Plant-based emulsion gels can be used as solid animal fat substitutes for vegan sausages. For this reason, commercially available protein isolates with different amino acid profiles from pea, soy and potato (Pea-1, Pea-2, Soy, Potato) have been tested for their ability to form shape stable emulsions gels at neutral pH and upon heating to 72 °C. In order to obtain emulsion gels that are as solid as possible, the protein concentrations in the continuous phase (C_PC, 8.0–11.5% (w/w)) and the oil mass fractions (65–80%) were varied. For leguminous proteins, a positive correlation of both parameters on emulsion rigidity was shown, indicating that both, interfacial and protein–protein interactions, are involved in structure reinforcement. Firmness increased with increasing content in cysteine (Pea-1 < Pea-2 < Soy) and the interactions were of electrostatic, hydrophobic and hydrophilic nature. Potato emulsion rigidity was independent of C_PC and oil content. The emulsions showed a much higher degree in crosslinking, and very low charge density. Temperature-sweep analysis and CLSM revealed that Potato protein gelled as consequence to low temperature stability. Hence, the structure reinforcement in Potato emulsions mainly contributed to the protein network, with 70% oil and C_PC 11.5% forming a hybrid gel with highest firmness. However, gelling of Potato protein also resulted in interfacial adsorption of protein aggregates and reduced interfacial stability with increasing C_PC. This was demonstrated in the amount of extractable fat which was 2.0 and 0.6% for Pea-1 and 2 emulsions, 6.4% for Soy and 34.4% of total fat for Potato emulsions.

In hamburger manufacturing, meat is subjected to four main processing steps (pre-grinding, mixing, grinding, and forming), whereby muscle fibers are disintegrated. In this study, the influence of these process steps was characterized by structural (amount of non-intact cells (ANIC), CLS-Microscopy), functional (drip loss) and qualitative (soluble protein content, lactate dehydrogenase (LDH) activity, myoglobin content (Mb)) parameters of the meat. Therefore, meat samples were analyzed after each process step. Histological analyses revealed an increased ANIC with progressive processing. Thereby, the first and second grinding steps caused the strongest increases (factors 2.43 and 2.69). Comparable results were found in the relative LDH activity (factor 2.20 and 1.62) and the Mb concentration (factor 2.24 and 1.33) of the extracted meat solution. The findings suggest that the disintegration of the meat structure increases with progressive processing, causing more vulnerable structures which result in increased leakage of intramuscular substances. Further, the type of stress acting on the meat determines the extent of the changes. The presented findings enable manufacturers to precisely adjust their process towards more gentle production parameters and thus, to meet the legal regulations.

Larger processing equipment to produce minced meat could affect its structure due to intensive processing and a high energy intake in the meat mass. To assess if this would result in alterations in the minced meat quality, finely chopped meat (FCM) was added in different concentrations (15, 30, 45, 60, 75, 90, and 100%) to minced meat and quality parameters were analyzed. FCM was used to simulate different intensity of an unintended destruction of meat cells due to various processes. The amount of non-intact cells (ANIC) was determined histologically and furthermore, soluble protein content, water holding capacity, mechanical and sensory texture, and scanning electron and confocal laser scanning microscopy was applied to analyze the meat structure and quality. ANIC indicated that even adding 15% FCM was statistically (p < 0.05) distinguishable from 100% minced meat and 30% FCM had already 50 Vol.-% ANIC. In contrast, the addition of 15% or 30% FCM did not result in significant differences in drip loss of raw and cooked meat as well as mechanical and sensory texture analysis. This study showed that intensive processing might be detectable via ANIC, but that the minced meat quality was not affected.