In this article, we explore the importance of bite and cohesion in plant-based products—two key attributes that directly influence the quality, stability and consumer acceptance of any plant-based food.

When developing a meat alternative, achieving an appealing flavour profile or strong nutritional credentials is not enough. Texture, bite and cohesion determine how a product performs throughout manufacturing, thermal processing, storage and consumption.

Beyond enhancing the consumer experience, a well-designed structure helps reduce production issues, maintain batch-to-batch consistency and support industrial-scale production. For this reason, these attributes should be considered from the formulation stage and validated under real manufacturing conditions.

What Do Bite and Cohesion Bring to a Plant-Based Product?

Bite and cohesion are among the most influential factors in how consumers perceive the quality of a plant-based product.

In applications such as plant-based burgers and chicken-style pieces, these characteristics determine whether the product maintains its structure, withstands processing effectively and delivers a consistent eating experience throughout its shelf life.

A strong formulation should allow the product to retain its integrity from the production line through to consumption, preventing changes that could negatively affect texture or appearance.

Bite: Firmness, Resistance and Mouthfeel

Bite refers to the firmness, elasticity and resistance to cutting of a product. It is not simply about replicating the texture of meat, but rather creating a mouthfeel that is appropriate for the intended application.

This attribute depends on the interaction between plant proteins, fibres, starches, fats and water, as well as how these ingredients behave during industrial processing.

For this reason, a formulation that performs well in laboratory conditions should also be validated at industrial scale, where factors such as mixing, heat treatment and storage can alter product performance.

Cohesion: Structural Integrity Throughout Processing and Consumption

Cohesion refers to a product’s ability to remain intact throughout all stages of manufacturing and distribution.

When cohesion is insufficient, issues such as breakage during forming, crumbling, loss of shape, water release and visual defects may occur, affecting both perceived quality and process efficiency.

As a result, cohesion should be assessed before and after operations such as cooking, pasteurisation, freezing and reheating, ensuring the product remains stable throughout its shelf life.

Why Are These Attributes Critical in the Plant-Based Industry?

In the food industry, bite and cohesion are more than sensory characteristics. They also influence industrial viability, batch repeatability and overall project profitability.

A consistent texture supports efficient production, reduces variation and helps ensure the product reaches consumers with the intended characteristics established during development.

Impact on Quality Perception and Repeat Purchases

When a product delivers a consistent texture and satisfying bite, it becomes easier to meet consumer expectations and encourage repeat purchases.

In categories such as plant-based burgers and meat analogues, texture plays a decisive role in the overall product evaluation. Even small variations between batches can influence perceptions of quality.

From an industrial perspective, maintaining this consistency also makes life easier for R&D, Quality and Production teams by reducing manufacturing deviations.

Relationship with Waste, Returns and Product Stability

Insufficient cohesion can lead to issues that directly affect manufacturing performance, including:

• Breakage during forming
• Reworking within production
• Loss of shape during transport
• Water release (exudation)
• Customer complaints or product returns

Minimising these problems not only improves product quality but also helps reduce costs, optimise production efficiency and increase stability throughout distribution.

Formulation Factors That Determine Bite and Cohesion

The texture of a plant-based product begins to take shape long before it reaches the production line.

Ingredient selection and the balance between ingredients determine how the product will perform during mixing, cooking, storage and consumption.

The objective is not to add more ingredients, but to select those that provide the functionality required for the specific application.

Selecting Proteins, Fibres and Structural Matrices

Textured plant proteins are one of the foundations of products with a satisfying bite.

Depending on the application, solutions such as pea TVP, soy TVP or protein blends like Legumeat may be used. These combine different raw materials to achieve a balance between nutritional value and technological functionality.

Plant fibres also play an important role, helping improve water retention, cohesion and structural stability.

Ultimately, the final result does not depend on a single ingredient but on how all components interact within the formulation.

Moisture, Fat and Binding Systems

The balance between water, fat and binding systems has a direct impact on texture and juiciness.

Excess moisture can lead to structural weakness or water release, while insufficient hydration may result in dry products with an unpleasant bite.

Likewise, ingredients such as functional starches and specialised binding systems help stabilise the matrix and improve product performance during processing and storage.

Texturisation and Matrix Optimisation

The internal matrix largely determines the final eating experience.

By adjusting ingredients, hydration levels and structural systems, manufacturers can develop textures that are softer, more fibrous or more resistant to cutting, depending on the end application.

Rather than simply imitating a specific texture, the goal is to create a product that is stable, reproducible and aligned with market expectations.

Industrial Processes That Affect Bite and Cohesion

Even an excellent formulation can lose part of its functionality if the industrial process is not properly optimised.

Mixing, Forming and Compaction

The early stages of processing are critical for achieving a uniform structure.

Insufficient mixing may result in uneven ingredient distribution, while poor compaction can lead to products that are either fragile or excessively dense.

Controlling these parameters helps deliver products with a uniform bite, improved cohesion and greater batch-to-batch consistency.

Heat Treatment and Structural Stability

Heat treatment sets the product structure, but it can also alter it.

Processes such as cooking, pasteurisation and reheating may affect firmness, juiciness and water retention.

This is why products should be developed with the entire industrial journey in mind, rather than focusing solely on the point of manufacture.

Chilling, Freezing and Storage

The cold chain also has a significant impact on the texture of plant-based products.

Validating product performance throughout its shelf life helps ensure consistent quality until it reaches the consumer.

How Are Bite and Cohesion Evaluated During Product Development?

Achieving excellent texture requires combining development expertise with objective validation tools.

The aim is to verify that the product behaves as expected during manufacturing and maintains consistency across production batches.

Sensory Testing and Internal Panels

Sensory assessments allow teams to evaluate characteristics such as bite, cohesion, juiciness and overall uniformity.

These tests help identify differences between formulations before scaling up production.

Instrumental Testing and Consistency Control

Instrumental measurements complement sensory evaluations with objective data.

They enable manufacturers to compare batches, validate formulation changes and reduce process variability, supporting the work of R&D, Quality and Production teams.

Combining both approaches provides a far more reliable understanding of real product performance.

Applications Where Bite and Cohesion Make the Difference

While these attributes are important across all plant-based products, there are certain applications where their influence is particularly critical.

