The search for realistic meat alternatives continues to push the boundaries of food science, and mycoprotein (MYC) has emerged as a promising contender. Its fibrous mycelial structure closely mimics meat fibres, yet achieving the same alignment and texture of real muscle fibres remains a significant challenge. A new study published in Food Chemistry explores the potential of extrusion-based 3D printing, enhanced with egg white proteins (EWP), to address this issue and produce mycoprotein-based meat alternatives with improved quality and texture.
The Role of 3D Printing in Meat Alternative Innovation
3D printing has shown transformative potential in food production, allowing precise manipulation of ingredients to achieve desired shapes, textures, and nutritional properties. Among its methods, extrusion-based 3D printing stands out for applications in meat alternatives, offering the ability to build fibrous, layered structures that simulate meat’s muscle fibres. However, the technology requires careful formulation of inks to ensure optimal printing performance and final product quality.
In this study, mycoprotein was used as the primary material due to its naturally fibrous mycelial structure, a hallmark of Fusarium venenatum fermentation. The researchers aimed to enhance the directional alignment of these fibres by incorporating EWP in varying concentrations (4%, 5%, 6%, and 7%). This combination was evaluated to determine its effect on the ink’s rheological properties, printing performance, and post-printing textural quality.
Image courtesy: Mycorena (Naplasol)
Formulating Mycoprotein-EWP Inks
The inks were prepared by blending fermented mycoprotein with EWP and carrageenan, creating a composite material with shear-thinning behaviour ideal for extrusion printing. Rheological tests revealed that increasing the EWP concentration altered the ink's viscosity and yield stress. Notably, the addition of EWP induced a non-linear viscoelastic state, with intra-ring strains limiting water mobility—a result attributed to hydrogen bonding between mycelium and EWP molecules.
During the extrusion process, these changes enhanced the structural integrity of the printed layers, enabling better alignment of the mycoprotein fibres. The stacking of printed filaments further consolidated the fibre arrangement, producing a transverse alignment that closely resembled natural meat.
Achieving Meat-Like Textures
Post-printing, the mycoprotein-EWP matrix underwent heat treatment to set the structure and enhance its textural properties. Among the formulations, the 6% EWP blend demonstrated the most promising results. Textural analyses showed significant improvements in hardness, chewiness, and water retention compared to lower EWP concentrations.
These enhancements brought the 6% EWP formulation closer to the sensory qualities of beef, particularly in bite and mouthfeel. This suggests that EWP plays a critical role in not only aligning fibres but also improving the mechanical and sensory properties of the printed products.
Image courtesy: Revo Foods
Understanding the Science Behind the Improvements
The interplay between EWP and mycoprotein fibres is central to these advancements. EWP is known for its excellent gelling properties, which are enhanced through hydrogen bonding and electrostatic interactions with mycoprotein. These interactions stabilise the mycoprotein structure during extrusion and heating, creating a more ordered and compact arrangement.
Additionally, the reduction in water mobility, facilitated by EWP, contributes to improved moisture retention—a key factor in mimicking the juiciness of real meat. The resulting texture aligns with consumer demands for meat alternatives that replicate the sensory experience of traditional meat.
Implications for the Meat Alternative Industry
The study provides a proof of concept for using extrusion-based 3D printing to enhance the fibre alignment and textural quality of mycoprotein-based meat alternatives. By incorporating optimised levels of EWP, the process addresses a major challenge in the industry: replicating the complex fibrous structure of real muscle tissue.
The implications extend beyond mycoprotein. The findings suggest that similar strategies could be applied to other protein sources, potentially expanding the applications of 3D printing in the alternative protein market. Moreover, the ability to fine-tune texture and structure through printing technology opens doors for customised products tailored to consumer preferences.
Image courtesy: Revo Foods
Future Implications
While the results are promising, further research is needed to refine the technology and make it scalable for commercial production. Challenges include standardising the fermentation and ink preparation processes, as well as reducing the variability inherent in natural mycelial materials.
Additionally, the use of egg white protein, while effective, may limit the product’s appeal to vegan consumers. Future studies could explore plant-based alternatives that provide similar functional properties, ensuring broader market compatibility.
This study demonstrates that extrusion-based 3D printing, coupled with optimised mycoprotein-EWP formulations, has the potential to revolutionise the meat alternative sector. By achieving directional fibre alignment and enhancing textural qualities, this approach brings mycoprotein products one step closer to replicating the look, feel, and taste of real meat.