Dry plant-based texturates, commonly known as Textured Vegetable Protein (TVP), are a versatile solution for developing plant-based foods with a defined structure, reliable performance after hydration, and easy storage and transportation. Their use extends far beyond meat alternatives, as they can be incorporated into burgers, fillings, Bolognese sauces, nuggets and ready meals.

In this article, we explain what they contribute to industrial formulations, the raw materials and formats available, how they are manufactured, and the key criteria to consider when selecting a texturate for a specific application.

What are dry plant-based texturates and what role do they play in formulation?

Textured vegetable protein (TVP) are ingredients made from plant-based raw materials that, through an extrusion process, develop a structure that enables them to absorb water and create a specific texture during hydration.

For food manufacturers, their value goes beyond protein content alone. Texturates can provide structure, bite, volume and formulation integration, while also making it easier to store and handle the ingredient before it is incorporated into the final product.

Their dry format also allows manufacturers to work with a stable, easy-to-dose ingredient that can be incorporated into recipes according to the specific requirements of the finished product.

The difference between dry texturates and other plant-based matrices

Not all plant-based solutions meet the same industrial requirements.

A textured vegetable protein can be particularly interesting when manufacturers need an ingredient that can be stored, transported and dosed before being incorporated into a formulation. Compared with pre-hydrated plant-based matrices or finished products, the dry format offers greater flexibility in deciding when and how the ingredient is added to the recipe.

It also allows both the raw material and physical format to be tailored to the final product. A fine granule may integrate easily into certain mixes or fillings, while a larger piece may be preferred when a more defined presence is required within the finished preparation.

In industrial applications, this has a practical implication: the choice of texturate should be based on the final product and manufacturing process, not solely on the ingredient itself.

Technological functions in finished products

Texturates can fulfil a variety of functions within a formulation:

• Providing bite and structure to plant-based products.
• Integrating into blends for burgers, nuggets and fillings.
• Contributing to texture in sauces and ready meals.
• Absorbing water and flavours during hydration.
• Maintaining appropriate structure throughout subsequent cooking or reheating processes, depending on the formulation.

This is why two products made with the same protein source can deliver very different results. The format, degree of texturisation and method of incorporation all have a direct impact on the final outcome.

Main formats and raw materials used in dry plant-based texturates

The raw material determines much of a texturate’s behaviour, but so does its physical structure.

When developing an industrial solution, both variables should be considered together: which ingredient is used and what texture is required.

At Sanygran, we primarily work with texturates made from soya, pea and blended plant-based ingredients, such as Legumeat®, a combination of soya flour, bean flour and rice flour.

The most common plant proteins in dry texturates

Soya remains one of the most widely used raw materials in plant-based texturates and enables the development of solutions suitable for a wide range of applications.

Pea protein has become one of the fastest-growing raw materials within the plant-based sector. In addition to offering strong technological performance, it allows manufacturers to develop formulations that avoid some of the industry’s most common allergens, such as soya and gluten.

There are also solutions based on blends of plant-based raw materials. This is the case with Legumeat®, Sanygran’s proprietary development, which combines soya flour, bean flour and rice flour to create a plant-based matrix that differs from texturates made from a single protein source.

The choice should not be based solely on the origin of the protein. It is equally important to consider texture, flavour, colour, hydration behaviour and end-use application.

Granulated, chunk and flake formats

The physical format influences how a texturate is incorporated into a recipe.

At Sanygran, we offer soya and pea texturates in fine granulated formats, particularly suited to formulations requiring homogeneous integration.

In the case of Legumeat®, in addition to fine granules, we also offer larger formats such as chunks and fillets for applications where a more defined plant-based structure is required.

Format selection depends on factors including:

• The type of final product.
• The desired level of integration.
• The target texture.
• The hydration process.
• The mixing system.
• The intended cooking or reheating method.

As a result, the same concept of a dry texturate can lead to very different solutions depending on the application.

How are dry plant-based texturates manufactured?

The production of a textured vegetable protein begins long before the ingredient reaches the customer’s production line.

Extrusion transforms plant-based raw materials into structures with specific physical characteristics. During the process, operating conditions within the extruder influence how this structure develops and, consequently, how the product performs afterwards.

The objective is not simply to create a plant protein with a specific shape, but to obtain a texturate that is stable, reproducible and suitable for subsequent hydration and industrial use.

Extrusion, drying and product stabilisation

Extrusion combines different processing conditions to transform raw materials and develop the texturate’s structure.

The product is then dried to achieve the conditions required for storage and handling.

This stage is particularly important because the end result must be consistent not only visually but also in its subsequent performance. When a customer incorporates a texturate into an industrial formulation, they need the ingredient to respond predictably from batch to batch.

In other words, the quality of a textured vegetable protein is measured not only when it leaves the extruder, but also by how it performs once rehydrated and incorporated into a formulation.

