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.

Finding a supplier of plant-based ingredients for ready meals that guarantees industrial performance, stability and adaptability to each production process is a key factor for any manufacturer of ready-to-eat plant-based solutions.

In an environment where efficiency, consistency and scalability make the difference, the goal is not simply to incorporate plant-based ingredients, but to do so with full reliability: ensuring they perform on the production line, maintain their behaviour after thermal processing, and deliver a consistent final product experience.

In this article, we explore what a specialised supplier of plant-based ingredients for ready meals should offer and how to evaluate them from a technical and industrial perspective.

What should a supplier of plant-based ingredients for ready meals guarantee?

B2B customers are not looking for isolated ingredients, but for solutions that work within their real production environment.

A supplier of plant-based ingredients for ready meals must guarantee:

• Seamless integration into existing production lines
• Stability during processing (cooking, freezing, regeneration)
• Batch-to-batch consistency
• Adaptability to different recipes

The real value lies in ensuring that the ingredient performs consistently across development, validation and full-scale production.

Specialisation in industrial ready meals

Not all plant-based suppliers are prepared to operate within industrial ready meal environments.

This type of application requires expertise in:

• Thermal processes (pasteurisation, sterilisation, regeneration)
• Performance under chilled and frozen conditions
• Integration into complex matrices (sauces, fillings, composite recipes)

Sanygran works with a clear industrial focus, developing plant-based ingredients that maintain their functionality throughout the entire product lifecycle.

This level of specialisation helps prevent:

• Texture loss
• Poor absorption
• Instability during processing

Adaptability to different production lines

One of the main challenges when incorporating plant-based ingredients is maintaining line efficiency.

It is essential to work with a supplier capable of delivering solutions that:

• Fit into existing processes
• Do not require changes in machinery or parameters
• Maintain operational times and yields

The ingredient should be designed to integrate naturally into the client’s workflow, not the other way around.

Which plant-based ingredient formats work best in ready meals?

When selecting plant-based ingredients for ready meals, it is more effective to think in terms of industrial application format rather than ingredient type.

This helps optimise:

• Process integration
• Final product performance

Plant-based ingredients with texture and bite

When the ingredient needs to be visible in the dish, add volume and deliver a defined sensory experience, structured formats are required.

Common applications:

• Stir-fries
• Prepared bowls
• Ready meal combinations
• Fillings with visible ingredients

In these cases, the key is not using a standard format, but designing the ingredient based on the application.

As a manufacturer of plant-based ingredients for ready meals, Sanygran adapts each development to:

• Required size and shape
• Target firmness or juiciness
• Sauce absorption capacity
• Stability during cooking, freezing and regeneration

This ensures consistent presence, performance and industrial reliability.

Plant-based ingredients for sauces, fillings and complex matrices

In many applications, the ingredient must fully integrate into the recipe rather than stand out.

Key factors:

• Homogeneity
• Absorption capacity
• Thermal stability
• Ease of dosing

Typical uses:

• Prepared sauces
• Stews
• Fillings (lasagne, cannelloni)
• Culinary bases

Development focuses on:

• Uniform distribution
• Seamless integration
• Stable behaviour throughout processing

This results in balanced, scalable and easy-to-process products.

Custom development of plant-based ingredients for ready meals

A key differentiator in any supplier of plant-based ingredients for ready meals is the ability to customise solutions.

Standard products are often not enough when there are specific targets in:

• Cost
• Performance
• Market positioning

Texture, flavour and nutritional profile optimisation

Each recipe requires a specific ingredient behaviour.

Common adjustments include:

• Juiciness vs firmness balance
• Neutral or enhanced flavour profiles
• Improved sauce absorption
• Adapted nutritional profile

As a manufacturer with proprietary technology, Sanygran controls the full process, enabling tailor-made development from origin.

This improves both:

• Industrial integration
• Final product quality

Adaptation to private label, retail and industry

Requirements vary depending on the customer and sales channel.

A supplier must adapt to:

• Private label (retailer brands)
• Food industry manufacturers
• Retail environments

This requires flexibility in:

• Portion sizes and formats
• Target cost
• Shelf life
• Labelling requirements

Sanygran also offers multiple supply formats:

• Frozen → ideal for preserving shelf life in industrial integration
• Chilled → for immediate applications
• Dry → for logistics efficiency and flexibility

Technical criteria for approving a supplier of plant-based ingredients for ready meals

Choosing the right supplier directly impacts:

• Product stability
• Production efficiency

Batch-to-batch consistency and quality control

The ingredient must deliver consistent performance every time.

Critical factors:

• Stable texture
• Consistent yield
• Uniform absorption
• Reproducible dosing

Inconsistencies can lead to:

• Production deviations
• Final product quality issues

Technical specifications and food safety

A plant-based ingredient supplier for ready meals must provide:

• Full technical datasheets
• Allergen information
• Microbiological parameters
• Traceability
• Usage instructions
• Defined tolerances

This is essential for approval processes and audits.

Scalability for new product launches

A reliable supplier must support:

• Product development
• Industrial validation
• Ongoing production
• Category expansion

This requires:

• Production capacity
• Supply stability
• Continuous technical support

Sanygran as a supplier of plant-based ingredients for ready meals

Sanygran is a specialised supplier of plant-based ingredients for ready meals, with a strong industrial and B2B focus.

