Optimizing a Coproduct from Maize Ethanol Production for Sustainable Plant-Based Food Ingredients

Abstract

Due to the increased demand for high-protein plant-based raw materials, several alternatives have been explored in formulating ingredients, such as textured vegetable proteins (TVPs), for use in plant-based processed food products. During the production of ethanol from maize, a coproduct called distiller’s dried grains with solubles (DDGS) is generated, which contains a high protein content and is currently primarily used as animal feed. This study evaluated the processing of DDGS via low-moisture thermoplastic extrusion, both independently and in combination (7, 25, 43, and 50% of DDGS) with soy protein isolate (SPI), to develop textured protein ingredients for plant-based burgers. A 2² central composite rotatable design (CCRD) with 11 experiments was employed. Parameters assessed included the moisture content, color, hydration capacity, density, and texture profile of the TVPs. DDGS alone did not yield stable products, necessitating the addition of SPI. The formulation with 43% DDGS and 18% feed moisture showed favorable attributes and holds promise for plant-based products.