Process variables affecting texture and performance

Final texture depends on several extrusion process variables and the characteristics of the raw material itself.

These include factors such as:

• Temperature, which influences raw material transformation.
• Moisture, which affects structure development during extrusion.
• Pressure and extrusion conditions, which determine the texture achieved.
• Product size and shape, partly defined by the die system.
• Final drying level, which is essential for product stability.

There is no universal combination that works for all applications. A texturate intended for a Bolognese sauce will not necessarily require the same characteristics as one designed for larger meat-free pieces.
For this reason, process control is just as important as raw material selection.

Criteria for selecting a dry texturate for plant-based applications

Selecting a texturate should not be reduced to comparing ingredients or prices per kilogram.

For R&D and purchasing teams, it is far more relevant to evaluate the performance the ingredient delivers within the intended application.

A texturate may be technically sound yet still not represent the best solution if it fails to suit the process, format or sensory objectives of the final product.

Compatibility with ready meals, fillings and meat alternatives

Dry texturates can be incorporated into a wide range of applications.

In burgers and nuggets, they can help create an integrated structure within the product matrix.

In fillings and Bolognese sauces, a granulated format can provide structure and recognisable texture without dominating the overall recipe.

In ready meals, selection must also take into account what happens after production, including cooking, reheating, storage and consumption.

For this reason, Sanygran works with different formats and raw materials suited to applications ranging from formed products to more complex prepared foods.

Selection factors: hydration, flavour, texture and cost

One advantage of dry texturates is that they can be designed around their behaviour during hydration.

At Sanygran, our texturates are manufactured in a neutral format, enabling them to absorb the flavour profile required by each formulation.

This is particularly valuable for manufacturers developing products with different sensory profiles. The same structural base can be used across multiple recipes with different seasonings, sauces and flavour directions without the ingredient competing with them.

When selecting a solution, it is also important to consider:

• Hydration capacity and yield within the recipe.
• Texture and bite after hydration.
• Neutral flavour and aroma profile.
• Batch-to-batch consistency.
• Format and dosing convenience.
• Actual application cost, rather than ingredient price alone.

This final point is especially important. The cost per kilogram of a texturate does not tell the whole story. It is essential to evaluate the value it adds to the formulation and the yield it delivers in the finished product.

Industrial advantages of dry plant-based texturates

The benefits of a dry format extend beyond formulation itself.

For food manufacturers operating at industrial scale, factors such as storage, transport, dosing and ingredient stability prior to use are equally important.

Shelf life, storage and logistics

As dry ingredients, texturates can be stored without the refrigeration requirements associated with pre-hydrated plant-based matrices, provided the recommended storage conditions are respected.

This can simplify logistics and allow manufacturers to stock ingredients before production begins.

In addition, the dry format can simplify handling and dosing operations, particularly in formulations requiring multiple ingredients to be added in controlled quantities.

Scalability and production repeatability

Moving from laboratory trials to industrial-scale production involves much more than simply increasing quantities.

Formulations must remain stable at larger scale, and ingredients must perform consistently across different batches.

In this context, a standardised textured vegetable protein supports accurate dosing, formulation control and process repeatability.

For manufacturers, this results in greater predictability when producing the same product repeatedly over time.

Food safety and quality control considerations for dry plant-based texturates

When an ingredient is destined for industrial food production, functionality is only one part of the equation.

Specifications, traceability, stability and storage conditions must also be controlled to ensure compliance with the requirements of the intended application.

Technical specifications and control parameters

Relevant texturate specifications may include:

• Moisture content.
• Particle size and format dimensions.
• Batch uniformity.
• Hydration performance.
• Sensory characteristics.
• Storage stability.

These parameters are not valuable in isolation. What matters is that they provide an ingredient that is predictable and compatible with the customer’s formulation and process.

For R&D teams, this predictability is essential when moving from initial trials to regular production.

Critical points in storage and handling

Although the dry format simplifies certain operations, the ingredient must still be protected from conditions that may compromise its stability.

Environmental moisture, cross-contamination, storage conditions and proper handling are all factors that must be considered during industrial use.

Furthermore, once hydrated, the texturate behaves very differently and becomes part of a matrix with its own storage requirements. For this reason, usage conditions should take into account both the dry ingredient and the finished product.

How can dry texturates be integrated into an industrial plant-based formulation?

Incorporating a dry texturate involves much more than simply adding it to a recipe.

Hydration, mixing and subsequent processing all influence the final outcome. Before scaling up a formulation, it is advisable to validate ingredient performance under real manufacturing conditions.

The relationship between hydration and final yield

When a texturate absorbs water, it increases in both weight and volume while developing the texture characteristics required in the formulation.

The amount of water used and the method of incorporation should be standardised to avoid production variability.

This has a direct impact on yield, as even small differences in hydration can affect texture, mixture consistency and subsequent product performance.

