TFTAK and Vegestar developed a tasty, allergen-free, and additive-free chicken meat alternative based on legume protein using high-moisture extrusion. Read more about the challenges the development team had to overcome!
Plant-Based Meat Alternatives Gaining Momentum
Meat alternatives are no longer only for vegans; they are increasingly preferred for their taste, health benefits, and sustainability. According to a study conducted in Europe, vegans consume only up to 7% of the total volume of meat alternatives. Meat and dairy alternatives reduce the environmental impact of animal husbandry, resource waste, and meet the growing population's needs while promoting animal welfare.
Food manufacturer Vegestar has made significant strides in creating plant-based meat alternatives, bringing several successful products to the market. Through previous collaboration, we developed a technology for producing dry extrudates used in minced-type products (Thormi burgers, nuggets, sausages, dumpling fillings). As Vegestar wanted to expand its product profile, the goal of this project was to create technology for producing fillet-type products.
The New Product Had to Be Authentic, Tasty, Additive-Free, and Allergen-Free
Together with the client, we set the criteria that the new chicken meat alternative should meet to succeed in the market:
The goal was to use local raw materials whenever possible.
The product had to contain as few additives as possible and be clean-label.
While soy and wheat products dominate the European vegan market, our ambition was to offer an allergen-free solution, focusing on peas and field beans.
The Key to Success Was the Right Combination of Protein Powder and Extrusion Technology
How does it work? Extrusion is a process where high pressure, temperature, and pressure are used to give plant protein powder a fibrous texture. Extrusion process takes place using a special device – an extruder. When creating meat alternatives, two technologies are used – high-moisture or low-moisture extrusion: the result is either soft, large chunks or dry, small pieces. We chose the high-moisture technology.
We started technological development by screening raw materials: we selected a range of protein powders that suited our goal, and extruded test samples in TFTAK's laboratory. We tested various combinations of protein powders, starches, and spices to create a material that mimicked chicken fillet fibers and had a neutral taste.
Plant-based products often have a distinct strong, sometimes unpleasant taste, but by combining raw materials and optimizing parameters, we were able to reduce off-flavors. We tested dozens of combinations before finding one with a truly neutral taste and a good fibrous structure.
Scaling the Product Journey from Lab to Factory
After developing a suitable product with TFTAK’s laboratory extruder, we needed confirmation that the same texture could be achieved in a larger-scale extruder. This is where the German Institute of Food Technology (DIL) helped us. With pilot plant tests at DIL, we gained confidence that our developed technology could be scaled up excellently.
Vegestar, which was taking its production capabilities to the next level, purchased a large industrial extruder, and our team helped set it up and launch the new chicken meat alternative production. We are pleased to have been involved in the selection and start-up of the industrial extruder, supporting our valued client and gaining valuable technical experience while learning about the potential limitations of industrial processes.
Thormi Chicken Meat Alternatives Now on Supermarkets Across Estonia, and Gaining Recognition Beyond
Before the meat alternative became a real product, we had to find the best post-processing method for the material. We explored possible techniques for cutting and seasoning the extrudate. We tested various marinating techniques and equipment to highlight pleasant savory flavors and provide the product with a juicier mouthfeel. Thanks to TFTAK’s sensory panel, we were able to select the best combinations.
Thanks to the developed technology, Vegestar launched a new fillet product line called Chickenless in September 2024, available in three different sauces, which has been well received in the Estonian and Finnish retail markets. It has also found a place in bulk packaging for the HoReCa sector.
In February 2025, Vegestar's “Shredded Chickenless in Coconut-Curry Sauce” won an innovation award in the ready to eat category at Gulfood, the world’s largest food exhibition in Dubai. The Gulfood Innovation Award recognizes pioneering products, technologies, and ideas shaping the future of food and beverages. We are proud to have contributed to bringing this prestigious award to Estonia.
In collaboration with Vegestar, we have increased our competence in producing high-moisture meat alternatives and gathered valuable knowledge about the details of scaling. Thank you to our client for their trust and cooperation. Many thanks also to Enterprise Estonia, who supported the funding of the project!
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