Prepared Meals and Ready-to-Eat Solutions

In prepared meals, products must maintain their structure after processing, transport and reheating.

Good cohesion helps prevent breakage and preserve presentation, while a balanced bite enhances the eating experience even after warming.

Chilled and Frozen Products

Products intended for chilled or frozen distribution must withstand temperature fluctuations without losing firmness or stability.

A well-developed formulation reduces issues such as water release, loss of cohesion and texture changes following thawing.

Retail Formats

In retail environments, products must maintain a consistent appearance throughout the entire supply chain.

Withstanding handling, transportation and shelf display is just as important as delivering excellent flavour, as any deterioration in texture can affect quality perception and purchasing decisions.

What Should Food Manufacturers Look for in a Plant-Based Supplier Regarding Bite and Cohesion?

When developing a plant-based product, selecting the right ingredients is only part of the equation. It is equally important to work with a partner who understands how formulation, processing and storage conditions interact to achieve a stable and consistent texture in production.

At Sanygran, we work with both functional ingredients and finished plant-based products, allowing us to validate the performance of textured proteins, fibres, starches and protein blends in real-world applications.

Because a satisfying bite and reliable cohesion do not depend on a single ingredient. They are the result of the right balance between formulation, industrial processing and validation.

Contact:

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

Multifunctional ingredients in plant-based products are becoming increasingly important for the food industry, helping manufacturers develop products with a better nutritional profile, improved texture, greater process stability and enhanced industrial performance.

Choosing ingredients that perform multiple technological functions can simplify formulations, optimise production and support the development of high-quality plant-based foods for retail, foodservice and prepared meals.

What does a multifunctional ingredient contribute to a plant-based formulation?

In the plant-based food industry, ingredients are no longer valued solely for their nutritional contribution. They also play a fundamental role in the structure, stability, juiciness, texture and overall behaviour of the product throughout the manufacturing process.

A multifunctional ingredient stands out because it can solve several formulation challenges simultaneously. Instead of incorporating multiple ingredients to perform separate functions, it delivers several technological benefits within a single solution.

For R&D, production and procurement teams, this can help develop more consistent products, simplify raw material management and reduce formulation complexity.

Technical functions a multifunctional ingredient can combine

Depending on its composition and the final application, a multifunctional ingredient can perform several technological roles within the same formulation.

The most common include:

• Plant protein enrichment
• Texture and bite development
• Water retention
• Improved cohesion
• Stability during cooking or reheating
• Enhanced processing efficiency

A good example is Legumeat, a solution developed by Sanygran that combines soy, rice and beans to deliver both nutritional value and technological functionality within a single ingredient.

In addition to providing a high protein content (50 g per 100 g), this blend helps build product structure, improves hydration and contributes to more consistent performance during industrial processing.

Similarly, textured pea proteins combine a high protein content with structural properties that help create the product matrix and improve processing performance.

Why do multifunctional ingredients reduce formulation complexity?

The more functional ingredients a recipe contains, the more complex product development, sourcing and quality control tend to become.

In many cases, the goal is not to add more ingredients, but to choose those that genuinely deliver greater value.

An ingredient capable of performing several functions can help reduce the number of raw materials required, simplify supplier management and improve both traceability and process standardisation.

This does not mean that a shorter ingredient list is always better. Rather, a more efficient formulation is often easier to control, reproduce and scale industrially.

Industrial applications where multifunctional ingredients deliver the greatest value

Multifunctional ingredients do not perform the same way in every product category. Their behaviour depends on both the formulation and the manufacturing process, as well as the characteristics required in the final product.

For this reason, selecting the right ingredient for each application is far more important than simply choosing the option with the highest protein content or the lowest cost.

Prepared meals and ready-to-eat products

In plant-based prepared meals, formulations must maintain their properties throughout manufacturing, storage, distribution and, in many cases, consumer reheating.

Multifunctional ingredients help maintain stable texture, effective water retention, consistent batch-to-batch performance and overall product stability throughout its shelf life.

Refrigerated and frozen plant-based products

Refrigeration and freezing expose products to particularly demanding conditions.

During these processes, issues such as syneresis, moisture loss and texture changes may occur.

Selecting ingredients capable of performing multiple functions helps minimise these effects and improves product performance after thawing or reheating.

Retail products requiring high stability

Products destined for the retail market must remain consistent from the production line to the consumer’s table.

In categories such as plant-based burgers, prepared meals, chilled products and meat alternatives, visual appearance and functional stability are just as important as nutritional quality.

Technical criteria for selecting a multifunctional ingredient

Ingredient selection should never rely solely on a technical specification sheet or on the number of functions an ingredient claims to perform.

There is no universal multifunctional ingredient. A solution that performs exceptionally well in a plant-based burger may behave very differently in a filling, sauce or prepared meal.

The key lies in understanding how the ingredient interacts with the rest of the formulation and how it behaves throughout the industrial process.

Compatibility with the formulation and processing conditions

The performan76ce of any ingredient depends on the environment in which it operates.

Factors such as hydration, temperature, mixing, thermal processing and the composition of the plant-based matrix can significantly influence its functionality.

For this reason, validation should always be carried out within the specific application for which the product has been developed.

Impact on texture, flavour and appearance

Technological functionality must always go hand in hand with a positive sensory experience.

An ingredient may improve protein content or processing stability, while also influencing bite, juiciness, flavour profile or the final appearance of the product.

Therefore, the formulation should always be assessed as a whole rather than focusing on a single parameter.

Industrial advantages of using multifunctional ingredients

Using multifunctional ingredients provides benefits beyond technical performance. It can also improve the overall efficiency of a project.

A well-optimised formulation can simplify purchasing, reduce the number of raw materials, streamline supplier approval and improve process repeatability.

Furthermore, reducing formulation complexity makes it easier to maintain consistent quality between production batches and achieve more reliable manufacturing performance.

Another important consideration is that the value of an ingredient should never be assessed solely by its price per kilogram. Manufacturers should also evaluate its yield, its ability to reduce waste, the stability it provides and its overall impact on industrial performance.

Formulation challenges and critical validation points

Despite their many advantages, multifunctional ingredients must be carefully validated before industrial production.

