Plant-based protein is no longer a short-lived trend; it has become a staple in products ranging from meat substitutes to dairy-free beverages, protein powders, and functional foods. As more of these products hit the shelves, consumers expect higher standards. Simply labelling a product as “plant-based” is not enough. If a product lacks great taste, has a strange mouthfeel, or spoils too quickly, it will not succeed. The challenge for manufacturers is clear: plant proteins are complex, unpredictable, and often difficult to work with.

Animal proteins have evolved to perform specific functions in food, which makes them predictable and easy to handle. Plant proteins, however, were never meant to be processed into burgers or shakes. Their proteins act differently depending on factors such as the variety used, where and how it was grown, when it was harvested, and even how the protein is extracted. You can take two batches of the same protein and end up with completely different results in your recipe. For consumers, this means one product tastes great and the next is bland or has a strange mouthfeel. For manufacturers, it is a constant challenge: they have to tinker with recipes and processes all the time, and scaling up from test kitchen to factory floor is a gamble. Understanding how these proteins behave during processing is essential to getting it right.

Taste is still the biggest hurdle. Many plant-based foods continue to have unmistakable beany, grassy, or bitter flavors. These off-flavors come from compounds naturally found in plants, especially legumes, and from changes that occur during protein processing. Lipid oxidation is the main culprit behind beany notes, while overheating or excessive protein breakdown intensifies bitterness. Sure, flavor masking can help, but it often makes recipes more complicated and usually clashes with the “clean label” trend consumers want.

 Fortunately, there are smarter ways to address flavor challenges. Gas chromatography–mass spectrometry (GC–MS) can identify the exact compounds responsible for off-flavors, so you can compare ingredients and adjust processes based on real data. Differential scanning calorimetry (DSC) reveals how heat changes protein structure, which influences both flavor and functionality. The better these changes are understood, the more flavor issues can be solved at the source rather than masked.

Texture is just as important. Consumers do not want a chalky shake or a dry, crumbly burger. Beverages can become gritty if the proteins clump together or fail to mix well. Meat alternatives may lack a satisfying bite when the protein network is not strong enough. These texture issues often get worse as batch sizes increase.

Rheological analysis comes into play by translating attributes like creaminess and chewiness into measurable numbers such as viscosity and viscoelasticity. This helps producers understand how proteins behave when mixed, pumped, or extruded. Particle size analysis shows when proteins are clumping or failing to disperse properly, which leads to texture issues. DSC also reveals how much of the protein’s original structure survives the heating process.

Stability and shelf-life matter. Plant proteins react to heat, pH changes, mechanical stress, and even prolonged storage. Over time, they may clump, settle, or lose structure, affecting texture and overall quality. By tracking rheological properties, particle size, and DSC over time, producers can predict these changes and build longer shelf life into their products instead of fixing problems after they appear.

Consistency is critical, too. Nature never makes two plants exactly the same, and processing adds even more variables. One batch of protein can behave very differently from the next. Analytical tools help map each batch’s strengths and weaknesses so producers can adjust formulas and processes before problems reach the customer.

Making great plant-based products means balancing science, processing know-how, and consumer expectations. Taste, texture, shelf life, and consistency are all connected, and they all depend on how these proteins handle the journey from field to factory to fork. DKSH Technology supports this process with a mix of tools such as DSC, rheometers, particle size analyzers, and GC–MS systems to help the industry turn plant protein challenges into real opportunities for better, more dependable foods.

Sources:

• Physico-Chemical Properties and Texturization of Pea, Wheat and Soy Proteins Using Extrusion and Their Application in Plant-Based Meat | MDPI
• Effect of Textured Vegetable Protein Type on Quality of Plant-Based Meat Product | Journal of Food Technology
• Current challenges of alternative proteins as future foods | npj Science of Food
• Plant-protein isolates and flavour perception: Understanding mechanisms and strategies to balance flavour retention and release | ScienceDirect
• Functional characterization of plant-based protein to determine its quality for food applications | ScienceDirect