How High-Moisture Extrusion Enhances Fibrosity in Meat Analogues

When it comes to plant-based products, texture is not a detail—it’s the dealbreaker.
And for meat analogues, achieving a fibrous, juicy texture with a good bite is key to replicating the experience of eating animal meat.

High-moisture extrusion makes it possible without relying on animal-derived ingredients. But like any technology, its power lies in how it’s used.

In this article, we’ll explore how each technical parameter plays a role, which raw materials we use at Sanygran, and how we achieve realistic textures tailored to different channels and formats—ready to launch to market.

The Technical Parameters That Define Meat Analogue Texture

High-moisture extrusion uses plant proteins combined with pressure, temperature and moisture to create a fibrous structure.

The result? A plant-based matrix that mimics animal muscle—ready to cook, marinate, or infuse with flavour.

Controlling each variable allows us to adjust the texture, juiciness and appearance according to the final use.

Which Raw Materials Do We Use to Achieve Fibrosity?

Not all proteins behave the same in high-moisture extrusion.
At Sanygran, we work with specific blends to deliver different textures depending on client needs:

• Soy flour: widely used for its ability to form long, defined fibres.
• Soy and pea flour blend: offers a good balance of bite and juiciness.
• Brewer’s spent grain: a sustainable alternative that contributes protein and good texture (more information).
• Oats: ideal for a softer, smoother texture, perfect for certain consumer groups or categories.

Thanks to this flexibility, we adapt recipes to suit Retail, Foodservice or Industrial applications, delivering a consistent sensory experience that aligns with each brand.

Temperature, Pressure and Shear: The Trio Behind Texture

During extrusion, the protein mix reaches temperatures between 140 and 180°C under controlled pressure.

This triggers denaturation and realignment of proteins, which then form aligned fibres.

The higher the pressure and shear, the more defined the fibres—and the more they resemble animal muscle.

Technology with purpose

High moisture extrusion doesn’t just mimic meat — it enables the design of unique products with their own identity.

Why Moisture Matters More Than You Think

Moisture is everything here. The right moisture content (typically 40–80%) allows for:

• A juicier structure
• Lower risk of dryness or crumbliness
• Better absorption of sauces and marinades

But too much moisture can cause spongy or unstable textures.
That’s why we fine-tune the moisture level depending on the raw materials, format and end use.

Why High-Moisture Extrusion Creates Fibrous Texture

What makes this technology stand out is its ability to replicate animal muscle structure on a microscopic level.

This is thanks to shear force and controlled thermal processing. Once extruded, the product is rapidly cooled, forming protein layers that solidify into aligned fibres.

This stratification recreates the structure of real meat.

At Sanygran, we control this process to offer a variety of formats:

• Strips
• Chunks
• Pulled-style fibres
• Cubes
• Shavings
• Flakes

Impact on Nutrition and Flavour

In addition to mimicking meat texture, high-moisture extrusion also affects the nutritional value and sensory profile of plant-based products.

Its precise control helps to preserve ingredient quality while enhancing mouthfeel and flavour.

Enhanced Flavour Absorption

One of the most appreciated features is the ability to soak up marinades, seasonings and sauces, thanks to:

• A fibrous, porous structure
• A plant-based matrix that retains liquid
• The option to add flavour directly in-mass or post-extrusion

At Sanygran, we offer a wide range of flavour profiles—from chicken or beef to kebab, plant-based tuna or vegan salmon.

Retention of Essential Nutrients

High-moisture extrusion allows for gentler cooking, which helps preserve:

• Essential amino acids
• Heat-sensitive vitamins

The result is a product with a more complete nutritional profile, aligned with the expectations of conscious consumers.

Ready to Transform Your Product Line?

If you’re looking for a manufacturer with real expertise in high-moisture extrusion and the ability to develop customised solutions, we’re here to help.

At Sanygran, we offer a wide portfolio of plant-based solutions, with formats tailored to your brand and distribution channel—plus the option to develop unique flavours.

📞 +34 948 488 501
📩 info@sanygran.com

Let’s take your next innovation to the next level.