Proteins, starches, fats and fibres interact continuously within the formulation. Changing one component can influence the behaviour of all the others.

For this reason, validation should always focus on the complete formulation rather than on individual ingredients in isolation.

Before industrial scale-up, pilot trials are recommended to evaluate performance, stability, processing behaviour and batch-to-batch consistency.

How Sanygran supports plant-based ingredient development

Developing a multifunctional ingredient does not end with selecting the right raw material. Its real value is demonstrated when it performs consistently under real inddustrial manufacturing conditions.

At Sanygran, we develop textured pea and soy proteins, protein blends such as Legumeat, as well as functional ingredients including yellow pea protein concentrate and pea starch, all of which are incorporated into our own plant-based finished products.

This dual expertise, as both an ingredient manufacturer and a finished product manufacturer, gives us first-hand knowledge of how these solutions perform during processing, storage and throughout the product’s shelf life.

As a result, we help food manufacturers select the most appropriate ingredients for each application, reducing development iterations and facilitating successful industrial scale-up.

Because a multifunctional ingredient proves its value not on a specification sheet, but on the production line, where it consistently delivers the quality, stability and performance required for a successful finished product.

In this post, we explain how to prepare a plant-based product for export, a process that goes far beyond simply manufacturing a product and shipping it abroad. Exporting involves strategic decisions, technical product adaptation, and ensuring it performs under real market, logistics, and production conditions.

Define your plant-based export strategy

Before exporting, it is essential to define a clear and realistic strategy. Not all markets offer the same opportunities or require the same resources.

You should evaluate:

• priority countries
• commercial opportunities
• sales channels
• positioning and pricing

The objective is to determine whether your company is ready to compete internationally, and under what conditions.

Analyse your target market and sales channel

Demand for plant-based products varies by market. Countries such as the Netherlands or Germany show higher maturity, while others are still developing.

It is key to analyse:

• consumer profile
• competition
• price range
• trends (clean label, high protein, sustainability)

You should also define the most suitable channel: retail (supermarkets), distributors, foodservice or specialised stores. Not all products fit equally well in each.

Distinguish between EU and non-EU sales

Exporting within the EU allows for a more streamlined operation thanks to the single market.

However, when exporting to markets such as the United States or Asia, you must consider:

• customs controls
• tariffs
• sanitary requirements
• additional documentation

This adds complexity and requires careful planning.

Choose your importer and business model

The local partner is key to success. You should assess their experience in plant-based products, logistics capacity, commercial network and payment conditions.

Adapt your product to each market

A product developed for one country does not always perform well in another. Technical and commercial adaptation is essential.

Review your ingredients and novel foods

It is essential to verify that all ingredients are authorised in the destination market.

In the European Union, an ingredient may be classified as a novel food if it was not consumed significantly before 1997, which means it requires prior authorisation before being marketed.

👉 More information: EU Novel Food Regulation

This is particularly relevant in plant-based innovation, where new proteins and functional ingredients are frequently used.

Validate shelf life and safety

Exporting increases the time between production and consumption, so shelf life must be validated under real conditions.

This includes stability studies, microbiological testing, and preservation trials.

You should take into account the full journey: production → storage → transport → distribution → point of sale

Adjust your formulation to the consumer

Each market has different preferences.

Depending on the product, it is advisable to adapt flavour, texture, format, or even nutritional profile in line with local consumption trends.

For example:

• Europe → greater sensitivity to clean label
• United States → focus on protein content
• Asia → different sensory expectations

Ensure regulatory compliance, labelling and documentation

This is one of the most critical areas to avoid rejections or delays.

Prepare your labelling for the European Union

Food labelling in the EU is regulated by Regulation (EU) No 1169/2011, which requires clear information on ingredients, allergens, nutritional values and storage conditions to ensure informed consumer decisions.

Mandatory elements include:

• product name
• ingredient list
• highlighted allergens
• nutritional information

👉 You can check the full requirements here: EU food labelling rules

Organise your certificates and traceability

A robust export process requires complete, well-structured technical documentation, including technical datasheets, analytical certificates, allergen declarations and up-to-date production records.

Beyond compliance, well-managed traceability facilitates audits, speeds up customer approval processes, and enables efficient handling of potential issues.

Adapt compliance for the United States

Entering the US market involves meeting FDA requirements.

According to the agency, exporters are responsible for complying with both US regulations and those of the origin country, ensuring product safety and proper documentation.

This includes:

• facility registration
• adapted labelling
• food safety compliance

Ensure your logistics and international scaling

Exporting is not just about selling — it is about ensuring the product arrives in optimal condition.

Define your Incoterms and transport

Incoterms®, defined by the International Chamber of Commerce, are global rules that establish how costs, risks and responsibilities are shared in international trade.

Using them correctly avoids disputes and ensures clarity in operations.

👉 More information: Incoterms rules – ICC

Carry out your first pilot shipment

Before scaling up, it is recommended to carry out a pilot shipment.

This allows you to validate timings, product condition, documentation and potential issues.

It is a critical step before increasing volumes.

Scale your plant-based export with a specialised manufacturer like Sanygran

Preparing a plant-based product for export requires combining strategy, formulation, regulatory compliance and industrial capability.

Working with a specialised manufacturer such as Sanygran allows you to:

• develop products adapted to different markets
• reformulate according to international regulations
• produce in various formats (chilled, frozen or ambient)
• scale production with flexibility

With experience in European markets such as Italy and the Netherlands, Sanygran acts as a strategic partner or private label manufacturer, helping turn ideas into real, stable and export-ready products.

Because in export, success does not depend only on the product itself, but on whether it performs in the market, in logistics and in industrial production.

Contact:

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

Improving the nutritional profile of plant-based products involves much more than simply increasing protein content or modifying a label. In the food industry, the selection of functional plant-based ingredients directly influences nutritional value, but also the texture, stability and industrial performance of the final product.

Developing a successful formulation requires understanding how ingredients interact with one another and how they behave throughout the entire process, from manufacturing and storage to final consumption.

Before reformulating a product, it is also important to define the objective clearly: higher protein content, a more balanced nutritional profile, a cleaner label or improved functionality. Only then is it possible to identify the most suitable combination of ingredients.