For this reason, industrial development requires more than simply knowing that a texturate “absorbs water”. Manufacturers need to understand how it performs within a specific formulation and under actual processing conditions.

Process adjustments during cooking, mixing and reheating

Every application has its own requirements.

A burger, a Bolognese sauce and a filling do not behave in the same way during mixing and cooking. Nor will they necessarily require the same conditions if the product is reheated later.

Before scaling up a formulation, it is therefore advisable to validate:

• Texturate hydration.
• Integration within the mix.
• Texture after processing.
• Behaviour during cooking.
• Stability during reheating, where applicable.

The objective is to reach production with a formulation that not only works in the laboratory but is also fully reproducible in industrial manufacturing.

What can Sanygran offer as an industrial supplier?

Choosing a dry texturate is ultimately about choosing how a key part of the formulation will perform.

Having access to different raw materials, formats and adaptation possibilities allows product development to begin with the final application in mind rather than a standard ingredient.

At Sanygran, we work with soya, pea and blended plant-based ingredients such as Legumeat®, developing texturates for applications including burgers, nuggets, fillings, Bolognese sauces and ready meals.

Tailored development according to application and sales channel

Not all applications require the same size, texture or raw material.

For this reason, we can tailor different texturisation variables, including size, texture, ingredient and flavour.

All our texturates are manufactured with a neutral profile, making it easier to incorporate the desired flavour profile during hydration. This allows products with distinct sensory characteristics to be developed from the same technological base, adapting to each recipe and brand positioning strategy.

Technical support from formulation to industrialisation

The value of a texturate supplier extends beyond simply supplying an ingredient. To achieve successful industrial performance, it is essential to understand how the ingredient integrates, hydrates, processes and contributes to the final product.

At Sanygran, we support development from raw material selection and identification of the most suitable solution through to formulation trials and adaptation to production requirements.

In this way, texturates become more than just raw materials. They become a development tool that delivers structure, texture and functionality from the earliest stages of a project.

Contact:

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

Achieving a convincing plant-based texture is no longer solely a matter of formulation. High-moisture plant-based texturates have become one of the most promising technologies for developing plant-based alternatives with a fibrous structure, juicy bite and stable performance throughout the manufacturing process.

Thanks to high-moisture extrusion, it is now possible to create products capable of replicating the eating experience of meat while adapting to applications as diverse as ready meals, foodservice solutions, and products intended for retail and private label markets.

In this article, you will discover what high-moisture texturates are, how they are manufactured, the benefits they bring to the food industry, and why more and more manufacturers are incorporating them into new product developments.

What Are High-Moisture Plant-Based Texturates?

High-moisture plant-based texturates are products made from plant proteins that, through a high-moisture extrusion process, develop a fibrous structure very similar to that of meat.

Put simply, these are plant proteins that move beyond the form of powders or granules and become structured pieces with a defined texture, a juicy bite and suitability for a wide range of food applications.

The main difference compared with a traditional textured vegetable protein (TVP) is that the product leaves the process with a high moisture content, making it possible to achieve a more fibrous texture, a more realistic bite and greater juiciness.

For food manufacturers, this represents a significant advantage, as it facilitates the development of plant-based products ready to be incorporated into recipes, reducing processing stages and improving consistency in the final result.

In addition, these texturates can be used in both chilled and frozen products, adapting to different preservation, distribution and shelf-life requirements.

Industrial Applications of High-Moisture Texturates

The principal advantage of this technology is its versatility.

Depending on the formulation, cut and flavour profile, the same process can deliver completely different applications.

Chilled and Frozen Ready Meals

Ready meals are one of the categories where these products provide the greatest value.

Their structure remains intact throughout cooking, regeneration, chilling and freezing processes, enabling manufacturers to develop recipes that remain consistent right up to the point of consumption.

For this reason, they are particularly attractive for producers of ready meals, premium convenience foods and ready-to-eat solutions.

Fillings, Sauces and Mixed Preparations

They also perform exceptionally well in applications where they are combined with other ingredients.

Plant-based Bolognese sauces, pasta fillings, pizzas, wraps, tacos, prepared rice dishes and sauces are just some examples where texturates provide structure while maintaining stability throughout the product’s shelf life.

Their ability to absorb flavours makes them easy to incorporate into complex recipes while retaining a distinct texture.

Products for Retail and Private Label

In products intended for large-scale retail distribution, consistency is just as important as the recipe itself.

High-moisture texturates make it possible to achieve uniform products from batch to batch, with excellent appearance and stable performance during chilled or frozen storage.

This facilitates the launch of new retail and private-label products, where product consistency is a key requirement.

How Are High-Moisture Texturates Produced and Processed Industrially?

Final product quality does not depend solely on machinery.

The selection of raw materials, formulation design and control of the entire production process determine the texture, juiciness and subsequent performance of the product.

