Plant-based protein-rich foods are now one of the fundamental pillars in the development of plant-based products within the food industry. They not only provide nutritional value, but also help build texture, stability, yield and scalability in applications such as plant-based burgers, ready meals and meat analogues.

In this article, we explore the different industrial formats, how they are used in manufacturing, and the key technical criteria to consider when selecting the most suitable solution for each end product.

Industrial formats of plant-based protein-rich foods

In the food industry, these ingredients are not treated as a single category, but as different levels of processing, each responding to specific technical, cost and application requirements.

Flours, semolina and whole-food bases

These formats are the closest to the original raw material matrix.

They are typically used when the goal is to:

• maintain a more recognisable formulation
• optimise formulation costs
• work with more traditional or less processed textures
• support simpler labelling strategies

They require more formulation work, but offer flexibility in early-stage product development.

Concentrates and isolates

Protein concentrates and isolates allow for greater functional control within industrial formulations and are essential where precision is required.

They are used when there is a need for:

• higher protein purity
• neutral flavour profile
• consistent process performance
• easier dosage and formulation control

In this context, yellow pea protein concentrate offers a strong balance between functionality, cost efficiency and product positioning, particularly in plant-based applications and clean label strategies.

Additionally, ingredients such as pea starch play a key role in water retention, texture development and product stability, complementing protein functionality within the formulation.

They are especially valuable in applications where batch-to-batch consistency and industrial yield are critical.

Textured vegetable protein and ready-to-formulate systems

Textured vegetable protein (TVP) is one of the most widely used formats in the plant-based sector due to its ability to create structure and functional performance.

In this segment, Sanygran works mainly with:

• soy-based textured proteins
• pea-based textured proteins
• blends such as Legumeat (bean + rice + soy) in formats like chunks, fine granules and “beef-style” fillets

These solutions are essential in plant-based burgers, nuggets, fillings and ready meals, where texture defines the final product experience.

Which protein source or system to choose based on the final product?

The selection of plant-based protein-rich foods depends directly on the end use, the industrial process and the market positioning of the product.

Chilled and frozen ready meals

In these applications, the priority is to ensure recipe stability throughout the product’s entire lifecycle.

Proteins must provide:

• strong water retention after cooking
• freeze-thaw stability
• consistent behaviour during reheating/regeneration
• stable integration with sauces and liquid systems

Typical applications include lasagne, cannelloni, bowls and ready-to-heat meals.

Fillings, toppings, sauces and spreads

In these formats, plant-based proteins act as functional carriers within the matrix.

Their main role is to ensure:

• stable viscosity
• uniform texture
• reduced syneresis
• consistent processing performance

They are commonly used in plant-based Bolognese sauces, fillings and ready-to-use preparations.

Retail-ready plant-based products and private label

In retail environments, these ingredients must meet strict market requirements.

Key factors include:

• batch-to-batch consistency
• cost control
• compliance with labelling requirements
• scalability of production
• consistent final product quality

Here, protein is not just a functional ingredient, but a strategic element for commercial viability.

How we integrate high-performance plant-based proteins into your value chain?

At Sanygran, plant-based protein-rich foods are approached from a complete industrial perspective: ingredient, process and final application.

Our expertise in dry and wet extrusion, combined with the development of solutions such as Legumeat, pea and soy textured proteins, as well as pea protein concentrate and pea starch, allows us to adapt ingredient functionality to each specific product.

This translates into direct benefits for manufacturers:

• tailored solutions adapted to each application
• process optimisation and reduced operational complexity
• flexibility in formats and packaging
• stable supply and consistent batch performance
• reduced time-to-market
• seamless integration into existing production lines

The goal is not just to supply plant-based protein, but to ensure that the product performs in real industrial conditions, scales efficiently and reaches the market with consistent quality.

Understanding what plant-based protein is for is essential for any company developing competitive food products today. Beyond its nutritional role, it is a functional and technological ingredient that helps build structure, texture, stability and process efficiency across a wide range of applications.

In this article, we explore its real industrial functions, its business benefits, and how to choose the right type depending on the final product.

What is plant-based protein used for in prepared food development?

Plant-based protein is primarily used to formulate products with nutritional value, technological functionality and industrial viability. It is not just an ingredient, but a product development tool.

Increasing the protein content of finished products

One of the main benefits of plant-based protein is its ability to improve the nutritional profile of recipes. It allows the development of higher-protein products in categories such as:

• ready meals
• snacks
• fillings
• complete recipe bases

This supports stronger market positioning, particularly in segments where high protein content is a key purchase driver.

Replacing animal-derived ingredients fully or partially

Another major advantage of plant-based protein is its role in reformulation. It enables the replacement of animal ingredients in:

• plant-based burgers
• nuggets
• meatballs
• lasagne and cannelloni
• Bolognese-style sauces

It also enables hybrid formulations, combining plant proteins with other ingredients to optimise cost, performance or nutritional profile.

Meeting evolving market demand

Plant-based protein supports the development of products aligned with current trends:

• plant-based and flexitarian diets
• clean label positioning
• more sustainable food solutions

This is not only about following trends, but about unlocking new commercial opportunities and responding to demand from retail and foodservice.

What is plant-based protein used for at a technological level?

Beyond nutrition, plant-based protein plays a key functional role in food formulation.

Improving texture and structure

One of its core functions is delivering:

• bite
• fibrous texture
• structure
• consistency

This is essential in products such as burgers, fillings and protein bases, where structure defines the eating experience.

Supporting emulsification, gelling and water retention

Plant-based protein acts as a functional ingredient that helps:

• bind phases together
• stabilise emulsions
• improve juiciness
• reduce cooking losses

A common industrial issue is products that release water and fall apart. Adjusting protein functionality helps stabilise the formulation and improve performance.