Plant Proteins to Improve Protein Content and Quality

Plant proteins are one of the main tools for improving the nutritional profile of a plant-based product, but simply increasing the percentage of protein is not always enough.

In an industrial formulation, it is essential to evaluate factors such as amino acid profile, digestibility and technological behaviour of each protein source.

A protein may offer excellent nutritional value, but if it is not properly integrated into the formulation, it can negatively affect texture, hydration or product stability.

For this reason, in plant-based food development, protein should be considered not only as a nutrient, but also as a functional ingredient.

Protein Concentrates, Isolates and Textured Proteins

Each plant protein format fulfils a different role within a formulation.

Protein concentrates help increase protein content while maintaining a balance between functionality and cost.

Protein isolates provide a higher concentration of protein, although they generally require greater formulation control to avoid impacts on texture and processing performance.

Textured vegetable proteins (TVP) play a distinct role: in addition to providing protein, they contribute to the structure and functionality of the final product.

In applications such as plant-based burgers, nuggets, fillings and ready meals, textured proteins help build the product matrix, improving texture, bite and processing stability.

The most suitable ingredient will depend on the desired final result and how the product is expected to perform during manufacturing and scale-up.

Combining Protein Sources for a Balanced Nutritional Profile

Relying on a single protein source is not always the most effective approach.

Combining different raw materials helps balance nutritional value while improving functional performance.

For example, blending proteins derived from legumes and cereals can deliver better results from both a nutritional and technological perspective.

In practice, formulation is not determined only by protein percentage, but also by how proteins interact with the rest of the ingredients and the industrial process.

Optimise Your Formulation Without Losing Functionality

Improving nutritional value should never come at the expense of manufacturing performance.

The challenge lies in balancing:

• nutritional value
• texture
• stability
• cost
• sensory acceptance

A formulation change may improve one parameter while negatively affecting others.

For example, modifying a protein source can alter water absorption, cohesion and final structure.

This is why successful optimisation requires analysing the formulation as a complete system.

Preserve Texture, Flavour and Stability

In plant-based products, texture depends on the interaction between proteins, water, starches, fibres and fats.

Functional ingredients play a crucial role in this matrix. Natural starches, for example, improve structure, water retention and stability.

Incorrect selection may lead to:

• loss of juiciness
• dry texture
• poor cohesion
• phase separation

A shorter ingredient list does not automatically mean a better formulation. Removing ingredients without understanding their function can compromise product quality and shelf-life performance.

Reduce Sugar, Sodium and Saturated Fat

Reducing specific nutritional components is a growing priority in the food industry.

However, these adjustments must be made while considering the formulation as a whole system.

Changing one ingredient can directly affect flavour, texture and consumer perception.

For this reason, nutritional optimisation often involves combining different strategies, including the selection of proteins, fibres, starches and functional ingredients.

The objective is not simply to remove ingredients, but to develop balanced and functional products.

Protect Nutrients During Processing

Industrial processing has a direct impact on the nutritional profile of the final product.

Factors such as temperature, processing time and storage conditions can affect the behaviour of proteins, fats and other nutrients.

Therefore, formulations must be validated across the entire production chain, not only during development.

Validate Plant-Based Ingredients at Industrial Scale

An ingredient may perform well in the lab but require adjustments in full-scale production.

Industrial validation ensures consistent performance under real manufacturing conditions.

Assess Shelf Life and Scalability

It is important to evaluate:

• product stability
• texture evolution
• storage behaviour
• batch-to-batch consistency

The goal is to ensure consistent performance from pilot to industrial scale.

Verify Labelling and Nutritional Claims

Any improvement in nutritional profile must be supported by accurate data.

This includes ensuring consistency between:

• formulation
• nutritional analysis
• final labelling

This is especially important for protein-related claims and other nutritional statements.

Develop a Formulation Tailored to Your Brand

Every product has different needs depending on application, channel and positioning.

Defining objectives early helps select the right ingredients and avoid unnecessary reformulation cycles.

The key is finding the optimal combination to achieve a product that performs both nutritionally and industrially.

Improve the Selection of Ingredients for Your Plant-Based Products with Sanygran

Developing products with an improved nutritional profile requires a complete approach covering both ingredients and application.

At Sanygran, we develop functional plant-based ingredients including yellow pea protein concentrate, pea starch and textured vegetable proteins.

As manufacturers of plant-based products, we also use our own ingredients in real applications such as burgers, nuggets and other plant-based solutions, giving us first-hand knowledge of how they behave during industrial processing.

Improving the nutritional profile of a plant-based product is not simply about adding more protein. It is about developing a complete, stable and functional solution capable of performing at industrial scale.

Contact:

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

In this article, we explore how to reduce the ingredient list in plant-based products — a growing challenge in the food industry that goes far beyond simply “removing items from the label”. In reality, it involves reformulating without losing functionality, stability, or industrial performance, while ensuring the product remains viable under real production conditions.

Reducing ingredients may seem like a straightforward goal, but in practice it requires reviewing the entire formulation as a system: ingredients, process, and final product behaviour are all interconnected.

Simplifying Plant-Based Formulations Without Risk

Reducing the ingredient list in plant-based products requires a clear understanding of the role each component plays within the recipe. The most common mistake is removing ingredients without analysing their technological function, which can directly impact texture, stability, cost, and production performance.

In industrial formulation, fewer ingredients do not always mean a better product. At best, they result in a more optimised formulation.

Distinguishing a Short Ingredient List from Clean Label

A shorter ingredient list does not automatically mean a more “clean label” product.

The clean label concept also depends on:

• consumer understanding
• transparency in labelling
• ingredient origin
• perceived naturalness

Some functional ingredients are essential, even if they are not visually appealing on the label. The challenge lies in balancing technological function with market perception.

Identify Ingredients with Overlapping Functions

One of the keys to simplification is auditing the formulation and identifying ingredients that perform redundant roles.

For example:

• two systems delivering the same texture
• redundant stabilisers
• duplication in water retention or emulsification
• ingredients used purely as a process safety net

Eliminating redundancies helps reduce complexity without compromising performance.