Raw Materials and Formulation

The plant proteins selected play a major role in determining the final result.

At Sanygran, we primarily work with soy and pea proteins, two raw materials that offer excellent functional properties for these applications.

In addition, our R&D team has developed projects using ingredients such as brewers’ spent grain, which contributes to circular economy initiatives and has been used in products such as our plant-based beef alternative, as well as oats, which provide a softer bite and a particularly pleasant texture.

Each raw material behaves differently during extrusion, making the right combination essential to achieving the desired product performance.

Texturisation and Moisture Control

During extrusion, controlling moisture is one of the most critical aspects of the process.

Variables such as water content, temperature and processing speed directly influence the formation of plant-based fibres.

Precise control allows manufacturers to obtain highly juicy products with a uniform texture and excellent storage stability.

By adjusting these parameters, it is also possible to develop products with either a denser or a lighter structure, depending on the requirements of the final application.

Cooling and Conditioning

Once the desired structure has been achieved, an equally important phase begins.

Cooling helps to stabilise the internal structure and preserve the texture obtained during extrusion.

The product is then conditioned according to the target application and required final format.

At Sanygran, we commonly work with formats such as chunks, pulled-style strands and flakes, among others.

This variety enables each customer to find the most suitable solution for their recipe without modifying their manufacturing process.

Functional Benefits of High-Moisture Plant-Based Texturates for Food Manufacturers

High-moisture texturates do more than replace animal-derived ingredients. They can also help optimise processes, improve product stability and reduce development times.

Texture and Eating Experience

One of the main challenges in any meat analogue is delivering a convincing eating experience.

Thanks to high-moisture extrusion, it is possible to achieve different levels of fibrousness, juiciness, firmness and bite, tailoring the product to the outcome each customer is seeking.

Developing strips for fajitas requires a different texture from that needed for a plant-based lasagne filling or chunks designed to accompany a rice dish. Each application demands a specific texture and therefore a dedicated manufacturing approach.

In addition to texture, the sensory profile can also be customised. At Sanygran, we develop different flavour profiles, including chicken, beef and seafood-inspired concepts such as plant-based tuna or salmon, enabling each development to align with the brand’s positioning.

Formulation Efficiency and Manufacturing Performance

One of the less visible but most important advantages for manufacturers is process efficiency.

As ready-to-use ingredients, these products can simplify certain production stages and contribute to greater consistency between batches.

This translates into:

• More efficient processes.
• Reduced preparation time.
• Greater manufacturing repeatability.
• Improved utilisation of raw materials.

For manufacturers producing high volumes, these improvements can have a direct impact on productivity and product consistency.

Versatility Across Recipes and Formats

A single technology can be used to develop a wide variety of solutions.

Depending on the application, texturates can be used:

• As a plant-based alternative to meat or fish, ready for incorporation into recipes.
• As a base ingredient for developing higher-value plant-based products such as burgers, nuggets, meatballs and various finger food concepts.

This versatility enables manufacturers to address different market needs and develop multiple applications from a single technology platform.

Technical Criteria for Selecting a High-Moisture Texturate

Not every project requires the same type of texturate.

Before selecting a solution, it is important to analyse how the product will perform throughout its entire lifecycle.

Texture Profile and Cooking Performance

Initial texture is important, but maintaining it after cooking is even more critical.

For this reason, product performance should be validated during processes such as:

• Cooking
• Regeneration
• Reheating
• Freezing and thawing

The objective is to ensure that the texture remains stable from production through to the moment of consumption.

Shelf Life, Preservation and Microbiological Stability

When working with high-moisture products, preservation becomes a critical factor.

Formulation, packaging systems and storage conditions all directly influence shelf life.

For this reason, each development should be validated under real manufacturing and distribution conditions to ensure stability throughout the commercial lifecycle.

Compatibility with the Customer’s Production Process

Developing a good product is only part of the challenge. It must also integrate easily into the customer’s manufacturing process.

Factors such as mixing, dosing, filling and packaging can influence overall performance.

For this reason, during development it is important to adapt the behaviour of the texturate to the customer’s real manufacturing requirements and not solely to its organoleptic properties.

Challenges in Manufacturing High-Moisture Plant-Based Texturates and How to Overcome Them

High-moisture extrusion offers significant opportunities, but it also presents technical challenges that must be controlled from the outset.

Moisture Management and Syneresis Prevention

One of the main challenges is maintaining the correct balance between juiciness and stability.

Excess water or insufficient process control can lead to liquid release during storage or changes in texture.

This is why both formulation and extrusion parameters must be carefully optimised, alongside appropriate preservation conditions.

Batch Consistency and Industrial Scale-Up

Achieving good results at pilot scale is only the first step.

The real challenge lies in reproducing exactly the same texture when producing thousands of kilograms at industrial scale.