Ensuring stability during processing, freezing and reheating

In ready meals, plant-based protein helps maintain performance during:

• cooking
• pasteurisation
• freezing and thawing
• regeneration

This directly affects final product quality and batch-to-batch consistency.

Which plant-based protein sources work best depending on the application?

Not all plant proteins behave the same. Selecting the right source is critical to maximise the benefits of plant-based protein.

Pea protein for clean label plant-based development

Pea protein is widely used due to:

• strong clean label positioning
• good consumer acceptance
• versatile functionality

It is particularly suitable when reducing allergen complexity and simplifying ingredient lists is a priority.

Soy protein for maximum functionality and versatility

Soy remains one of the most technically robust options:

• high texturisation capacity
• strong water retention
• stable processing behaviour

It is widely used in meat analogues and complex formulations where technical performance is essential.

Legumes, rice and blends for tailored sensory and nutritional profiles

In many cases, the best solution is not a single protein but a blend.

Blends allow manufacturers to:

• balance flavour
• improve texture
• optimise amino acid profile
• manage cost efficiency

This approach is particularly effective when developing differentiated products without compromising functionality.

What is plant-based protein used for in specific product categories?

The real value of plant-based protein becomes clearer in real industrial applications.

Meat analogues and restructured products

It is widely used in:

• plant-based burgers
• nuggets
• meatballs
• minced-style fillings

Here it provides structure, juiciness and yield, all essential for retail competitiveness.

Chilled, frozen and ready-to-heat meals

In these products, plant-based protein ensures:

• recipe stability
• texture after reheating
• batch consistency

It is a key ingredient in convenience food solutions.

Snacks, protein bases and retail-ready solutions

It also enables innovation in:

• extruded snacks
• high-protein products
• private label bases

Here, plant protein adds not only functionality but also product differentiation and added value.

How plant-based protein improves industrial performance?

One of the main benefits of plant-based protein is its direct impact on manufacturing efficiency.

Standardising processes and reducing variability

A well-selected protein helps achieve:

• higher repeatability
• lower batch variation
• improved production control

This reduces production issues and improves operational efficiency.

Optimising yield, cost per formulated kilo and waste reduction

Plant-based protein affects:

• water absorption
• cooking yield
• raw material efficiency

This leads to a lower functional cost per kilo, not just ingredient price.

Supporting industrial scale-up and product development

It enables manufacturers to:

• adapt formulations to existing production lines
• accelerate product launches
• develop new ranges without starting from scratch

A key factor for companies aiming to scale efficiently.

What should companies evaluate when choosing plant-based protein?

Choosing plant-based protein is both a technical and strategic decision.

Final application and manufacturing process

It is essential to consider:

• product category
• thermal processing
• final format
• production conditions

The same protein behaves differently depending on the application.

Sensory profile, allergens and labelling strategy

Key considerations include:

• target taste and texture
• labelling requirements
• allergen presence
• positioning strategy

This helps avoid costly reformulations later.

Supply capability, technical support and custom development

Beyond the ingredient itself, manufacturers should evaluate:

• supply reliability
• technical support
• formulation flexibility

Because in industrial food production, success depends on performance at scale, not just in the lab.

SANYGRAN: plant-based protein solutions to drive food innovation

Working with plant-based protein is not just about selecting an ingredient, but ensuring it performs within your process and final product.

When integrated from the early stages with a technical approach, it helps to:

• reduce production losses
• improve manufacturing stability
• optimise overall cost efficiency
• accelerate new product development

If you are developing or reformulating a product, combining ingredient expertise, application knowledge and industrial process understanding can make the difference between a concept that works in the lab and a product that performs in production.

📞 +34 937 132 324 | ✉️ info@sanygran.com

A textured vegetable protein supplier is a strategic partner for the food industry aiming to develop stable, scalable plant-based products ready for retail or foodservice.

Choosing the right supplier directly affects texture, industrial performance, final product stability and cost per functional kilo, especially in categories such as plant-based burgers, ready meals and meat alternatives.

In this article, we explore what a supplier should offer, how to choose one based on your application, and which technical factors are key to making the right industrial decision.

What should a textured vegetable protein supplier offer to the food industry?

A textured vegetable protein supplier should go beyond simply providing an ingredient. The industry requires consistency, reliability and technical support throughout the entire development cycle.

The goal is not just to source protein, but to ensure it works in production, behaves consistently and integrates into existing industrial processes.

Supply capacity and batch-to-batch consistency

Consistency in texturised protein is critical in industrial production. Even small variations can directly impact the final product.

A reliable supplier should guarantee:

• consistent hydration behaviour
• uniform texture between batches
• stable production performance
• reduced line incidents

When consistency fails, the consequences are immediate: waste, recipe adjustments and quality issues.

Technical support and development assistance

The real value of a supplier becomes clear during the development phase.

Technical support helps optimise:

• hydration of the texturised protein
• final cooked texture
• integration into complex matrices (sauces, fillings, ready meals)
• industrial scale-up from pilot trials to full production

This support reduces development time and improves launch efficiency.

How to choose a textured vegetable protein supplier based on your application

Not all textured vegetable proteins are suitable for every application. The right choice depends on the final product, industrial process and sales channel.

Solutions for chilled and frozen ready meals

In these applications, the texturised protein must ensure stability throughout the product lifecycle.

Key requirements include:

• resistance to freezing and thawing
• strong water retention
• stability after cooking or regeneration
• consistent performance in sauces and fillings

Typical uses include lasagne, cannelloni, filled pasta, empanadas and prepared bowls.

