A complete vegetarian food production line can be mainly divided into the following four systems:
1、 Raw material pretreatment system
This is the front end of the production line, responsible for preparing the basic raw materials.
Feeding and metering system:
Composition: Raw material warehouse, vacuum suction system, automatic scale.
Function: Responsible for precise and hygienic transportation and weighing of major protein powders such as soy protein, pea protein, wheat protein, as well as auxiliary materials such as starch and dietary fiber according to the formula ratio. The automation system ensures the accuracy and consistency of the formula.
Mixing and Mixing System:
Composition: High speed rotating mixing tank, premix tank.
Function: Mix weighed protein powder, water, vegetable oil, seasonings (such as soy sauce, yeast extract), pigments (such as beet red juice), adhesives (such as methyl cellulose, modified starch), etc. evenly to form a wet slurry (dough) with specific viscosity and composition. This step is crucial for the formation of flavor and basic texture.
2、 Core texture system
This is the "heart" of the vegetarian meat production line, which determines the final fiber and chewiness (texture) of the product.
High moisture extruder:
This is currently the most essential equipment for producing high-end Whole Muscle Analogues.
Composition: Twin screw extruder, feeding system, barrel, mold, cutting device.
Working principle: The pre mixed wet slurry is fed into the extruder through the feeding system. Inside the barrel, materials undergo a series of complex processes such as conveying, compression, shearing, heating, and melting. Under the action of high temperature, high pressure, and high shear force, the protein molecular structure is opened, redirected, and cross-linked, forming a layered structure similar to muscle fibers. Finally, the molten material is extruded through a specific mold and cut into the desired shape (such as chicken breast chunks, meat strips, etc.) by a rotating blade.
Features: Able to produce products with a moisture content between 50% -70%, juicy taste, strong fiber sensation, and very close to real meat.
Low moisture extruder:
Composition: Similar to a high moisture extruder, but with different process parameters.
Function: Mainly used for producing dried plant protein tissue proteins. The product has low moisture content and appears as a porous sponge. It can only be used after rehydration. Commonly found in vegetarian meat filling, minced meat products, or as a snack food.
Spinning technology:
A more traditional method is to press protein solution into an acidic coagulation bath through thousands of small holes (spinnerets) to form protein fiber bundles (similar to marshmallows), and then bind, shape, and cut the fiber bundles with adhesives (such as egg whites and colloids).
Characteristics: It can produce a very clear fiber structure, but the process is more complex and the cost is higher. It is now less commonly used in mainstream vegetarian meat production.
3、 Seasoning and Forming System
The extruded vegetarian meat base material needs further processing to enhance flavor and form the final product form.
Marinating/Seasoning and Marinating System:
Composition: Vacuum rolling machine, soaking tank, injection machine.
Function: Put the extruded vegetarian meat base, seasoning sauce, and marinade into a rolling machine and roll it in a vacuum environment. A vacuum environment helps seasoning penetrate better into the fiber structure of the product. For larger block products, injection curing is sometimes used.
Forming system:
Composition: mold, cake press, meat grinder, enema machine.
Function: Formulate according to the final product requirements.
Hamburger pancake: Use a pancake press to press the mixed filling into a meat patty with a fixed thickness and diameter.
Meat filling/minced meat: processed using a meat grinder.
Sausage: Use an enema machine to pour the material into the casing.
4、 Post ripening and packaging system
This is the end of the production line, ensuring product safety, extending shelf life, and completing commercialization.
Cooking/maturation system:
Composition: Steam oven, deep fryer, smoking oven, cooking line.
Function: By heating, the product is solidified, matured, and undergoes Maillard reaction to enhance the "meat aroma" and burnt flavor, while also killing microorganisms to ensure food safety.
Rapid cooling system:
Composition: Cooling tunnel, vacuum cooling machine.
Function: Quickly cool products cooked at high temperatures to a safe temperature to prevent bacterial growth and product quality degradation.
Packaging system:
Composition: Automatic vacuum packaging machine, modified atmosphere packaging machine, labeling machine, sealing machine.
Function:
Vacuum packaging: extracting oxygen to extend shelf life, mainly used for raw or refrigerated products.
Modified atmosphere packaging: filled with a mixture of nitrogen, carbon dioxide, and other gases to replace oxygen in the packaging, which can better maintain the shape, color, and quality of the product. It is commonly used for ready to eat products.
Finally, label and pack.