Its approach is based on:

• Tailor-made plant-based ingredient development
• Full customisation of format, texture and functionality
• Complete control of the production process
• Real integration into industrial production lines

More than a supplier, Sanygran acts as a technical and industrial partner, capable of developing fully customised solutions for each project.

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

Syneresis in plant-based food production is one of the most critical phenomena in the development of plant-based products, as it directly impacts texture, stability, appearance and industrial performance. In this article, we explore what syneresis actually is, why it occurs in plant-based formulations, how it affects production processes, and which industrial strategies are commonly used to control it in products such as plant-based burgers, ready meals and fillings.

What is syneresis?

Syneresis is the expulsion or separation of the liquid phase (water or other liquids) within a food matrix, resulting in the loss of structure, stability and product cohesion.

In food science, this phenomenon is described as the release of liquid phase in gelled or structured systems, especially when the network formed by proteins, starches or hydrocolloids is not stable enough to retain water during storage or processing (Phillips & Williams, Food Hydrocolloids, Woodhead Publishing).

In plant-based food production, this issue is particularly relevant because the product structure depends on a complex combination of plant proteins, starches, fibres, fats and hydrocolloids. When this network is not properly balanced, water separates and the product loses consistency.

How does syneresis appear in a plant-based product?

In an industrial environment, syneresis is not a theoretical concept, but a visible issue in the finished product:

• liquid appearing in trays or packaging
• surface exudation after storage
• loss of body and firmness
• less homogeneous texture after cooking or reheating
• phase separation in sauces or mixed matrices

In short, the product stops behaving as a stable structure and begins to show visible physical instability throughout the supply chain and at retail level.

Effects of syneresis in plant-based food production

Syneresis does not only affect the final product, but also impacts industrial efficiency, perceived quality and production profitability.

Impact on texture, appearance and product stability

One of the most immediate consequences is the loss of functional texture:

• reduction in controlled juiciness
• loss of creaminess or bite
• lower stability during cutting or forming
• less attractive appearance

In plant-based products, where the sensory experience is essential, this becomes critical: if the product “sweats” or loses structure, the perception of quality quickly declines.

Impact on shelf life, waste and complaints

From an industrial perspective, syneresis has direct business consequences:

• increased production waste
• batch-to-batch variability
• reduced commercial shelf life
• potential complaints or product returns
• need for product reformulation

During the development of new plant-based burgers, for example, it is common to encounter these issues in early stages. In many cases, small adjustments in formulation and ingredient selection are enough to stabilise the system and restore the expected production performance.

Which plant-based categories are most sensitive to syneresis?

Not all applications behave in the same way. Some matrices are particularly sensitive to water instability within the system.

Fermented products, desserts and chilled plant-based bases

In products such as plant-based yoghurts, spoonable desserts or chilled creams, syneresis may lead to:

• visible liquid separation
• loss of creamy textura
• instability throughout shelf life

In these products, gelled or semi-gelled structures are especially sensitive to small formulation imbalances.

Sauces, fillings, spreads and plant-based ready meals

This is one of the most critical segments in plant-based food production.

It includes products where stability is essential:

• plant-based Bolognese-style sauces
• fillings for pasta or prepared meals
• ready-to-use bases for foodservice or retail

Syneresis directly affects homogeneity, viscosity and processing performance, especially during chilled or frozen storage and distribution.

How to reduce syneresis through the industrial process?

Controlling syneresis does not depend only on formulation, but also on the entire industrial process.

Critical parameters to validate at industrial plant level

Among the most relevant factors are:

• ingredient addition sequence
• hydration times
• mixing and homogenisation intensity
• cooking or pasteurisation thermal curve
• product cooling and stabilisation

In plant-based products, the way the matrix is structured during processing is just as important as the ingredients themselves.

How to verify that the solution works beyond the laboratory

A development is not validated in the laboratory alone, but under real production and distribution conditions:

• shelf-life testing
• accelerated stability tests
• behaviour after transport and storage
• batch repeatability
• validation under real commercial conditions

This is what ensures that the product behaves consistently in production, logistics and at point of sale.

What should the industry look for in a solution to control syneresis?

There is no universal solution for every case. The key lies in adapting the strategy to the complete system.

Adaptation to matrix, process and sales channel

Syneresis control depends on three key variables:

• type of food matrix
• industrial process used
• sales channel and distribution conditions

In this context, expertise in the formulation of functional plant-based ingredients is essential for designing stable systems that perform under real production conditions and not only in laboratory environments.

Our solutions: Ingredient innovation for complete stability

At Sanygran, controlling phenomena such as syneresis is approached from a complete industrial perspective: ingredient, process and final application.

Our expertise in manufacturing pea and soy textured proteins, together with the use of pea starch and pea protein concentrate, allows us to develop solutions that help improve water retention, matrix stability and process performance.

This translates into direct benefits for the industry:

• improved stability in plant-based products
• reduction of exudation and structure loss issues
• optimisation of industrial production processes
• greater batch-to-batch consistency
• fewer incidents during retail distribution

The objective is not only to make the product work in formulation, but to ensure that it maintains its structure and behaviour throughout the entire value chain, from production to final consumption.