Plant-based & vegetarian food

Trusted partner for the plant-based and vegetarian industry

Meat replacement & vegetarian food

Plant-based and vegetarian applications

Discover our extrusion technology of Texturized Vegetable Proteins, cutting, mixing, emulsifying and grinding of ingredients to form a dough, and further down the line to forming, coating, frying or cooking, chilling, freezing and ultimately packaging of plant-based and vegetable-based foods and components.

Packaging for plant-based and vegetarian foods

Packaging is crucial for distribution, preservation, and presentation, and helps your product stand out on the shelf.

Plant-based chicken with nutri crumb coating

Discover a typical process from extrusion to a finished product

Extrusion

Textured Vegetable Proteins (TVP) are created by extruding the mix of flours, which deconstructs the globular structure and then realigns it into fibers to obtain customizable products that mimic the texture of meat or fish. GEA, with its proven XTru Twin extrusion technology, offers the ability to manage variable thermo-hygrometric conditions to adapt to the characteristics of the raw material, maintain high-process temperatures for optimal texturization and protein denaturation leading to reduced solubility and water loss. This process is applicable for both dry and wet vegetable protein texturization.

Cutting

GEA CutMaster bowl chopper prepares each element of the mix starting with rehydration of the Textured Vegetable Proteins, cutting the coconut butter and emulsifying the ingredients. Thanks to its vacuum technology, high rotation speed and robust design, water, oil and plant-proteins and/or binding agents are emulsified, delivering the optimum consistency, temperature and texture for the next step.

Mixing

The way the ingredients are mixed defines the success of the final food product. GEA ProMix, is a flexible twin shaft mixer that caters variety of purposes. When frozen vegetables are used, tempering by steam under vacuum shortens the process and ensures workable consistency. The hydration of the plant-based proteins under vacuum, speeds up the process while moisture is better absorbed in the dough. Finally, emulsions can be mixed with herbs, spices, starch, flavor, salt and binding agents depending on the desired end product.

Grinding

Griding can be used at the preparation step before mixing or after mixing of the dough in order to control the fiber length, which is important of the final product. For example, plant-based chicken needs longer fibers and minced meat or burger mimics need shorter fibers and bite. GEA ComboGrind technology can be used in combination of the respective whole plates and knifes to suit the recipe.

Forming

With GEA forming equipment there is almost no limit to the shapes and sizes you can create. Mixes are handled appropriately by different forming systems to preserve quality and structure while achieving maximum quality down the line. MaxiFormer is a high-capacity drum former for high-speed production of long-run products with excellent shape retention and weight accuracy. Alternatively GEA MultiFormer is an excellent choice when flexibility in shapes during production is required.

Coating

The right coating adds value to your food products. And now, in line with the trend towards healthier eating and lower fat intake, you need more accurate control over coating parameters. GEA industrial food coating solutions give you this control - plus the capability to cost-effectively produce an appetizing variety of products. GEA offers complete solutions for crumb breading, tempura coating and flour coating.

Heat Treatment

Frying sets the coating and cooks the substrate while enhancing taste and appearance, adding crispiness and crunch. Should you not use frying, cooking, steaming and even smoking in our spiral ovens is an option to finalize your consumer product.

Freezer

GEA spiral freezers and chillers discretely handle products at capacities up to 7 tons per hour. Using high-efficiency airflow and evaporators, they maximally transfer heat and optimize product quality and yield. Through energy-efficient design, our spiral freezers also satisfy industry requirements while saving costs to boost your profit.

Packaging

GEA’s Vertical Form Fill Seal (VFFS) and horizontal thermoforming packaging technology are both flexible solutions that cover various packaging styles suited for high speed, high quality packing of your finished product in reliable, sustainable and highly efficient way.

Vivera, the Netherlands | Formed plant-based products coming out MultiFormer

Vivera, the Netherlands

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