To achieve this, it is necessary to maintain strict control over raw materials, moisture, temperature and extrusion parameters, ensuring maximum batch-to-batch repeatability.

This consistency is particularly important for retail and private-label products, where consumers expect the same product every time they purchase it.

Tailoring Solutions to Each Project

Every customer has different requirements.

Some are looking for a highly fibrous texture for a chicken alternative, while others require a softer structure for ready meals or seafood-inspired solutions.

For this reason, at Sanygran, development begins by understanding the final application and adapting both the formulation and the process to achieve exactly the performance required for each project.

What Should a B2B Supplier of High-Moisture Plant-Based Texturates Offer?

Choosing a supplier is not simply a matter of comparing technical specifications.

It also means working with a team capable of supporting product development from the earliest trials through to full-scale production.

Joint Development and Specification Optimisation

Every project starts with different requirements.

That is why we work closely with customers to define aspects such as:

• Texture
• Format
• Flavour profile
• Shelf life
• Preservation system

This collaborative approach helps reduce development times and minimise adjustments once production begins.

Technical Support During Industrial Implementation

Introducing a new ingredient into a manufacturing process requires validation and adjustments to ensure optimal performance at industrial scale.

During this phase, factors such as texture, moisture, dosing and integration into the production line may need to be addressed.

Having specialised technical support facilitates implementation, reduces adaptation time and helps minimise risks before commercial launch.

A Partner for Developing High-Moisture Plant-Based Solutions

At Sanygran, we develop and manufacture high-moisture plant-based texturates tailored to the requirements of each project.

We collaborate with food manufacturers, private-label brands and the wider food industry to create customised solutions in terms of format, texture and sensory profile.

We support our customers from product development through to industrial implementation, helping bring new products to market efficiently and successfully.

Contact:

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

In this article, we explore traceability in plant-based products, a key element in ensuring control over raw materials, manufacturing processes and finished products throughout the production of plant-based foods.

Traceability enables manufacturers to track the complete journey of a product, from ingredient intake to delivery to the end customer. In the plant-based sector, where multiple raw materials, suppliers and formulation variations are involved, having a robust traceability system simplifies quality control, improves responsiveness to issues and provides greater security throughout the production process.

Furthermore, for manufacturers supplying retailers, private label brands and foodservice operators, traceability has become an essential requirement for guaranteeing supply reliability, meeting quality standards and responding quickly to audits or incidents.

What Does Traceability Require in the Plant-Based Supply Chain?

Traceability requires manufacturers to identify which raw materials are included in each batch, how they have been used during production and to which customers the final products have been supplied.

To achieve this, it is necessary to maintain organised records covering ingredients, batches, manufacturing processes, formulations and product dispatches. It is not simply about regulatory compliance; it is about having reliable information available to make rapid decisions when issues or customer complaints arise. Well-managed traceability also supports continuous improvement, enabling manufacturers to identify deviations, analyse trends and optimise both production processes and product quality.

Critical Traceability Points for Ingredients and Finished Products

Traceability must be maintained from the receipt of raw materials right through to finished product dispatch. The most sensitive stages are typically:

• Ingredient intake
• Formulation
• Manufacturing
• Packaging
• Storage
• Distribution

Any loss of information at these stages can make it difficult to reconstruct the complete history of a production batch. Information commonly recorded includes:

• Raw material batch numbers
• Production orders
• Quality control checks
• Production dates
• Finished product destinations

This makes it possible to rapidly reconstruct the complete journey of any product reference whenever required.

Internal Traceability vs Customer Traceability

Internal traceability allows manufacturers to monitor the movement of raw materials within the production facility and understand how they are transformed into finished products.

Customer traceability, on the other hand, identifies which batches have been supplied to each manufacturer, distributor or retail chain.

These two levels are complementary. While internal traceability supports production process control, customer traceability enables the rapid localisation of specific batches in the event of an issue, minimising the impact on wider production.

How Is Traceability Applied in Plant-Based Manufacturing?

Traceability should be embedded within day-to-day operations and maintained throughout every stage of production.

In plant-based food manufacturing, where it is common to work with different plant proteins, fibres, starches, functional ingredients and frequent formulation adjustments, precise monitoring is essential to ensure product consistency and repeatability.

Raw Material Intake and Supplier Control

Every traceability process begins with ingredient receipt. Each raw material should be correctly identified and linked to the relevant documentation, including:

• Supplier details
• Original batch number
• Date of receipt
• Technical specifications
• Applicable certificates

Whenever a new supplier is introduced or a specification changes, the raw material must also be validated and documentation updated to maintain the integrity of the traceability system.

Monitoring During Formulation and Production

Traceability does not end once ingredients enter the factory. Throughout production it is equally important to record information relating to:

• Recipes used
• Formulation versions
• Manufacturing orders
• Process parameters
• Quality control activities

In plant-based products, even minor adjustments can influence texture, stability or industrial performance. Maintaining a detailed production history makes it easier to investigate deviations and consistently reproduce manufacturing conditions.