Solutions for meat analogues and plant-based products

In products such as burgers, nuggets or plant-based meatballs, the objective is to replicate structure and sensory experience.

Key solutions include:

• textured soy protein
• blends such as Legumeat (bean + rice + soy protein), an innovative formulation with a complete amino acid profile

These solutions help build texture, bite and juiciness in high-value plant-based products.

Technical factors when sourcing textured vegetable protein

The decision to purchase textured vegetable protein should be based on technical criteria, not just protein origin.

Protein source, format and level of texturisation

The protein base (soy, pea or blends such as Legumeat) directly influences:

• base flavour
• final colour
• hydration capacity
• processing behaviour

The format (fine granules, chunks or “beef bean” steak-style) determines its final application.

Hydration, yield and processing behaviour

Hydration ratio is one of the most critical factors for industrial performance and cost control.

A high-quality texturised protein should:

• absorb water in a controlled way
• maintain structure after cooking or regeneration
• reduce losses during processing
• ensure batch-to-batch consistency

This directly impacts the cost per functional kilo, not just the ingredient price.

Sensory profile and recipe integration

The ingredient must integrate seamlessly into the recipe without limiting the final product.

Key attributes include:

• neutral or easily adjustable flavour
• strong absorption of marinades and sauces
• adaptable texture depending on application
• stability after cooking

Applications of textured vegetable protein in the ready meals industry

Textured vegetable protein is a key functional ingredient in the ready meals sector.

It is commonly used in:

• plant-based fillings for pasta and pastries
• Bolognese-style sauces
• ready-to-heat meals
• protein bases for bowls and complete recipes

Its main role is to provide structure, protein and industrial performance in complex formulations.

Cost optimisation and performance in plant-based formulations

Selecting the right texturised protein improves overall product efficiency.

This results in:

• higher volume per kilo of raw material
• reduced production waste
• more stable formulations
• better control of cost per portion

Collaborative innovation: co-development of finished products with Sanygran

Developing plant-based products increasingly requires collaboration between manufacturer and supplier.

The value lies not only in supplying textured vegetable protein, but in co-developing solutions tailored to each industrial application.

Experience in dry and wet extrusion allows texture, functionality and processing behaviour to be adjusted according to the final product requirements.

Logistics and scalability for large volumes

In large-scale projects, industrial capacity is key to ensuring market success.

This includes:

• stable supply at scale
• industrial packaging formats (bags, big bags)
• batch-to-batch consistency
• ability to respond to demand peaks

The goal is to ensure products reach the shelf without disruptions or quality variations.

Do you need a textured vegetable protein supplier for your next development?

If you are developing a plant-based product — whether a ready meal, a plant-based burger or a retail solution — choosing the right textured vegetable protein supplier can make the difference between a project that progresses and one that stalls in production.

If you are in the development or reformulation phase, a technical approach from the start helps you validate earlier, scale more efficiently and launch with greater confidence.

Plant-based proteins have become a strategic ingredient for food innovation and the development of new product categories. More and more manufacturers, ready-meal companies, and retail chains are incorporating plant protein into their formulations to meet the growing demand for more sustainable, nutritious, and versatile foods.

Key takeaway: plant-based proteins allow the creation of foods that are sustainable, functional, and aligned with modern consumer preferences.

Beyond consumption trends, plant-based proteins offer technological advantages for industry: they enable new textures, enhance nutritional profiles, and optimise production processes across multiple applications.

This article explains what plant proteins are, the main sources of plant protein, how they are used in the food industry, and the techno-functional properties they contribute in ready-meal and plant-based product development.

What Are Plant-Based Proteins?

Plant-based proteins are derived from raw materials such as legumes, cereals, or seeds, and are used as functional ingredients in the food industry.

When discussing what plant proteins are, we refer to proteins obtained from plant sources like legumes, cereals, and seeds.

These proteins can be processed into different functional ingredients for food manufacturing, such as:

• protein flours
• protein concentrates
• protein isolates
• texturised plant protein

The main plant protein sources used in industry include:

• soy
• pea
• wheat
• rice
• other legumes

In short: plant proteins not only provide nutritional value but also serve as essential functional ingredients in product development.

From a nutritional perspective, plant-based proteins supply essential amino acids and can be evaluated using metrics such as PDCAAS (Protein Digestibility Corrected Amino Acid Score) to measure quality and digestibility.

Strategic Value of Plant Proteins for B2B Industry

Plant protein is not just a trend; it is a strategic opportunity for food manufacturers.

The interest in plant protein in the food industry responds to both consumer demand and strategic business factors.

The growth of flexitarian diets is driving the development of plant-based foods across categories such as:

• ready meals
• meat alternatives
• protein snacks
• ready-to-eat products

In Europe, this trend is significant: according to ProVeg International, around 40% of European consumers identify as flexitarians, boosting demand for plant-based ingredients.

From an industrial perspective, plant-based proteins offer key advantages:

• more stable costs compared with some animal proteins
• lower environmental impact
• alignment with ESG and sustainability goals
• opportunities for innovation in product development

Integrating plant protein allows manufacturers and distributors to innovate with lower risk and greater market alignment.

Functional Classification of Protein Sources for Industry

Not all plant proteins behave the same during production.

Different plant protein sources have distinct properties in key areas such as:

• hydration
• emulsification
• texturisation
• process stability

Choosing the right plant protein depends largely on the final product application.

Soy and Wheat Protein: The Pillars of Texture

Technical highlight: soy and wheat proteins excel in texturisation and structuring.

Soy protein and wheat gluten are among the most widely used ingredients in plant-based product development.

Their main advantage is their excellent behaviour in extrusion processes, which enables the creation of fibrous structures that mimic meat.