Prioritising Multifunctional Ingredients in Recipes

True simplification comes not only from removing ingredients, but from selecting multifunctional ingredients.

This approach helps:

• reduce reliance on stabilisers
• maintain control over texture and structure
• simplify the overall formulation

Choose Proteins That Enhance Texture

Functional plant proteins provide more than nutrition — they can define the product’s structure.

Depending on the type, they contribute to:

• bite
• cohesion
• water retention
• cooking behaviour

For example, proteins from peas or soya can play a key structural role in burgers, nuggets, or fillings, reducing the need for additional ingredients.

Reduce Stabilisers Through Plant-Based Systems

In many formulations, stabilisers can be reduced by using well-designed combinations of proteins, fibres, and starches.

The goal is to integrate functionality into the product matrix, allowing:

• simpler labels
• stable performance
• fewer added ingredients

Maintaining Flavour and Texture

One of the biggest challenges when reducing ingredients is maintaining the sensory experience. Consumers do not buy a shorter label — they buy taste, texture, and consistency.

Control Vegetal Notes in the Protein Base

Simplifying formulations can make the natural flavour of plant proteins more noticeable.

Key factors to manage include:

• raw material selection
• appropriate heat treatment
• combining protein sources
• balancing cereals and pulses

A simpler formulation must remain pleasant, balanced, and consistent.

Validate Texture, Juiciness, and Stability

Every formulation change must be validated in real industrial conditions.

Critical parameters include:

• bite and cohesion
• juiciness after cooking
• storage stability
• performance during reheating

Without proper validation, simplification can lead to inconsistent products.

Adjusting the Process to Use Fewer Ingredients

Simplification is not just about the recipe. The industrial process plays a key role in reducing ingredient dependency.

Variables such as mixing, hydration, and temperature control can significantly impact the need for stabilisers.

Optimise Hydration, Mixing, and Cooking

Small process improvements can deliver major benefits:

• more efficient mixing times
• better protein hydration control
• optimised cooking temperatures
• correct ingredient incorporation order

These adjustments often allow for fewer ingredients without sacrificing performance.

Avoid Compensating Issues with New Additives

A common mistake in reformulation is adding new ingredients to fix existing problems.

When processes or formulations are not properly optimised, companies tend to add instead of simplify, leading to:

• more complex labels
• higher costs
• less efficient formulations

Reformulating with an Industrial Perspective

Reducing ingredients only works if the product remains viable, scalable, and profitable.

Evaluate Cost, Scalability, and Shelf Life

An optimised formulation must perform in real-world conditions:

• continuous production
• effective cost control
• stability throughout shelf life
• batch-to-batch consistency

Simplicity must never compromise scalability.

Ensure Food Safety and Compliance

Fewer ingredients do not reduce requirements.

All reformulations must ensure:

• food safety
• regulatory compliance
• allergen control
• consistency of product claims

Develop Your Plant-Based Range with Experts

Reducing the ingredient list in plant-based products is not a cosmetic exercise — it is a process of full industrial optimisation.

It requires strategic decisions about:

• ingredients
• processing
• product positioning

Working with a specialised partner enables brands to translate innovation into scalable, stable solutions.

At Sanygran, as an industrial partner in plant-based food manufacturing, we develop solutions designed for real production environments, helping companies balance functionality, simplicity, and performance.

Because in practice, a shorter ingredient list is only better if it performs just as well — or even better.

Contact:

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

Preparing a plant-based product for food audits requires much more than developing an attractive recipe for consumers. In the food industry, a product must demonstrate that it is safe, stable, traceable and reproducible at industrial scale.

This becomes especially relevant when working with large retailer audits, approval processes, private label projects or professional customers who need to ensure that the product meets all technical requirements before reaching the market.

From formulation to documentation, every stage of development must be aligned to guarantee that the product works not only in the laboratory, but also during manufacturing, distribution and throughout its shelf life.

What is reviewed during a food audit for a plant-based product?

An audit does not only assess the final product. Behind every plant-based product there is a complete system that needs to be controlled: ingredients, suppliers, processes, traceability and quality.

When preparing for large retailer audits, these controls are usually even more demanding, as retailers look for products that can maintain consistent quality across high production volumes and different commercial cycles.

Beyond sensory aspects such as flavour or texture, audits typically review:

• food safety
• regulatory compliance
• product stability
• batch-to-batch consistency
• manufacturing capacity
• supplier control

Food safety, compliance and product quality

The starting point is ensuring that the product complies with applicable regulations and remains safe throughout its shelf life.

This involves controlling:

• microbiological stability
• product specifications
• labelling requirements
• storage conditions

For chilled, frozen or ready-to-eat plant-based products, shelf life validation is particularly important, as it must guarantee not only safety, but also the quality perceived by consumers.

A product may perform well during initial development but require adjustments when scaled up industrially. This is why validation under real manufacturing conditions is essential.

Consistency between formulation, label and commercial claims

One of the most reviewed aspects during an audit is ensuring consistency between what the product communicates and what it actually contains.

In private label projects, it is common for the retailer itself to define the labelling and commercial claims. However, the manufacturer must ensure that these claims are technically achievable and properly supported by:

• product formulation
• ingredients used
• manufacturing process
• available documentation

This becomes particularly important when working with functional ingredients such as plant proteins, texturised proteins or starches, where each component has a direct impact on the final product performance.

Industrial capacity and supply reliability

For a retailer or industrial customer, a product is not validated simply because it works once. It must demonstrate that it can remain stable over time.

Industrial capability means ensuring:

• process repeatability
• batch consistency
• raw material availability
• supply reliability

In plant-based development, ingredient selection and behaviour during processing can make the difference between a recipe that works during initial trials and a solution ready for continuous production.

Technical documentation required before an audit

Documentation is a key part of any approval process. Having information available is not enough: it must be updated and accurately reflect the product being manufactured.

Product specification and technical data sheet

The technical data sheet must include the information required to evaluate and control the product:

• composition
• format
• storage conditions
• shelf life
• preparation instructions
• nutritional information
• microbiological and physicochemical parameters

One of the most common issues during audits is finding differences between approved documentation and the actual product manufactured.

Ingredients, allergens and raw material origin

Each ingredient must be correctly identified and documented.