Batch Identification During Packaging and Dispatch

The final stage involves correctly identifying the finished product. Effective coding systems enable every unit to be linked to:

• Raw materials used
• Manufacturing date
• Production line
• Packaging format
• Destination customer

This information is essential for warehouse management, logistics efficiency and rapid intervention whenever a specific batch must be blocked, isolated or recalled.

Traceability, Food Safety and Risk Management

Traceability is directly linked to food safety and a company’s ability to manage risk effectively.

A comprehensive traceability system has limited value if information cannot be retrieved quickly when an issue occurs. The ability to rapidly identify a batch, determine which raw materials were used and establish which customers received the product can make the difference between a minor corrective action and a major operational problem.

Allergen Control and Cross-Contamination Prevention

Many plant-based products contain potentially allergenic ingredients such as soya or gluten. For this reason, it is essential to maintain records relating to:

• Batches used
• Production sequences
• Cleaning procedures
• Verification activities

These controls help prevent cross-contamination, support internal investigations and strengthen audit readiness.

Product Recall and Reverse Traceability

Reverse traceability enables manufacturers to determine precisely which raw materials were used in any particular batch and where that product has been distributed. This makes it possible to identify:

• Affected product references
• Customers who received the products
  Products requiring withdrawal or market recal

The faster and more accurately this process can be completed, the lower the financial, operational and commercial impact on the manufacturer.

Traceability Requirements by Sales Channel

Not all customers require the same level of information. Traceability in plant-based products must be adapted to the sales channel, product category and documentation requirements of each project.

Requirements for Prepared Meal Manufacturers

Companies incorporating plant-based ingredients or products into their own recipes require reliable information regarding:

• Batch identification
• Product specifications
• Shelf life
• Product stability
• Processing performance

A well-structured traceability system simplifies ingredient integration, reduces uncertainties during product development and provides greater confidence when formulations are modified or scaled up.

Expectations of Food Manufacturers and Distributors

Manufacturers and distributors often require a high degree of documentation and process control to guarantee supply continuity.
In addition to technical specifications, they frequently request information on:

• Batch history
• Formulation changes
• Certifications
• Audit results
• Incident management procedures

Having this information available and organised strengthens supplier-customer relationships and supports successful audits and supplier approvals.

Traceability for Retail and Private Label Products

Projects supplying retailers and private label brands generally require particularly robust traceability systems.

Accurate batch identification, shelf-life control, supporting documentation and the ability to quickly locate individual product references provide reassurance for both manufacturers and distribution partners. In these projects, traceability forms a fundamental requirement for maintaining a stable and consistent supply.

Technologies and Systems That Improve Traceability in the Plant-Based Industry

Digitalisation has transformed traceability management in plant-based food manufacturing.

Today, many businesses operate with integrated ERP systems, data capture solutions and document control platforms that enable real-time information recording while reducing errors associated with manual processes.

The goal extends beyond storing information; it is ensuring that information can be recovered quickly whenever it is needed.

Coding, Labelling and Data Capture

Correct identification through batch coding and labelling systems enables products to be tracked from raw material intake through to dispatch. This helps organisations to:

• Quickly identify any batch
• Accelerate audits
• Reduce identification errors
• Improve logistics management

A clear coding system also simplifies communication between production, quality, warehouse and customer teams.

Digital Records and Document Control

Digital management systems make it possible to centralise all manufacturing-related information. This allows rapid access to:

• Formulation changes
• Supplier history
• Technical specifications
• Production records
• Quality control documentation

A complete traceability system is only effective if information can be retrieved quickly when incidents occur. Accessible records improve decision-making and reduce response times when problems arise.

How Does Traceability Impact Product Quality, Shelf Life and Scalability?

Traceability is not simply a documentation requirement. It also contributes directly to product quality, process repeatability and industrial scalability.

When information is correctly recorded throughout production, manufacturers can more easily identify deviations, implement corrective actions and maintain product consistency.

Organoleptic Consistency Between Batches

Accurate recording of ingredients, formulation versions and manufacturing conditions helps maintain greater consistency in:

• Texture
• Flavour
• Appearance
• Cooking performance

If a deviation occurs, traceability enables its origin to be identified quickly and corrective measures implemented before future production runs are affected.

Shelf Life and Supply Chain Stability

The stability of a plant-based product depends on numerous factors that must remain under control throughout the supply chain.

Traceability links each production batch to manufacturing, storage and transport conditions, supporting the investigation of issues related to shelf life, cold chain integrity and product performance during distribution.

Industrial Scale-Up Without Losing Batch Control

As production volumes increase, process complexity grows accordingly.

A robust traceability system enables manufacturers to manage multiple product references, suppliers and production orders without losing visibility over individual batches.