These proteins are commonly used in:

• meat analogues
• plant-based nuggets
• plant-based burgers
• protein fillings for ready meals

Result: they replicate bite, juiciness, and texture in plant-based products.

Pea Protein and Legumes: The Clean Label Alternative

Trend insight: pea protein has become one of the most demanded plant proteins in Europe.

Pea protein stands out for:

• hypoallergenic profile
• good digestibility
• excellent functional behaviour in food formulations
• suitability for clean label products

Industries also use texturised pea protein or legume proteins to develop various plant-based applications.

In summary: it is ideal for clean-label products with high nutritional value.

Emerging Proteins: Rice, Hemp, and Mycoprotein

Innovation focus: new protein sources to differentiate products.

The development of new plant-based foods has driven the exploration of emerging protein sources such as:

• rice protein
• hemp protein
• mycoprotein

According to the Plant-based: State of the Industry 2023 report by Good Food Institute Europe (GFI), innovation in alternative proteins is expanding beyond soy and pea, with growing interest in sources that enhance functionality, nutritional profile, and product differentiation.

These proteins help manufacturers innovate and stand out in competitive plant-based categories.

Techno-Functional Properties in Ready Meal Formulation

The main value of plant protein in industry lies in functional properties.

For food manufacturers, plant-based proteins help optimise texture, stability, and performance during production.

Emulsification and Water Retention

Primary function: maintain product juiciness and stability.

Many plant proteins offer:

• improved juiciness
• recipe stability
• prevention of texture loss during freezing and reheating

Impact: products remain stable after freezing, prolonged refrigeration, or microwave/oven reheating.

Texturisation and Structure Formation

Core function: recreate meat-like texture in plant-based products.

Using wet or dry extrusion, fibrous structures can be developed in formats such as:

• fine granules
• bites
• strips
• flakes

In short: texturisation is key to creating competitive plant-based foods.

Gelation and Viscosity

Direct application: structuring and stabilising food matrices.

Certain plant-based proteins act as:

• thickeners
• stabilisers
• structural agents

Technical Challenges: Flavour and Industrial Scale-Up

Common issue: lab formulations may not scale easily to production.

During the development of plant-based foods, adjustments are often needed when moving to industrial scale.

Frequent challenges include:

• overly soft texture
• production line difficulties
• unexpected behaviour during processing
• flavour profile differing from expectations

Conclusion: using pre-validated industrial ingredients reduces development time and risk.

Market Trends for Retail and Food Service

Key fact: the plant-based market continues to grow across Europe.

Plant-based products are increasingly popular due to demand for sustainable, nutritionally balanced foods.

Ready meals with plant protein are seeing significant growth, combining:

• convenience
• nutritional value
• ingredient innovation

According to NielsenIQ, plant-based alternatives continue gaining shelf space in European retail, particularly in ready-to-eat and refrigerated categories.

Takeaway: opportunities abound for manufacturers and food service operators incorporating plant protein.

SANYGRAN: Tailored Plant-Based Ingredient Solutions

Value proposition: ingredient development and industrial capacity from a single partner.

SANYGRAN is a specialised partner for plant-based solutions in the food industry.

Expertise includes:

• pea protein
• soy protein
• proprietary solutions like Legumeat: soy, rice and bean

Additionally, Sanygran has extensive industrial capabilities, including wet and dry extrusion, mixers, forming machines, cooling, enrobing, and packaging systems, allowing the development of both functional plant-based ingredients and ready-to-use solutions for integration into final products.

Final takeaway: partnering with a specialised provider accelerates development, reduces technical risks, and delivers competitive plant-based products to market.

Reducing time-to-market for new plant-based products has become a strategic priority for food manufacturers and retailers looking to compete in the rapidly growing alternative protein sector. In a market where food trends evolve quickly and innovation cycles are increasingly short, accelerating the process from product concept to commercial launch can determine whether a brand leads a category or arrives too late to the shelf.

Market growth reinforces this urgency. According to industry estimates (Fact.MR), the European plant-based meat market could exceed $15 billion over the next decade, driven by increasing demand for alternative proteins and ongoing innovation in plant-based food development.

In Spain, the trend is equally strong. The plant-based sector reached €572 million in sales in 2023, growing by 9.4%, with forecasts pointing to annual growth of around 10% in the coming years.

In this article, we explore how to optimise each stage of plant-based product development — from concept creation to industrial production — to shorten development cycles, reduce reformulation work, and ensure an efficient and profitable product launch.

Why Reducing Time-to-Market in Plant-Based Products Is an Industrial Priority?

¿The plant-based food market in Europe continues to grow, driven by changing consumer habits, increased environmental awareness and the rise of flexitarian diets.

In Spain, more than one third of consumers already buy plant-based products regularly or occasionally, confirming that the category has moved beyond niche status and is becoming mainstream.

Retail channels also play a crucial role. Supermarkets represent around 76% of plant-based product sales, making retail the main gateway for consumers.

In this environment, reducing product development timelines has become a strategic necessity due to:

• rapidly evolving consumer trends
• growing competition between brands and private labels
• high shelf turnover in emerging food categories
• the need to launch profitable products faster

Simply put, the faster a plant-based product reaches the market, the greater its ability to capture emerging demand.

Stages of Plant-Based Product Development and Where Delays Occur

Developing a plant-based food product usually involves several stages before reaching the market:

1. product conceptualisation
2. initial formulation
3. laboratory prototype development
4. pilot testing and industrial scaling
5. sensory and technical validation
6. industrial production

Where Do Delays Typically Occur?