This includes information about supplier, origin, technological function, allergens and technical specifications.

In plant-based solutions, ingredients such as plant-based texturisers, proteins or functional systems can directly influence texture, stability and industrial performance.

Shelf life studies and product performance

Shelf life should not only be evaluated from a microbiological perspective.

It is also important to assess how the product evolves during storage:

• texture
• appearance
• stability
• behaviour after preparation or regeneration

This is especially relevant for products where plant-based structures may change over time.

Traceability, suppliers and incident management

Traceability allows manufacturers to demonstrate that every product can be tracked from raw materials through to the final batch.

A robust system should connect:

• ingredient batch
• production order
• quality controls performed
• finished product
• customer receiving the product

Approval of critical suppliers

Suppliers are part of the final product quality system.

Before working with an ingredient, it is important to evaluate aspects such as:

• supply reliability
• available documentation
• quality control
• technical capability

For plant-based ingredients, working with a specialised manufacturer helps .

Managing non-conformities and product recalls

Any company prepared for audits must have clear procedures to manage potential incidents.

This includes:

• identifying the issue
• blocking affected product
• investigating root causes
• implementing corrective actions
• carrying out recall simulations

How to prepare an audit with a practical approach

An audit does not start when the auditor arrives. It starts during product development.

Before presenting a product to a retailer or industrial customer, it is important to ensure consistency between:

• formulation
• manufacturing process
• documentation
• labelling
• suppliers

In addition, all teams involved — quality, production, purchasing and R&D — must be aligned.

Experience shows that many issues do not come from a lack of information, but from small differences between departments that eventually affect the final product.

How Sanygran helps develop plant-based products ready for approval

At Sanygran, we approach plant-based development from a complete industrial perspective: ingredient, process and final product.

As a manufacturer of plant-based solutions, we do not only develop ingredients such as plant-based texturised proteins, concentrates and starches, but also use them in our own finished products. This allows us to understand first-hand how to integrate them into real formulations and industrial processes.

We support manufacturers, plant-based brands and customers working with retail in areas such as:

• ingredient selection and adaptation
• texture and stability optimisation
• formulation adjustments
• industrial scale-up
  adaptation to channel requirements

Because a food audit — and especially a large retailer audit — is not passed by preparing documents at the end of the process. It is built from the beginning by developing a product that is stable, safe and ready to perform both in the factory and in the market.

Contact:

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

When looking for plant-based fillet suppliers, the goal is not simply to find a product, but a solution that truly works in an industrial environment: one that fits production processes, remains stable and can be scaled efficiently. This article will help you understand what to consider when choosing a supplier and what key aspects to evaluate when incorporating this type of product into your portfolio.

Plant-based fillet supplier for the food industry, prepared meals and retail

The fillet format is becoming increasingly relevant in plant-based product development, especially for industrial applications.

Many prepared meal manufacturers are looking for a fillet that can be integrated into existing production processes without redesigning their systems.

Choosing the right supplier is essential. It is not only about taste, but about performance on the production line, structure retention, behaviour after processing and whether costs remain competitive when scaling up.

What should an industrial plant-based fillet supplier offer?

From a B2B perspective, expectations are clear: the product must perform consistently and reliably. This requires:

• Production capacity
• Supply continuity
• Consistent quality
• Adaptation to customer requirements

This is where the difference lies between a catalogue supplier and a tailored solutions partner.

Finished product, semi-finished ingredient or customised formulation

One of the most important factors is the format. At Sanygran, different formats are used depending on customer needs and final application:

• Finished product: ready to use
• Chilled or frozen formats: direct integration into production
• Dry format: greater flexibility, adjustment of hydration, flavour and texture, and longer shelf life

Each format responds to a different production model.

Adaptation to private label and retail projects

When a product is developed for private label or large-scale retail, requirements become more complex.

It is not only about the fillet itself, but about everything around it: weight, format, packaging, labelling, shelf life and target price positioning.

A strong supplier adapts without adding complexity or compromising the final result.

Key technical characteristics of a plant-based fillet for industrial production

A vegan fillet is not only evaluated by flavour, but by its performance throughout the process.

Structure and performance of plant-based fillet alternatives

The objective is not simply to create a product with a similar appearance to meat, but to achieve the right structure, bite and resistance during handling and cooking. Fibre structure, elasticity and cutting behaviour have a major impact on the final experience.

Technologies such as extrusion play a key role, as they allow manufacturers to build this structure from the beginning.

Once the product enters cooking or industrial processing, weaknesses become visible if the formulation has not been properly designed. Weight loss, lack of juiciness or inconsistent performance across different cooking methods are common challenges when the fillet is not optimised.

Storage and stability

Another critical factor is storage. The product must maintain its texture and quality throughout the supply chain, including after freezing.

It must also be compatible with standard packaging solutions used in the industry.

Ingredients and protein bases for developing plant-based fillets

Behind every plant-based fillet there is a formulation that determines its final performance.

The combination of proteins and functional ingredients makes the difference between a product that works and one that struggles during production.

At Sanygran, we work with combinations of plant-based proteins and ingredients, including soy, pea, bean and rice, allowing us to adjust nutritional profile, texture and industrial performance.

Textured vegetable proteins and extrusion as a functional base

Extrusion technology creates the fibrous structure and defines product behaviour. Without a strong foundation at this stage, it becomes much harder for the final product to perform consistently throughout production.

Clean label formulation, allergens and nutritional profile

Beyond technical performance, labelling and nutritional profile are becoming increasingly important.

Some projects require a simpler ingredient list, while others focus on protein content or specific nutritional claims. These factors must be considered from the beginning, as they directly influence product development.

Plant-based fillet applications in prepared meals and professional channels

Plant-based fillets deliver the most value when connected to real applications.

Chilled and frozen prepared meals

This format works particularly well in complete ready meals, products with sauces or heat-and-eat solutions. It provides an alternative to more traditional formats such as burgers or nuggets and allows manufacturers to create more varied plant-based ranges.

Foodservice, catering and central kitchens

In this channel, practicality is essential.

A vegetarian fillet that is easy to regenerate, maintains quality and provides consistent portioning can significantly improve operational efficiency.

