The Importance of Texture in Plant-Based Products

The importance of texture in plant-based products goes far beyond mouthfeel. In categories such as meat alternatives, achieving the right structure, bite and juiciness can make the difference between a product that performs well in an initial trial and one that becomes part of a consumer’s regular shopping basket.

However, there is no single texture that works for every application. A chicken-style plant-based piece requires a specific structure and bite, while a plant-based burger, tofu or hummus each have completely different requirements.

For this reason, developing the right texture involves working with raw materials, formulation and manufacturing processes together, always considering how the product will be consumed and what performance is expected from the final application.

Why Does Texture Influence the Success of a Plant-Based Product?

Texture is one of the key attributes that defines the eating experience of a plant-based product.

In categories such as plant-based chicken-style chunks, a structure that is too soft, overly compact or insufficiently defined can move the product away from the experience consumers expect. On the other hand, a well-developed texture can provide a more satisfying bite and a structure that matches the intended application.

The same principle applies to other product categories. A plant-based burger may require a compact yet juicy matrix; tofu may need firmness and elasticity; while hummus should deliver a smooth and creamy texture.

This demonstrates that a texture that works perfectly in one application may not work in another.

In addition, texture affects more than just the final eating experience. It also influences industrial factors such as:

• Product handling.
• Performance during cooking.
• Resistance during packaging.
• Integration into prepared meals.
• Stability during storage.
• Consistency between batches.

For this reason, texture should be defined during the earliest stages of product development and validated under real manufacturing and consumption conditions.

Which Texture Attributes Are Critical in Plant-Based Formulation?

The attributes that need to be prioritised depend on the product and the experience being targeted. Some of the most important parameters in plant-based product development include the following.

Firmness

Firmness determines the resistance a product offers during handling and consumption.

For example, tofu may require a firm and stable structure to facilitate cutting and handling. In other products, excessive firmness might create an unpleasant eating experience.

The objective is not simply to make a product firmer, but to achieve the appropriate level of firmness for each application.

Juiciness

Juiciness is particularly important in products designed to replicate foods of animal origin, such as burgers or chicken-style chunks.

A structure that can manage moisture effectively may contribute to a juicier eating experience. However, the challenge is always to balance moisture and structure to maintain product stability.

Cohesion

Cohesion ensures that the different components of the matrix remain bound together.

This attribute is particularly important in products that need to withstand handling, cutting, packaging or cooking. Insufficient cohesion can result in breakage or fragmentation, while an excessively compact structure may negatively affect mouthfeel.

Bite

Bite describes how a product responds during chewing and is especially important in the development of meat analogues.

In a plant-based chicken-style chunks, for example, developers may seek an initial resistance followed by a pleasant chewing experience. The final result depends on the raw materials, formulation and manufacturing technology used.

Fibrousness

Fibrousness is one of the most valuable texture attributes when developing products such as chicken-style chunks produced using high-moisture technology.

This technology makes it possible to work with protein structures at different levels of organisation, creating products with textures tailored to specific applications.
Size, structure, bite and cooking performance must all be developed together.

Creaminess

Not all plant-based applications require a fibrous structure or pronounced bite.

For products such as hummus, the target texture is entirely different. Creaminess, uniformity and the absence of graininess are among the attributes that influence quality perception.

This reinforces an important principle: texture should always be developed with the final application in mind.

How Is Texture Built in Industrial Processes?

The final texture of a plant-based product is the result of multiple interacting variables. It does not depend solely on selecting a specific protein or ingredient, but on how raw materials, formulation and manufacturing processes work together.

Ingredient Selection and Functionality

Each raw material offers specific functional characteristics and may influence structure, water retention, cohesion and mouthfeel.

At Sanygran, we work with a range of raw materials including soy and pea proteins, as well as other ingredients used in certain developments, such as gluten and oats.

The choice depends on the intended result. Different combinations of raw materials can also be used to adjust product characteristics according to the application.

For high-moisture chunks, ingredient selection becomes particularly important because composition and process conditions must work together to achieve the desired structure.

Process Parameters That Alter Texture

Even a well-designed formulation can deliver different results if manufacturing conditions change.

Variables such as temperature, moisture, pressure, processing time, shear forces and cooling conditions can significantly influence the structure obtained.

This is especially relevant in high-moisture extrusion, where process control enables developers to create different texture profiles depending on the target application.

At Sanygran, production parameters are adjusted according to factors such as raw material selection, product size, texture requirements and target sensory characteristics, helping to achieve results that can be reproduced consistently at industrial scale.

Texture and Shelf Life: Balancing Stability and Sensory Quality

A suitable texture should not be evaluated solely at the point of manufacture.

A product must maintain its characteristics throughout storage, distribution, handling and, when applicable, cooking or reheating.

The Effect of Packaging and Distribution on Texture

Preservation systems and distribution conditions can influence the behaviour of plant-based products.