The most common delays in plant-based product development occur in three critical areas:

• multiple reformulations to improve texture or flavour
• difficulties scaling recipes from laboratory to industrial production
• technical adjustments in processing steps such as forming, cooking or coating

For example, a recipe that works perfectly in the R&D laboratory may behave differently at industrial scale. The mixture may stick to machinery, the product may become too soft or unstable, or the coating may fail to adhere properly.

When this happens, development teams must return to earlier stages of the process, significantly increasing time-to-market.

Market Research for Faster and More Viable Product Decisions

Before starting technical product development, it is essential to have clear market insights.

Effective plant-based market research usually includes:

• analysis of plant-based food trends
• benchmarking competing products
• identifying opportunities on retail shelves
• validating the product concept

Europe is one of the most dynamic regions for plant-based innovation. Spain is already the fourth largest plant-based market in Europe, highlighting the sector’s strong growth potential.

In many cases, private label plant-based products still have significant room for expansion, especially in categories such as meat alternatives and plant-based ready meals.
Validating opportunities early helps avoid strategic changes when development is already advanced.

Agile Development Methodologies for Plant-Based Innovation

Applying agile product development methodologies allows companies to shorten testing cycles and accelerate product launches.

The most effective practices include:

• iterative prototype development
• early technical validation
• continuous collaboration between R&D and commercial teams
• decision-making based on rapid testing

Clearly Defined Product Objectives from the Start

Defining key development parameters early is essential, including:

• target texture
• sensory profile
• product format
• distribution channel
• nutritional requirements
• target cost structure

The clearer the product objectives from the beginning, the fewer reformulations and delays will occur later.

Formulation and Ingredients Designed for Industrial Scaling

A well-designed formulation simplifies the transition from prototype to industrial production.

For plant-based food manufacturing, this means selecting ingredients that:

• provide structure and stability
• perform reliably in industrial food processing
• maintain flavour and texture after processing
• ensure consistency and repeatability

For example, plant proteins and functional textured ingredients allow manufacturers to develop meat analogues with improved texture and better performance during industrial processing.

Selecting Functional Ingredients Ready for Production

Using ingredients already validated at industrial scale significantly reduces the risk of costly reformulations.

Companies that develop plant proteins, textured ingredients and functional blends can integrate them directly into formulations, accelerating the development of products such as:

• plant-based burgers
• plant-based nuggets or schnitzel-style products
• protein bites for prepared meals
• plant-protein bases for ready meals

Rapid Prototyping and Efficient Technical Validation

Rapid prototyping is a key strategy for reducing time-to-market.

Early laboratory testing allows teams to:

• validate recipe feasibility
• adjust flavour and texture
• evaluate ingredient performance

Industrial pilot tests then confirm that the product behaves correctly under real production conditions.

Fast prototyping reduces the number of development iterations required before launch.

Industrial Scaling Without Friction or Quality Loss

The transition from laboratory development to industrial manufacturing is one of the most critical stages in plant-based innovation.

To avoid scaling issues, companies must consider from the beginning:

• mixture behaviour during mixing or kneading
• stability during thermal processing
• final product consistency at high production volumes
• process repeatability

Technologies such as wet extrusion and dry extrusion enable the production of textured plant proteins and meat analogues that can be used in multiple food applications.

Integrating Products into Existing Production Lines

A key factor in accelerating product launches is designing formulations that fit existing manufacturing infrastructure.

When a product requires major modifications to machinery or processes, development timelines increase significantly.

In contrast, recipes compatible with standard food processing technologies — such as mixing, forming, coating and packaging — allow faster industrial trials and quicker market entry.

Optimising the Supply Chain from the Development Stage

Another common cause of delays in plant-based product launches is ingredient or packaging availability.

For this reason, companies should anticipate:

• availability of plant protein ingredients
• supply chain stability
• required production capacity
• distribution logistics

Integrating supply chain considerations early helps avoid delays when the product is ready for manufacturing.

Managing Regulatory Requirements and Labelling Efficiently

Plant-based foods in Europe must comply with several regulatory requirements, including:

• nutritional labelling
• vegan claims
• organic certifications
• ingredient compliance

Considering these factors during product development allows companies to prepare packaging and technical documentation without delaying product launch.

Co-Development with Industrial Partners to Accelerate Time-to-Market

One of the most effective ways to accelerate plant-based product development is through co-development with specialised industrial partners.

This approach enables companies to:

• adapt formulations to existing manufacturing processes
• reduce unnecessary testing phases
• accelerate industrial scaling
• ensure technical feasibility

Working with partners who control multiple stages of the plant-based value chain — from ingredients and formulation to industrial production — allows for a faster transition from concept to market launch.

Contact Us to Reduce the Time-to-Market of Your Plant-Based Products
If you are developing new plant-based foods or meat alternatives and want to accelerate your product launch, our team can help optimise every stage of the process.
📞 +34 937 132 324 ✉️ info@sanygran.com

What major retailers are looking for in vegan brands has become a strategic question in a market worth nearly €600 million in Spain, with an estimated annual growth rate of 10%, according to the First Economic Impact Report of the Plant-Based Sector published by Vegeta/es.

In addition, 2 out of 3 people in Spain have purchased plant-based products, and 4 in 10 consume them regularly, according to the 2025 Plant-Based Food Consumption Observatory. This is no longer a passing trend, but a structural category within the food industry.

In this context, large retailers are not only assessing which brands to introduce onto the shelf. They are also evaluating when and how to develop their own plant-based private label ranges in order to improve margins, strengthen differentiation and gain greater strategic control. This article examines the criteria currently shaping those decisions.

Strategic priorities of major retailers in the plant-based category

The plant-based category has entered a phase of maturity. According to the second wave of the Consumption Observatory, 75% of the population believe these products expand and improve the available food offering.

