Engineering Processes for Plant-Based Meat Analogs: Current Status and Future Outlook

Plant-based meat analogs (PBMAs) have emerged as a promising alternative to conventional meat, driven by growing consumer interest in sustainability, ethical considerations, and health-conscious diets. However, despite initial market enthusiasm, PBMAs struggle with declining consumer acceptance due to their inability to fully replicate the texture, juiciness, and sensory experience of animal-derived meat. Key limitations include insufficient fibrous structure, reduced tenderness, poor moisture retention during cooking, inadequate lipid distribution mimicking marbling, and unsatisfactory mouthfeel. Addressing these challenges is critical for advancing PBMA development and securing long-term market success. Unlike most reviews that broadly examine PBMA, this review specifically explores the role of processing technologies and equipment designs in enhancing meat-like properties. In this review, we have analyzed the commonly used technique for creating PBMA, the high-moisture extrusion (HME), detailing its mechanisms, equipment configurations, and processing parameters. It also briefly covers some other techniques for creating fibrous structures. Furthermore, the critical interplay between equipment parameters, ingredient properties, and final product characteristics, considering factors such as die design, shear force, moisture content, temperature control, and gas incorporation, is also covered. Moreover, we highlight major technical challenges, including scalability, cost-effective production, molecular interactions during processing, and consumer-perceived authenticity. Finally, we propose future directions for refining processing techniques, innovating equipment designs, and overcoming commercialization barriers. By bridging existing knowledge gaps and offering practical insights, this comprehensive analysis aims to support researchers and industry professionals in advancing next-generation PBMA processing technologies for widespread industrial adoption to make more consumer-acceptable products.