The dry format can also provide additional flexibility from a logistics perspective.

Retail and consumer-facing products

In retail, vegan fillets help expand product ranges and offer more variety.

However, other factors become critical, including packaging, shelf life and ease of preparation, all of which influence consumer acceptance and product rotation.

How to choose a plant-based fillet supplier for large-scale production

Choosing a supplier is not only about testing whether a product tastes good. It is about confirming that it will perform consistently in everyday industrial conditions.

Batch-to-batch consistency and quality control

One of the most important aspects is consistency.

If the product changes between batches, production issues can quickly appear. Maintaining stable texture, weight and processing behaviour is essential to avoid quality deviations.

Traceability, technical documentation and food safety

A reliable supplier must provide complete documentation, including technical specifications, allergen information, microbiological parameters and traceability records. This ensures smooth product approval and supplier qualification processes.

Scalability, lead times and supply continuity

Finally, it is essential to ensure that the supplier can support future growth. Moving from initial trials to regular production requires capacity, organisation and reliability.

Sanygran as a plant-based solutions supplier for fillets and prepared products

Sanygran develops tailored plant-based solutions, offering finished products as well as intermediate formats (dry, chilled or frozen), depending on how the ingredient or product will be used.

This allows purchasing, quality and R&D teams to focus on what matters most: ensuring the product performs correctly within their process and can scale without unexpected challenges.

If you are considering incorporating this type of solution, the first step is understanding how it fits into your production line and defining the required format, shelf life and performance criteria.

Contact:

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

Reducing costs is a constant priority in the food industry, but in the current context it has become an even greater challenge. Rising energy costs, increasing raw material prices and higher logistics costs are having a direct impact on product margins.

In this scenario, understanding how to reduce costs in plant-based products goes beyond simply reformulating recipes. It requires reviewing the entire production system, from sourcing and manufacturing to distribution, while maintaining consumer acceptance, production stability and compliance with customer specifications.

The real cost of a plant-based product is not just in the formulation

Reducing costs is not just about replacing expensive ingredients with cheaper alternatives. The real cost of a plant-based product lies in how it performs in production and in the market.

A cheaper ingredient may lead to texture issues, higher waste, shorter shelf life or the need for additional corrections, ultimately increasing the real cost of the product.

In the current context of rising energy, transport and material costs, the impact is not only linked to formulation, but also to processing. Products that require multiple stages or manufacturing lines can significantly increase cost without adding real value.

Cost per kilo of ingredient vs cost of an acceptable finished product

Focusing only on the cost per kilo of ingredients can lead to inefficient decisions.

A cheaper raw material may result in:

• Higher water loss during processing
• The need to adjust flavour, colour or texture
• Batch-to-batch variability
• Reduced stability after cooking or freezing

The result is a less stable product, increased reprocessing and lower market acceptance.

The relevant metric is not the cost of the ingredient, but the cost of a finished product that meets specifications and is accepted by the consumer.

Variables to include in industrial cost analysis

Cost analysis must take into account all variables within the production system, not just formulation.

Key factors include:

• Type and proportion of plant protein
• Texture system
• Flavouring and sensory adjustments
• Purge losses
• Product shelf life
• Packaging
• Energy consumption
• Labour
• Waste and rework

Only by integrating these variables is it possible to truly optimise costs.

Use texture as a lever for industrial cost optimisation

In plant-based products, texture is not a final detail. It is a key variable that directly affects yield, ingredient usage, water retention and consumer acceptance.

A well-designed texture also contributes to product stability and reduces batch variability.

Hydration, mixing and water retention

Poorly adjusted hydration can lead to:

• Overly soft masses
• Loss of bite
• Purging in the final product
• Variability between production batches
• Reduced yield

Optimising hydration and mixing improves ingredient utilisation and reduces losses.

Fibres, hydrocolloids and functional starches

The use of fibres, hydrocolloids and starches can help reduce costs when applied correctly.

They contribute to:

• Improved cohesion
• Increased water retention
• Structural stability
• Bite adjustment

However, excessive use may lead to:

• Artificial textures
• Sticky or pasty mouthfeel
• Lower product acceptance

The balance between functionality and sensory perception is essential.

Texture after cooking, freezing and regeneration

The product must perform under real conditions of use:

• Oven or pan cooking
• Microwave heating
• Freezing and thawing processes
• Reheating in ready meals

If texture is not stable after these processes, it may lead to yield losses, sensory changes and potential complaints.

Reformulate based on application: not all plant-based products require the same solution

There is no single formulation suitable for all products. Each application has different requirements in terms of texture, cost, processing and final performance.

Additionally, requirements vary depending on the channel and product type, directly influencing cost decisions.

Products for retail, foodservice and ready meals

Each channel presents different demands:

• Retail → visual stability, shelf life and consumer experience
• Foodservice → ease of regeneration, consistency and cost per serving
• Ready meals → processing performance, integration into recipes and thermal stability

Adapting the product to each channel helps avoid unnecessary formulation costs or over-engineering.

Target cost per serving, not just per kilo

One of the key strategies for cost optimisation is shifting the focus from €/kg to cost per sellable portion.

This allows:

• Portion size optimisation
• Better formulation decisions
• Improved profitability
• Alignment between cost and market positioning

How Sanygran can help reduce costs without compromising sensory quality

Reducing costs in plant-based products requires a comprehensive approach. It is not just about reformulation, but about understanding how ingredients, processes and final applications interact.

In many cases, one of the main cost-saving levers lies in optimising the production process, particularly in products that involve multiple processing stages or lines.

Working with an experienced partner makes it possible to analyse these aspects in a structured way, identifying opportunities such as:

• Process simplification
• Reduction of production steps
• Improved ingredient integration
• Optimisation of time and resources

Tailored reformulation according to product, channel and production line

Development is adapted to each specific application, including burgers, nuggets, bases for ready meals or fillings.

This allows adjustment of parameters such as texture, hydration, yield and stability according to the target cost and the existing production setup.

Plant-based ingredients and finished products with an industrial approach

The selection of raw materials and auxiliary materials has a direct impact on final cost.