For retailers, this translates into clear objectives:

• Profitability per linear metre
• Strong rotation and repeat purchase
• Differentiation from competitors
• Attraction of the flexitarian consumer
• Alignment with sustainability commitments

In many European store checks, branded plant-based products still dominate certain subcategories, while private label penetration remains relatively limited. This is not contradictory; it is a typical consolidation phase.

Retailers often validate a category with established brands first. Once demand stabilises, they assess the opportunity to develop their own range in order to optimise margins and strengthen positioning.

Technical requirements demanded from vegan brands and manufacturers

Whether listing an external brand or developing a private label range, the technical criteria remain the same: reliability and consistency.

Major retailers prioritise:

• Consistent quality batch after batch
• Standardised processes
• Certified food safety
• Sustainable economic viability

A supplier must not only be innovative; it must be industrially robust.

Taste, texture and sensory experience comparable to conventional products

Taste and texture remain the main drivers of repeat purchase.

In a context where 80% of the population state they have reduced or are considering reducing their meat consumption (CECU), the success of the protein transition depends on plant-based products meeting sensory expectations comparable to conventional alternatives.

For retailers, this reduces commercial risk. For private label, it is even more critical: the product must protect the supermarket’s reputation.

Formulation, functionality and product stability

Success in large-scale retail depends on how the product performs in real conditions:

• Stability under chilled distribution
• Resistance to freezing and regeneration
• Appropriate shelf life
• Consistency across industrial production runs

Particularly within chilled categories — where rotation pressure is higher — technical stability is essential for both branded products and private label developments.

Production capacity, scalability and supply continuity

When a retailer decides to back a reference — whether branded or private label — supply security is fundamental.

This requires:

• Own production facilities and process control
• Ability to scale volumes
• Medium- and long-term planning
• Operational risk mitigation

In our case, technologies such as wet extrusion and dry extrusion, combined with forming, coating and processing lines for chilled, frozen and ambient solutions, enable us to adapt developments to different formats and commercial needs, ensuring scalability and industrial consistency across every plant-based project.

IFS certification further reinforces confidence in process stability, food safety and batch-to-batch consistency — key factors in large-scale retail.

Sustainability and coherence within the vegan business model

The plant-based category is directly linked to the wider protein transition.

100% plant-based products, particularly meat analogues, help diversify protein sources and reduce reliance on animal protein, aligning with the strategic commitments of many retail chains.

However, sustainability goes beyond formulation. It also involves coherence throughout the production model and value chain.

Functional packaging aligned with sustainability objectives

Packaging forms part of the retailer’s strategic decision.

Priority is given to solutions that:

• Optimise material use
• Improve logistics efficiency
• Integrate with internal recyclability policies
• Reinforce perceived quality

Managing the entire process in-house — from raw material to finished product and packaging — enables the delivery of integrated solutions adapted to both branded and private label ranges.

Transparency, traceability and regulatory compliance

Working with major retailers requires full transparency.

Ingredient traceability, regulatory compliance and clear documentation are essential to building stable, long-term commercial relationships.

For private label developments, this requirement is even greater, as the retailer assumes direct responsibility towards the consumer.

Consumer trends influencing retail purchasing decisions

Consumer behaviour ultimately drives retail strategy

According to Vegeta/es and organisations such as AINIA, ProVeg Spain, ANGED and the Good Food Institute, the plant-based sector is set to remain one of the most dynamic and innovative categories within the Spanish food industry through 2026.

Growth of ready-to-eat plant-based solutions

Ready-to-eat and plant-based prepared meals are gaining relevance.

Convenience, speed and everyday integration are particularly driving development within chilled categories. For private label, this subcategory represents a clear opportunity for differentiation and customer loyalty.

The flexitarian profile as a growth driver

The flexitarian diet is one of the main engines of category growth.

Consumers are not necessarily seeking to eliminate meat entirely, but to reduce consumption and incorporate attractive alternatives. This requires mainstream products that are price-accessible and sensorially competitive.

For major retailers, attracting the flexitarian consumer means consolidating a category that is already a regular part of the shopping basket.

The manufacturer behind the brand: how Sanygran adds value to plant-based positioning

Retailers do not only evaluate the product visible on shelf; they also assess who manufactures it.

For both branded ranges and private label developments, manufacturers must provide:

• Technical expertise in plant-based
• Industrial solidity
• Co-development capability
• Adaptation to different positioning strategies (clean label, premium, functional or mainstream)

Sanygran combines ingredient development with the manufacture of finished 100% plant-based products, offering experience in private label for national chains and export capacity.

Our approach is not about reformulating quickly, but about formulating properly: stability, taste, scalability and industrial coherence.

In a category now exceeding €600 million and continuing to grow steadily, the real question is no longer whether to invest in plant-based, but how to do so in a profitable, secure and strategically sustainable way.

Formulating plant-based products may seem straightforward. However, even small decisions regarding ingredients, processing parameters or recipe design can significantly impact texture, flavour and final consumer acceptance.

In this article, we explore the most common mistakes when formulating plant-based products and how to avoid them through proper recipe optimisation, process control and the right choice of functional ingredients.

Misalignment Between Sensory Expectations and the Final Product

One of the most critical issues in industrial plant-based products is failing to meet consumer expectations in terms of flavour, texture and overall eating experience. When this happens, repeat purchase drops and perceived product value decreases.

Inadequate Use of Proteins and Texturising Systems

Selecting plant proteins or texturisers without considering the final application often leads to dry, rubbery or unstable products.

In applications such as plant-based burgers and meat alternatives, adjusting protein combinations and functional systems is essential to guarantee homogeneous structure, juiciness and a defined bite throughout shelf life.

