Navigating the challenges and opportunities in alternative protein development

For food formulators, this shift offers an exciting opportunity to reformulate traditional products and create entirely new food innovations. However, developing alternative protein formulations isn’t without its challenges.

The 5 key challenges in alternative protein development

1. Flavour and texture profile

Traditional protein formulations have complex flavour profiles that need to be matched in reformulated products, requiring the blending of multiple ingredients to recreate. Alternative protein sources can have intrinsic unpleasant flavours, for example earthy, bitter or beany. These ​‘off’ flavours can be masked or reduced by altering the processing and formulation design.

2. Functional properties

Animal-derived proteins are valued for their versatility and are used as functional ingredients in a broad variety of formulations, from baked goods to confectionary. Used for their emulsification, foam stabilisation, gelling and water binding properties, individual alternative protein sources generally have a lower solubility and performance than their traditional counterparts. 

Enhancing their functionality may require enzymatic or physical treatments and the addition of ingredients to improve performance. Physical treatments like extrusion and shear cell technology can enhance textural properties, giving products the fibrous structure associated with meat products. 

3. Nutritional profile

While alternative protein formulations offer some nutritional benefits, including reduced cholesterol and saturated fats, they can lack key vitamins and micronutrients like B12, calcium, and iron. Many also contain antinutrients like lectins and phytates, which reduce key nutrient uptake. However, through the use of multiple protein sources, fortification and processing, these limitations can be overcome in alternative protein formulations.

4. Economically scaling up

Economically scaling up production presents a significant challenge – maintaining the performance of formulations produced at lab-scale whilst producing at larger scales. Techniques like a techno-economic analysis are used to predict the costs of processes at different scales and identify key roadblocks and areas for further development. For alternative protein formulations, pilot-scale production is often the most crucial scale of production – successful pilot-scale production can be the difference between the success and failure of a product. 

Production of materials at pilot-scale is essential for the supply of sufficient quantities of material to test market viability and attract investment. Due to the inherent short shelf life of foods this requires multiple smaller batches of production to continue to feed the market. Transitioning from lab-scale to pilot-scale production often requires costly equipment and infrastructure. Scale-up is a delicate balancing act of producing enough material to engage with consumers and potential stakeholders while managing costs to ensure economic feasibility and environmental sustainability. 

5. Consumer perception

A key driver in the commercial success of any food product is consumer acceptance. To facilitate this, alternative proteins must have a comparable sensory and nutritional performance to traditional protein products. Therefore, consumer testing in early-stage development is crucial. This involves engaging with both consumers and retailers to ensure the product will meet consumer expectations in taste, texture, and nutritional value. 

Sustainability is expected from alternative protein products, and therefore, claims around environmental benefits must be substantiated. This can be achieved through a life cycle analysis, which can provide an accurate picture of the environmental impacts of a product throughout its life cycle, enabling innovators to leverage the results during development. 

Additionally, with a growing awareness of ultra-processed foods, it’s crucial to consider how these products are perceived by increasingly health-conscious consumers. Identifying novel sources of functional ingredients can reduce the need for extensive processing. 

Overcome these challenges with CPI

In my experience, the key to overcoming challenges with alternative protein development is having food formulation and process experts work together to de-risk and accelerate time to market. At CPI, we have a team of food science experts who can support you on your journey from lab- to pilot-scale. 

We understand the complexities involved in creating alternative protein products, including flavour and texture profiles, and help optimise formulations to meet consumer expectations. Scaling from lab- to pilot-scale can present unique challenges, but we can work closely with you to develop processing methods tailored to your product requirements. 

Whether at the beginning of your product development journey or facing challenges in scale-up, we can help you bring your alternative protein products to market faster.

Get in touch to start your innovation journey.