Partially substituting cheese base with plant proteins to produce processed cheese: Textural, rheological, microstructural and sensory properties

The increasing demand for plant-based dairy alternatives, driven by sustainability and health concerns, has driven the development of hybrid processed cheeses (PC) that incorporate plant proteins. This study investigates the effects of replacing 5% of the dairy component (Mozzarella cheese base) with soy protein isolate (SPI), pea protein isolate (PPI), or mung bean protein isolate (MBPI) on the textural, rheological, microstructural, sensory properties of hybrid PC. Textural analysis revealed that hybrid PC with SPI exhibited the highest firmness and chewiness, attributed to a dense and cohesive protein network. Rheological testing indicated that all hybrid PC displayed shear-thinning behavior and gel-like properties, with hybrid PC with SPI showing the highest viscoelastic resistance. In contrast, hybrid PC with MBPI most closely resembled dairy PC in terms of textural attributes. Microstructural analysis demonstrated that hybrid PC formed denser networks with smaller, well-distributed fat droplets. Hybrid PC with SPI showed the strongest protein-fat interactions, whereas with PPI exhibited a weaker matrix structure. Sensory evaluation revealed that hybrid PC maintained acceptable sensory qualities comparable to dairy PC. Notably, hybrid PC with MBPI achieved the closest overall sensory profile to the dairy control. The presence of a beany flavor, primarily due to 2-pentylfuran, was most pronounced in hybrid PC with MBPI. However, this flavor was balanced by piperonal and ethyl vanillin, which contributed milky and vanilla-like aromas to the hybrid PC. These findings highlight the potential of plant proteins to enhance the nutritional, structural, and rheological properties of PC while maintaining sensory acceptability. Soy protein isolate was found to offer superior texture, whereas MBPI replicated dairy-like sensory qualities, providing a sustainable and high protein alternative to traditional dairy PC.