Proper plant-based formulation requires understanding how ingredients behave during mixing, forming, cooking and freezing at industrial scale.

Off-Flavours and Poorly Balanced Taste Profiles

Residual bitter, earthy or strong vegetal notes are common in plant-based products when flavour systems are not properly balanced during development.

At Sanygran, we conduct sensory trials and iterative formulation adjustments to minimise off-flavours and achieve well-rounded flavour profiles, even after thermal processing or freezing.

Nutritional Imbalance in Plant-Based Formulation

An unbalanced nutritional profile directly affects the perceived value of plant-based products, both for professional buyers and end consumers.

Protein Replacement Without Functional or Nutritional Equivalence

Replacing animal protein with plant protein without ensuring competitive protein content or functional equivalence can negatively impact market acceptance.

For food manufacturers developing meat alternatives, it is essential to maintain not only nutritional benchmarks but also structure, water retention and texture performance.

Overly Long Ingredient Lists

Overcomplicated recipes can create labelling challenges, commercial friction with retailers and negative quality perception.

Applying functional simplification principles allows manufacturers to maintain performance while avoiding unnecessary ingredients — a key factor in the European market.

Food Safety and Product Stability Failures

Controlling key parameters such as water activity, pH and thermal treatments is vital to ensure shelf life, microbiological safety and batch consistency in plant-based products.

Allergen Risks and Cross-Contamination

An incorrect combination of ingredients or improper process settings can reduce shelf life, affect texture, or cause loss of juiciness and colour. Early adjustments to moisture, protein levels and thermal treatments help maintain stability and minimise product returns.

Shelf-Life Issues Caused by Poor Formulation or Process Adjustment

Inadequate control of moisture, cooking or freezing processes can result in texture degradation, product returns and food waste.

We adjust industrial processes and equipment parameters to ensure that each batch maintains juiciness, bite and structural consistency throughout its intended shelf life.

Lack of Understanding of the Regulatory Framework for Plant-Based Products

Ignoring European regulations can delay product launches or require reformulations. Reviewing product names, nutritional claims and mandatory labelling from the start prevents blocks and protects your investment.

Incorrect Use of Product Names and Claims

Using inaccurate names or claims can have legal and commercial consequences. Ensuring alignment between formulation, nutritional profile and marketing communication guarantees products that are safe, compliant and market-ready.

Product Development Without a Clear Market Vision

Developing plant-based products without a clear understanding of the target market, sales channel or B2B client requirements often results in technically correct but commercially weak products.

Misalignment Between R&D, Marketing and the End Consumer

A disconnect between technical development and commercial expectations reduces competitiveness.

At Sanygran, we work closely with development teams and clients to ensure that plant-based formulations perform in real industrial and commercial environments, not just under laboratory conditions.

Industrial Scalability Challenges

Transferring a recipe from pilot scale to full industrial production can lead to texture loss, batch variability or unexpected cost increases.

We optimise processes and machinery settings to guarantee that the final product maintains juiciness, bite and consistency at scale.

How Sanygran Optimises Plant-Based Formulation for the Prepared Food Industry

Working with an experienced technological partner helps transform product concepts into scalable and consistent industrial solutions.

Sanygran supports European food manufacturers by:

• Adjusting plant-based recipes according to product type and post-processing requirements.
• Ensuring industrial batch control and consistent product quality.
• Optimising texture, flavour and stability across different plant-based applications.

With this approach, manufacturers reduce scale-up risks, improve product performance and accelerate time to market in the growing European plant-based sector.

Improving texture and bite in plant-based products is essential to make a product appealing, stable, and consistent in industrial production. This article explains how to enhance texture and bite in plant-based products through formulation design, process control, and the use of functional ingredients that deliver juiciness, structure, and an optimized mouthfeel.

Sensory and Technical Challenges in Plant-Based Product Texture

Plant-based products, especially meat analogues such as burgers or vegetable chunks, face technical and sensory challenges:

• Lack of bite or overly soft texture.
• Loss of cohesion in high-moisture formulations.
• Texture changes after pasteurisation, freezing, or regeneration.

These issues not only affect consumer acceptance but can also compromise industrial feasibility if not anticipated and corrected.

The Key Role of Texture and Bite in the Commercial Success of Plant-Based Products

According to data collected by specialised European food media (Food Navigator), almost 1 in 2 consumers would eat plant-based products more frequently if texture and flavour matched that of animal products.

Texture shapes how consumers perceive a product and therefore their likelihood to repurchase. Adjustments in formulation and industrial processing help maintain a defined bite, juiciness, and uniform mouthfeel.

Functional Ingredients to Enhance Texture and Bite in Plant-Based Formulations

Achieving the desired texture relies on combining functional ingredients that provide structure, cohesion, and stability.

Plant Proteins and Protein Systems

Choosing the right plant proteins and their proportion in the recipe affects firmness, elasticity, and the ability to retain water during cooking and freezing. Correct combinations ensure consistent products with defined bite and stable performance in industrial processes.

Hydrocolloids and Texturising Agents

For products with multiple ingredients, like plant-based burgers, maintaining a homogeneous and stable mass is crucial.

Hydrocolloids such as methylcellulose, commonly used in food formulations, combined with pea protein texturates or other protein sources, enhance water absorption and create firm, consistent structures. This ensures an appealing bite, juiciness retention, and stability, helping the final product meet both sensory and processing expectations.

Fibres, Salts, and Other Texture Modulators

Functional fibres, mineral salts, and other modulators help fine-tune texture and mouthfeel, providing uniform bite and juiciness, especially in cooked, frozen, or regenerated products.