This supports industrial growth while maintaining repeatability, quality control and supply reliability. In addition, historical records provide valuable information for continuous improvement, trend analysis and long-term manufacturing process optimisation.

What Should an Industrial Customer Expect from a Plant Based Supplier Regarding Traceability?

When selecting a plant-based manufacturing partner, traceability should be considered a key evaluation criterion from the outset.

It is not simply about receiving documentation; it is about working with a supplier capable of providing reliable information, responding rapidly to incidents and maintaining product consistency between batches.

Technical Documentation and Product Specifications

Among the most valuable documents are:

• Up-to-date technical data sheets
• Batch identification records
• Storage conditions
• Shelf-life information
• Product specifications
• Audit and traceability documentation

At Sanygran, we develop plant-based food manufacturing projects supported by traceability systems that allow complete product monitoring, from raw material intake through to final dispatch.

Working with a partner that integrates traceability throughout the entire manufacturing process enables companies to respond efficiently to audits, maintain documentary control and provide greater assurance when products are destined for retail, private label or highly demanding distribution channels.

Because effective traceability is not simply about recording information — it is about having access to that information when it truly matters, enabling informed decisions, rapid issue resolution and uninterrupted supply continuity.

Contact:

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

When a company searches for a chilled plant-based product supplier, it needs far more than a manufacturer capable of producing a recipe. Shelf life, product stability, food safety, supply reliability and compatibility with industrial processes are all decisive factors in determining whether a product can succeed in the marketplace.

In chilled categories, where the cold chain, logistics and storage times require greater control than dry or frozen products, choosing the right supplier can make the difference between a successful launch and a product that struggles to gain traction.

For this reason, manufacturers and distributors evaluate not only the finished product, but also the technical expertise, industrial experience and quality systems that support every development.

What Should You Expect from a Chilled Plant-Based Product Supplier?

A chilled plant-based product supplier should be able to ensure that a product maintains its characteristics from manufacture through to consumption or integration into another industrial process.

Achieving this requires a combination of production capacity, quality control, cold chain management and the flexibility to adapt to different technical and commercial requirements.

Capacity to Manufacture at Industrial Scale

Scalability is one of the most important considerations when developing chilled products.

A formulation that performs well at laboratory scale must be capable of being reproduced consistently at industrial scale, maintaining uniform quality between batches and ensuring continuity of supply.

It is equally important that the supplier can respond to increased production volumes, new product references or fluctuations in demand without compromising product stability, food safety or delivery schedules.

Quality Control and Food Safety

Chilled plant-based products require continuous monitoring of raw materials, production processes and storage conditions.

Factors such as traceability, microbiological control, shelf-life validation and strict hygiene procedures are essential to guarantee both product safety and stability throughout its intended lifespan.

For businesses supplying retailers or private-label brands, robust quality systems also support audits, approvals and compliance with the documentation requirements demanded by major retail chains.

Adapting to the Needs of Industrial Customers

Every project has different requirements.

Some manufacturers are looking for a plant-based ingredient to incorporate into their own formulation, while others need a finished product ready for sale under their own brand.

A reliable supplier should therefore be capable of adapting the formulation, texture, format, packaging type, shelf life and product performance according to the distribution channel, production process and customer objectives.

Types of Chilled Plant-Based Products for the Food Industry

Chilled plant-based products cover a wide range of categories, each with specific formulation, preservation and industrial application requirements.

Chilled Plant-Based Ingredients

Chilled ingredients allow manufacturers to incorporate plant protein and technological functionality into other formulations.

These solutions are commonly used in ready meals, chilled recipes and new product developments, where plant-based ingredients must be integrated without compromising stability throughout the cold chain.

Their main advantage is that they simplify the incorporation of plant-based ingredients while maintaining consistent performance during both processing and storage.

Finished Chilled Plant-Based Products

This category includes products such as plant-based burgers, plant-based nuggets, chicken-style pieces, tofu, hummus, seitan and falafel.

These products can be supplied as finished goods, ready for commercialisation or integration into professional foodservice channels and private-label projects.

For these applications, factors such as shelf life, microbiological stability, sensory profile and ease of handling are critical to maintaining consistent performance throughout the supply chain.

Technical Factors That Influence Chilled Plant-Based Product Formulation

The success of a chilled plant-based product depends on achieving the right balance between formulation, industrial processing and preservation. Ingredient selection is important, but understanding how ingredients interact and behave throughout manufacturing and shelf life is equally essential.

Texture, Flavour and Application Performance

Formulations should be designed according to the intended end use.

In products aiming to deliver a meat-like experience, attributes such as bite, cohesion, juiciness and sensory profile are particularly important.

It is also advisable to evaluate from the early development stages how the product performs during cooking, reheating, pasteurisation or incorporation into larger recipes, helping to avoid issues when moving to industrial-scale production.

