese, spreads and desserts, impose particular demands on processing and packaging. Subjects such as shelf life and sustainability play a special role here. Manufacturers are faced with several challenges: firstly, there may be a lack of know-how as regards product processing and packaging, as well as the machine technology required, and secondly, there are some issues to be aware of in the branding of the product. Producers, who also sell animal-based products alongside the alternative protein product, must ask themselves for example, whether highlighting the sustainability of plant-based cheese alternatives could be seen as a criticism of animal-based products. This risk can be avoided by marketing the alternatives through their own new brand. This does however mean, that the benefits of marketing the alternatives through an established and proven brand disappear, and manufacturers have to weigh this up.

Products, which are manufactured with plant-based ingredients, may differ from the animal-based equivalent in their processing: Animal-based cheese undergoes a ripening process. This can also be the case with plant-based cheese, if a ripening process is selected with cultures, which consist of a mixture of lactic acid bacteria. There is also a widespread manufacturing process, which does away with fermentation. Here the raw materials are mixed, and the texture and taste are created by means of food technology processes.

Vegan cheese alternatives have a particularly heterogeneous product consistency, ranging from soft to sticky and right up to very hard. This creates a challenge for slicing accurately to the required portion weight in a way that is gentle on the product. The necessary solutions have to be identified in discussions between machine manufacturers, such as MULTIVAC, and the producer of the product.

When processing and packaging food products of all types, the objective is to provide optimum protection for the product against external influences, as well as extending the shelf life within the pack. The resulting requirements for the processing and packaging solutions depend on the particular product. Whereas with animal-based food products the focus is mostly on preventing the product perishing, in the case of plant-based alternative products the critical factor is the tendency towards higher spore growth, which is triggered by the nature of the product. Machine manufacturers must therefore integrate suitable hygiene concepts into their machines.

In order to guarantee food safety up to the point of sale and extend the shelf life, various measures are used during the packaging process. For example, the products are often packed under vacuum or modified atmosphere (MAP, Modified Atmosphere Packaging), either on traysealers or thermoforming packaging machines. The particular requirements of the food product determine, which packaging method is used, and whether the best choice is a vacuum or MAP pack, or even a pack without any gas exchange. The manufacturing process, the desired minimum shelf life, and the preference for the pack design all play a role here.

A particular feature when packing plant-based cheese alternatives is the precise composition of the gas mixture, when modified atmosphere packaging is being used. If fermentation forms part of the manufacturing process for a plant-based cheese alternative, the oxygen content within the pack must be taken into account. Packaging gases such as carbon dioxide and nitrogen are generally used here to reduce the oxygen content. This ensures that the microorganisms, which are contained in the product, do not allow the product to continue ripening. When combined with a high-barrier film, where there is a particularly high barrier against oxygen, this produces a packaging concept, which first removes the oxygen from the pack, and then also protects the product against the permeation of oxygen. Packaging specialists must understand the upstream and downstream processes, as well as the requirements of the customer, so that they can develop an individual packaging concept. Food manufacturers, who are new to the market, as well as start-ups benefit in particular from the advice of MULTIVAC, which brings decades of widespread experience.