Formulation Strategies for Industrial Plant-Based Products

Designing recipes for industrial production requires balancing texture, performance, cost, and processing ease.

Optimising Recipes for Large-Scale Production

Starting with a solid recipe is essential. Adjusting ingredients, hydration, and water balance prevents loss of consistency, excess liquid, or soft textures during wet extrusion (plant-based chunks) or burger forming, always paired with precise machinery control to make necessary adjustments during processing.

Consistent Texture Across Applications and Formats

Adapting the formulation to the product type ensures that bite remains consistent, even after thermal treatments or freezing and regeneration processes.

Innovation in Plant-Based Texture: Trends and Opportunities

New Solutions to Improve Bite and Structure

Exploring ingredient combinations and innovative processes can create fibrous, juicy, and stable textures, enhancing perceived quality in high-value products.

Industrial Applications with High Demand for Texture Improvement

Structured products such as plant-based burgers or chunks require particular focus on texture. Optimising bite and juiciness is a key opportunity to differentiate products and ensure smooth integration into industrial processes.

Sanygran as a Strategic Partner for Developing Plant-Based Products with Optimised Texture

Partnering with a technology and process expert allows companies to transform ideas or initial recipes into scalable and consistent products. Sanygran supports brands and manufacturers throughout the full cycle:

• Adjusting recipes and textures according to the product and subsequent treatments.
• Industrial control of each batch, ensuring expected texture and bite.
• Integrating functional ingredients and extrusion, mixing, forming, and cooking processes adapted to the product.

This approach enables manufacturers to achieve juicy texture, defined bite, and industrial stability, reducing scaling risks and accelerating time to market.

Scaling a plant-based product from a laboratory concept or initial idea to full industrial production can be more complex than it appears. In this article, you’ll learn what to consider when scaling a plant-based product, from formulation validation and adaptation to industrial processes, to cost management, quality control, and meeting retail and foodservice requirements. All with a focus on how an industrial partner can help bring your product to market efficiently and consistently.

Validation of the Formulation Before Industrial Scaling

A recipe that works in the laboratory does not automatically translate to large-scale production. Industrial validation is crucial to ensure flavour, texture, yield, and cost remain consistent when increasing production volumes.

Pilot Trials and Formulation Adjustments

At Sanygran, we conduct industrial-scale trials tailored to the stage of the project:

• Concept stage: We help shape ideas and develop the initial recipe.
• Small-scale validated recipes: We scale and adjust to maintain texture, flavour, and consistency.
• Laboratory-validated recipes: We perform industrial-scale trials to ensure reproducibility before continuous production.

These trials help identify deviations in texture, juiciness, flavour, and performance—particularly in products like vegetable burgers or high-water content doughs—and recipes are adjusted in-house until the desired result is achieved.

Identifying Critical Process Variables

To guarantee consistency across batches, it is essential to define and control critical variables such as temperature, timing, humidity, viscosity, water retention, and ingredient behaviour during cooking or regeneration. These parameters are fundamental for reproducible industrial results.

Adapting Production Scale and Equipment

Scaling affects not only the recipe but also the production line. Assessing whether a product can be manufactured on existing equipment or requires adaptations is key to maintaining efficiency and cost control.

Compatibility with Current Production Lines

Before scaling, it is necessary to determine whether the product integrates seamlessly into existing lines or if adjustments are needed in mixing, cooking, forming, or packaging. This allows investment or equipment modifications only when truly necessary.

Key Technologies to Achieve Texture and Functionality

Sanygran’s full industrial capabilities allow any plant-based development to scale:

• Wet and dry extrusion
• Production of vegetable burgers, hummus, and organic tofu
• Mixing, forming, kneading, and breading
• Fryers, IQF tunnels

These technologies ensure texture, functionality, and stability without the need for small-scale prototypes, enabling even undeveloped ideas to become industrially ready products.

Cost Control and Economic Feasibility of Scaling

Scaling directly impacts unit costs and ingredient yields. Understanding how a recipe performs at industrial scale allows optimisation of costs and minimisation of waste without compromising quality.

Formulation and Process Optimisation to Reduce Costs

During scaling, Sanygran adjusts recipes and processes to:

• Maximise product yield and ingredient utilisation
• Reduce losses in texture or water during cooking
• Maintain consistency batch-to-batch and operational efficiency

This ensures accurate unit cost calculation and product economic feasibility.

Regulatory Compliance and Food Safety

Scaling a plant-based product requires compliance with regulations on labelling, allergens, hygiene, and specific market requirements. Ensuring compliance from the first batch is essential to avoid penalties or delays in market launch.

Verification of Product Quality and Consistency

Maintaining quality and consistency across production is essential for consumer trust and retail acceptance.

Sensory, Physicochemical, and Shelf-Life Control

Sanygran implements controls on:

• Texture, flavour, and colour
• Stability during cooking, pasteurisation, or freezing
• Shelf-life and behaviour after regeneration or cooking

This ensures each batch meets defined specifications, regardless of production volume.

Alignment with Retail and Foodservice Requirements

Retailers and foodservice operators value:

• Product stability and batch-to-batch consistency
• Regularity of supply
• Ease of integration into their range and preparation lines

Validating the product before industrial scaling ensures these expectations are met and facilitates a successful market launch.

The Role of a Technological Partner in Plant-Based Scaling

Working with an industrial partner allows:

• Transforming ideas or initial recipes into scalable products
• Minimising risks of deviations in texture, flavour, or yield
• Optimising development time and cost

Sanygran supports brands and manufacturers from the initial concept to industrial production, adapting recipes, textures, and formats to specific needs, ensuring products are consistent, cost-effective, and ready for consumers.