Sobatech’s 3-phase system combines TVP hydration, emulsion production, and final mixing into a single streamlined process. Delivering plant-based meat products with consistent quality, higher efficiency, and full process control.
Plant-based meat is a category of food products engineered to replicate the taste, texture, and nutritional profile of conventional meat. To support the growing global demand for meat alternatives, Sobatech has developed a fully continuous, three-phase process specifically for producing Texturized Vegetable Proteins (TVP)-based products, enabling efficient and scalable production. The system is also compatible with other plant-based formats, such as High Moisture Extrusion (HME) pieces. Each phase of the process requires distinct shear and kneading conditions. To optimize performance, Sobatech mechanically decouples the phases, ensuring precise shear management and overall process efficiency. The fully automated system guarantees consistent and uniform blending of all components, eliminating the need for manual intervention. Each phase can be purchased as a standalone module, offering flexibility for producers with specific process needs.
The continuous hydration system offers an efficient and scalable solution for hydrating TVP. Operating as a closed-loop system, it ensures a continuous feed of TVP into the unit, where uniform and consistent hydration takes place. This phase applies low shear to protect the fibrous structure of the TVP and prevent breakage during hydration. This process maintains the structural integrity of the TVP and guarantees lump-free, even hydration throughout. Available in multiple sizes and configurations.
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In this phase, water, oil, and methylcellulose powder are combined using high-shear mixing technology. As a specialist in high-shear mixing, Sobatech carefully controls shear forces to achieve optimal emulsification while preserving the quality of the raw ingredients. Unlike the first phase, this step requires high shear input to create a homogenous emulsion, essential for proper binding. The fiber structures remain intact throughout the kneading process—an essential factor in achieving the desired texture in the final product.
In the final phase, the hydrated TVP from Phase 1 and the emulsion from Phase 2 are continuously dosed into the mixing chamber, where they are combined in a controlled kneading process. Additional powder ingredients can also be incorporated at this stage. This step requires medium controlled shear to ensure homogeneous blending while avoiding damage to sensitive ingredients such as spices, colorants or protein blends. Product quality is closely monitored by measuring the kneading energy within the mixer, ensuring optimal consistency and texture in the final blend.
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