Working with solutions designed for industrial use enables:

• Reduced variability
• Fewer production issues
• Improved product stability
• Optimised performance

All of this contributes to achieving a balanced outcome between cost, sensory quality and industrial viability.

Because in the current environment, controlling costs is not the result of a single decision, but of how the entire production system is designed and executed.

Types of plant-based texturised proteins are one of the most widely used solutions in the food industry for developing plant-based products with structure, texture and functionality. These texturised ingredients are designed to deliver specific sensory characteristics while improving product performance during processing.

In this article, we analyse the main types of plant-based texturised proteins, their differences in terms of process, raw materials, formats and industrial applications, as well as the key criteria to consider when selecting the most suitable solution.

What is a plant-based texturised protein?

A plant-based texturised protein is an ingredient obtained from plant proteins that have been transformed through technological processes — primarily extrusion — to create an organised structure capable of delivering fibre, bite and water retention.

Unlike plant protein powders or concentrates, texturised protein does not only provide protein content; it also provides a physical structure that enables the development of products with specific sensory profiles.

In the food industry, it is used as a functional ingredient in products such as plant-based burgers, nuggets, fillings and ready meals.

Difference between plant protein, texturised protein and finished product

Although related, these are different concepts.

Plant protein is the raw material from which the ingredient is developed. It may come from sources such as soy, pea or other plant-based ingredients.

Texturised protein is that protein transformed through processes such as extrusion to achieve a specific structure. This is the ingredient that is later incorporated into a formulation.

A finished plant-based product is the final application where the texturised protein is part of a complete formulation, such as a burger, nugget or ready meal.
For this reason, selecting the right texturised protein depends not only on the source protein, but also on the intended final application.

Main types of plant-based texturised proteins by process

Within the plant-based industry, there are two main categories: dry texturised proteins (TVP) and high-moisture texturised proteins (HME).
Each offers different advantages and they are not interchangeable. The choice depends on factors such as final application, shelf life, storage, processing conditions and desired sensory experience.

Dry texturised proteins (TVP)

Dry texturised proteins are dehydrated ingredients that are rehydrated during the final product manufacturing process.

One of their main advantages is logistical stability, as they can be stored at ambient temperature for long periods.

They are commonly used in applications where structure and water absorption are required, such as:

• Plant-based burgers
• Nuggets
• Fillings
• Bolognese-style sauces
• Ready meals

They also offer high formulation flexibility, allowing manufacturers to adjust hydration, flavour and texture according to the final recipe.

High-moisture texturised proteins (HME)

High-moisture texturised proteins are produced through wet extrusion and allow the creation of more fibrous and juicy structures.

They are particularly suitable when a more structured, visually defined product is required, with a more pronounced bite.

Due to their higher moisture content, they require specific storage conditions, typically refrigeration or freezing.

When to choose dry vs high-moisture texturised proteins

There is no one-size-fits-all solution.

Dry texturised proteins are generally preferred when:

• Longer shelf life is required
• Easy storage is important
• Flexible dosing is needed
• Integration into multiple formulations is required

High-moisture solutions are more suitable when:

• Juicier textures are desired
• Products require strong visual presence
• Higher-value chilled or frozen products are being developed

The manufacturer’s expertise is key to balancing texture, process and cost.

Types of plant-based texturised proteins by raw material

The choice of raw material directly influences flavour, colour, texture, nutritional profile, allergen considerations and processing performance.

Soy texturised protein

Soy-based texturised protein is one of the most widely used ingredients in the plant-based industry due to its versatility, availability and strong functional performance.

It is commonly used in burgers, nuggets, fillings, sauces and minced-type products.

Its hydration capacity and structure make it a reliable solution, although alternatives may be explored when developing formulations without soy or with different positioning.

Pea texturised protein

Pea-based texturised protein is gaining increasing relevance in plant-based product development.

It is particularly suitable when there is a need to diversify protein sources, reduce soy dependency or align with specific clean label strategies.

Wheat or gluten-based texturised protein

Wheat-based texturised proteins can provide an elastic and fibrous texture, which is valuable in applications where bite is critical.

However, their use must be carefully considered due to gluten-related labelling and regulatory requirements.

Protein blends and customised texturised solutions

In many industrial applications, the optimal solution does not rely on a single protein source.

Blends allow combining different raw materials to achieve the right balance between:

• Texture
• Flavour
• Functionality
• Cost
• Availability

An example is Legumeat, a solution developed by Sanygran combining soy, rice and beans to deliver a versatile and adaptable sensory and functional profile.

Types of plant-based texturised proteins by application

The most effective way to select a texturised protein is not just by its origin, but by its role within the final product.

Texturised proteins for ready meals

In ready meals, the ingredient must perform consistently throughout the product lifecycle, including cooking, freezing and reheating.

Key factors include:

• Water retention
• Sauce integration
• Batch-to-batch consistency

Texturised proteins for meat alternatives

In products such as burgers, nuggets, meatballs or restructured alternatives, the objective is to create a balanced structure.

Critical aspects include:

• Bite
• Juiciness
• Cohesion
• Process resistance

Here, texturised protein plays a key role in the overall product architecture.

Texturised proteins for toppings, fillings and foodservice

In foodservice and convenience applications, functionality and ease of use are essential.

They are widely used in pizzas, wraps, bowls, fillings and prepared recipes where consistency and ease of dosing are required.

Texturised proteins for private label and retail

Retail developments require balancing multiple factors: cost targets, shelf life, format, labelling and consumer experience.

Working with a supplier capable of adapting the ingredient to specific project requirements is therefore a key differentiator.

Sanygran: plant-based texturised proteins and customised solutions for the food industry

At Sanygran, we develop plant-based texturised proteins for food manufacturers, brands, retail and foodservice, combining ingredient expertise, technology and industrial application.

We work with both dry extrusion (TVP) and high-moisture extrusion (HME), across different raw materials, formats and applications.

Our experience as manufacturers of finished plant-based products gives us a practical understanding of how these ingredients perform in real formulations — from burgers and nuggets to ready meals.

This enables us to support each project from ingredient selection through to industrial scale-up, adjusting parameters such as:

• Texture
• Format
• Processing
• Preservation
• Final application

Because a good texturised protein must not only perform in development — it must perform consistently in production and throughout the entire value chain.