The project will follow three objectives: (i) utilize and optimize cultivation approaches to efficiently produce alternative proteins, (ii) design downstream processes for obtaining protein-rich extracts, and (iii) evaluate structuring processes of alternative proteins to obtain delicious model food textures. In the first objective, we will utilize cultivation approaches to produce alternative protein biomass mainly by gas cultivation and fungi cultivation techniques. Well-studied hydrogenotrophic microorganisms will be used that are safe for human consumption. Cultivation parameters will be tested and evaluated to obtain protein-rich biomass based on hydrogen cultivation. Moreover, a common GRAS-certified fungi strain that efficiently grows using submerged cultivation will be used for the cultivation of fungi: Fusarium venenatum. To optimize the cultivation process, advanced computational modeling will be combined with experimental measurements. We will use two different types of the modeling approach. First, we will develop hybrid modeling by combining first principle-based simulations and kinetic models obtained based on experimental data. In addition, we will develop a black box neural network-based model to correlate cultivation parameters to biomass yield. We will then use optimization techniques such as genetic algorithms to search for an optimized condition over the cultivation parameter space.
In the second objective, we will optimize downstream processes for different raw materials such as fungi, bacteria, and plant raw materials. The aim is to obtain a functional protein extract that is produced through efficient extraction operations with optimum sidestream utilization. For example, a protein-rich extract will be produced by designing a downstream process for bacteria based on a combination of enzymatic and mechanical processing approaches that aim to release the proteins from the cells with low energy inputs. The physical and modeling principles of these operations are poorly understood when used with such novel raw materials. In these processes, a variety of equipment and processes are used, including high-shear blenders, homogenizers, and centrifuges. In addition, novel processing approaches such as hydrodynamic cavitation will also be used.
After protein ingredients have been obtained through extraction they have to be processed into different types of food structures. Most commonly, alternative proteins are used to formulate foods that mimic animal-based foods such as meat or dairy alternatives. In the last objective, we therefore aim to produce such meat and dairy alternatives and reveal the principles behind the structuring processes. This will help to optimize these processes and obtain foods with improved textures and flavors. For example, extrusion processing is a high-temperature and high-shear process that results in anisotropic textures that are almost similar to meat. However, it is not well understood how these fibrous structures are formed within the extrusion process and how other liquid ingredients can be injected into the extruder during processing (e.g., oils). To overcome these challenges, we will again develop hybrid models by combining advanced computational fluid dynamic (CFD) simulation that incorporates thermal dynamics phase-changing process that proceeds the structuring process. However, due to a lack of detailed understanding of the phase-changing process, an inversed data-driven approach will be used to identify relevant thermodynamic parameters. Finally, we will correlate material properties, and operating conditions from upstream to the thermodynamic parameters, which will be critical for better prediction of the structuring process.