Changes in moisture, temperature and storage conditions may affect attributes such as firmness, cohesion and juiciness.

For this reason, product development should consider the final format and storage conditions from the outset, particularly for solutions intended for retail or industrial applications.

How to Validate Texture Stability During Shelf-Life Testing

Texture should form part of any shelf-life validation programme.

Depending on the application, factors that may be assessed include:

• Retention of firmness.
• Structural stability.
• Evolution of bite.
• Performance after freezing and thawing.
• Response during cooking or reheating.
• Consistency between batches.

At Sanygran, in addition to laboratory testing, we carry out industrial-scale trials and sensory evaluations to verify that products meet the required criteria and to generate useful data when determining shelf life.

Texture and the Eating Experience in Plant-Based Applications

Texture should be designed around the intended use of the product and the eating experience it is expected to deliver.

Adapting Texture to Product Format

There is no universal texture for plant-based products.

A chicken-style piece may require a fibrous structure and a defined bite. A burger may require a compact and juicy matrix. Tofu may need firmness and elasticity, while hummus demands a smooth and creamy texture.

At Sanygran, we work with different sizes, structures, raw materials and flavour profiles, adapting these variables to each specific application.

For ingredients produced through high-moisture extrusion, for example, we can create different sizes, from smaller formats to the more common bite-sized chunks, depending on the intended use.

These products can be incorporated into ready meals, bowls, salads, wraps and sauces, or marketed directly in trays for consumers to use as they wish.

Texture Performance During Cooking and Reheating

Products must maintain their intended performance throughout normal use.

Depending on the application, it may be necessary to evaluate how they respond to cooking, reheating, regeneration or integration into other food preparations.

For a chicken-style piece, for example, it is not enough to achieve the right texture when cold. The structure and bite must also remain consistent after the intended preparation method.

For this reason, development trials should replicate, as closely as possible, the conditions the product will experience after commercialisation.

How to Evaluate and Control Texture During Product Development

Developing the right texture requires more than achieving a successful first prototype. The result must be compared, refined and validated until it becomes a reproducible industrial solution.

Sensory and Instrumental Indicators

Sensory evaluation allows developers to assess attributes that cannot always be captured through a single measurement.

At Sanygran, we perform internal tastings during both laboratory trials and industrial-scale testing before samples are sent to customers.

These evaluations involve different departments, including R&D, Quality and Marketing/Commercial teams.

Attributes typically assessed include:

• Texture.
• Bite.
• Flavour intensity.
• Aftertaste.
• Juiciness.
• Appearance.
• Suitability for the intended application.

This collaborative approach helps identify potential issues before products reach the customer sample stage.

Quality Criteria for Scaling Without Losing Texture

One of the biggest challenges in industrial development is maintaining the texture achieved during initial trials when production is scaled up.

Raw materials may vary, while manufacturing conditions can differ between equipment or production volumes. As a result, maintaining consistency requires careful control and standardisation of the variables that affect texture.

Industrial experience is particularly important at this stage: it is not enough to achieve the desired texture in the laboratory; it must also be reproducible in full-scale production.

Common Challenges When Developing Texture in Plant-Based Products

Achieving the desired texture often requires multiple development iterations. Small changes in formulation or processing can significantly affect the final result.

How to Correct Unstable or Inconsistent Textures?

When texture does not meet expectations, the entire process needs to be reviewed.

This may include evaluating:

• Raw materials.
• Ingredient ratios and combinations.
• Processing conditions.
• Product size and structure.
• Post-processing treatments.
• Storage conditions.

The objective is not to make isolated changes, but to identify which variable is genuinely influencing the result.

For example, a structure that performs well in a bowl application may not behave in the same way when incorporated into a sauce or prepared meal. In such cases, texture adjustments may be required to suit the new conditions of use.

What to Consider When Working with Tailor-Made Solutions?

Every application has its own requirements.

At Sanygran, we can work with different raw materials, sizes, textures and flavour profiles, adapting development to the specific needs of each product.

This flexibility is particularly useful when a company needs a solution that fits a particular product concept, manufacturing process or commercial format.

The key is first understanding what the product needs to do, and then defining the texture, structure and behaviour required to achieve that goal.

Sanygran, a Technical Partner for Optimising Texture in Plant-Based Products

Texture is the result of combining raw materials, formulation, technology and manufacturing processes.

At Sanygran, we develop plant-based solutions with particular expertise in high-moisture chunks, adapting variables such as size, structure, texture and flavour according to the application and project requirements.

Development combines laboratory testing, industrial validation and sensory evaluation to assess texture, bite, flavour intensity and aftertaste before samples are submitted to customers.

Because in plant-based products, there is no single texture that works for every application. Each product requires specific characteristics and a manufacturing process capable of reproducing them consistently.

Contact:

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