Chilled Stability and Shelf Life

Shelf life remains one of the greatest challenges in chilled products.

Maintaining microbiological stability while preserving sensory quality requires careful control of formulation, storage conditions, the cold chain and the packaging system.

For this reason, shelf-life validation should form part of the development process from the outset rather than being addressed at the end.

Technologies such as Modified Atmosphere Packaging (MAP) and post-pack pasteurisation can help extend shelf life, although the most appropriate solution depends on the product type, formulation and commercial objectives.

Compatibility with Industrial Processes

Products must also integrate efficiently into the customer’s production environment.

Factors such as mechanical resistance, ease of handling, cooking performance and compatibility with different production lines are essential for efficient manufacturing and for minimising issues during industrial scale-up.

How Chilled Plant-Based Products Fit into Production and Distribution Chains

Managing chilled plant-based products requires control at every stage, from manufacturing through to delivery. Maintaining the cold chain, ensuring traceability and protecting product quality are all crucial to ensuring products reach the market in optimal condition.

Packaging and Chilled Preservation

Packaging plays a critical role in protecting products throughout their shelf life.

In addition to simplifying storage and distribution, it must help preserve quality, minimise the risk of external contamination and maintain the required preservation conditions for each reference.

The choice of packaging system will depend on the product type, sales channel, logistics requirements and target shelf life.

Distribution and Cold Chain Maintenance

One of the greatest challenges associated with chilled products is maintaining an uninterrupted cold chain during storage, transportation and distribution.

Any deviation may affect food safety, microbiological stability, texture and actual shelf life.

For this reason, effective temperature control must be combined with comprehensive traceability systems that allow each batch to be tracked and facilitate rapid action in the event of any incident.

What Does a Specialist Chilled Plant-Based Supplier Offer Ready Meal Manufacturers and Food Producers?

Working with a specialist supplier does more than simplify production. It can also reduce development times, minimise technical challenges and accelerate the industrialisation of new products.

Support During Product Development

Many projects do not start from scratch. In some cases, the objective is to optimise an existing recipe, replicate a product already on the market or adapt it to new commercial requirements.

In these situations, collaboration between manufacturer and customer helps to adjust formulations, validate industrial performance and confirm that the product maintains its specifications before large-scale production begins.

Process Optimisation and Reduced Production Issues

A well-developed formulation can help minimise problems related to texture, exudation, stability and processing performance.

This contributes to reducing waste, rework and batch variations, leading to more efficient production and improved product consistency.

Adaptation to Sales Channels and End Use

Each channel presents its own technical requirements.

A product designed for retail distribution requires different characteristics from one intended for foodservice or from an ingredient destined for incorporation into a ready meal.

Consequently, elements such as format, preservation system, presentation and shelf life should be defined from the earliest stages of development to ensure the product meets the practical requirements of its intended application.

Criteria for Choosing a Chilled Plant-Based Product Supplier

Selecting a chilled plant-based product supplier involves evaluating much more than the finished product itself. The ability to support development, guarantee quality and ensure supply continuity is equally important.

Flexible Formulation and Custom Product Development

Each project has unique requirements regarding texture, sensory profile, shelf life and industrial performance.

Working with a supplier capable of developing bespoke formulations, conducting trials and validating modifications before industrialisation can significantly reduce development cycles and speed up market launch.

Consistency, Traceability and Technical Support

Batch consistency, traceability and technical support are essential to ensuring dependable supply.

In addition to facilitating issue resolution, they support formulation adaptation, process changes and compliance with audits and documentation requirements—particularly within private-label and large-scale retail projects.

Industrial Viability and Continuity of Supply

Suppliers must be capable of maintaining stable production and responding effectively to customer growth requirements.

Ensuring continuity of supply, batch repeatability and the ability to adapt to increased production volumes is essential when a product forms part of an established manufacturing process or commercial range.

Sanygran as a Supplier of Chilled Plant-Based Solutions for the Food Industry

At Sanygran, we develop and manufacture chilled plant-based foods for manufacturers, ready meal producers, distributors and private-label projects.

Our portfolio includes products such as plant-based burgers, nuggets, chicken-style pieces, tofu, hummus, seitan and falafel, alongside customised developments tailored to individual customer requirements.

Our experience as both ingredient manufacturers and finished product producers allows us to understand how formulation, processing and preservation influence final product performance. This helps validate solutions under real manufacturing conditions and identify potential improvements before industrial scale-up.

We also offer technologies such as Modified Atmosphere Packaging (MAP) and post-pack pasteurisation, enabling the most appropriate preservation strategy to be selected according to the product, target shelf life and logistical requirements.

For companies seeking a specialist industrial partner in plant-based food manufacturing, working with a supplier involved from formulation development through to production and long-term supply can help reduce development times, minimise industrialisation issues and bring more stable and competitive products to market.

Contact:

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

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