Progress 05/01/23 to 04/30/24
Outputs
Target Audience:This project is dedicated to pioneering a new approach for additive manufacturing of plant protein-based fish substitutes. By introducing a novel processing technique, we aim to enhance our understanding of biopolymer physicochemical properties and advance the development of bio-inks for use in food additive manufacturing. This research will be valuable to academics, industrial scientists, and engineers engaged in alternative protein technologies and food processing. Additionally, the findings will be of interest to those studying the fundamental properties of biopolymers and computational fluid dynamics related to free surface flows. A significant aspect of this project within this reporting period involves advancing high-fidelity simulations. We have integrated a microscopic scale fiber orientation module with free surface coating flow simulations to accurately predict microstructures. The insights and tools generated from this research will not only impact food technology but also provide benefits to broader additive manufacturing fields, including bioprinting. Results will be disseminated through peer-reviewed articles and presentations at scientific and industry conferences such as COFE. Changes/Problems:We have applied and were granted an extension of the project till the end of the year 2024. What opportunities for training and professional development has the project provided?The project has provided substantial opportunities for training and professional development. Two graduate students were hired, one of whom graduated in August 2024 with a thesis focused on this project. This student actively contributed to the development of the novel 2D coating technology and presented their work in a 3-minute thesis competition, where they won first place for their innovative approach to creating fish meat alternatives. Additionally, the project supported the professional growth of a postdoctoral researcher who continued to refine the bioink formulation. We also integrated aspects of this research into the food engineering curriculum, allowing students to gain practical experience with cutting-edge technologies and contributing to their academic and professional development. This exposure has not only enhanced their technical skills but also provided them with a platform to showcase their work in academic and industry settings, thereby broadening their career prospects. How have the results been disseminated to communities of interest?We have presented this work in the annual industrial and alumni meeting taking place in the department of food science at UMass Amherst. In addition, a poster related to this work was sent to COFE. What do you plan to do during the next reporting period to accomplish the goals?In the next reporting period, we plan to focus on optimizing bioink formulations for the production of fish analogs by refining the coating parameters. We will fully characterize the texture profiles of various bioink formulations to determine their effectiveness in replicating the desirable internal structures of fish meat. Additionally, we will complete and submit manuscripts detailing our findings and ensure that the knowledge generated is disseminated through peer-reviewed publications and presentations at scientific and industry conferences. This will help us advance the development of high-quality fish analogs and contribute valuable insights to the field of food manufacturing.
Impacts
What was accomplished under these goals?
This year, we made significant strides in both experimental and computational aspects of our research. We advanced the bench top coating rig for evaluating potato protein (PP200)-based bioinks, testing formulations at concentrations of 10%, 15%, and 20%, and exploring pregelling conditions including preheating at 45°C for 20 to 50 minutes. Our findings highlighted the critical need to fine-tune coating speed and bioink extrusion flow rate to prevent issues such as weeping and air entrainment. We observed that the performance of the coating is highly dependent on the rheological properties of the bioink, underscoring the importance of precise adjustments for optimal results. In parallel, we developed high-fidelity simulations by integrating a microscopic scale fiber orientation module with free surface coating flow simulations. This approach allowed us to predict microstructures under various processing conditions and revealed that the unique coating flow, where bioink rapidly expands upstream of the coating layer, generates a strong extensional flow that influences the initial fiber orientation in the sheet. This insight is crucial for designing process conditions that produce fish analogs with desired internal structures. Additionally, we tested several bioink mixtures--PP200 at 15%, PP200 at 15% with Acyl Gellan Gum, and PP200 at 15% with 1% cellulose nanofiber. After printing five layers of 'fish analog,' we used confocal microscopy to analyze the internal structure. The mixture with cellulose nanofiber produced an anisotropic structure with fibers oriented transversely to the muscle layer, effectively segregating the protein gel. This structure closely resembled real fish meat in texture when compared to Atlantic salmon muscle layers, showing promising potential for creating realistic fish analogs.
Publications
- Type:
Journal Articles
Status:
Submitted
Year Published:
2024
Citation:
Ubal, S., McClements, D.J., Corvalan, C.M., & Lu, J.* Controlling elongated particle alignments in slot coating flows. Journal of Food Engineering
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Progress 05/01/22 to 04/30/23
Outputs
Target Audience:The aim of this project is to develop a novel proof of concept additive processing method for creating plant protein-based fish analogs. This endeavor will also contribute to fundamental scientific knowledge about biopolymer physicochemical properties and aid in the development of bio-inks for food additive manufacturing. Additionally, the project will develop computational tools that use numerical simulations and data-driven algorithms to facilitate the development of the new processing technology. The primary audience for this project includes academics, industrial scientists, and engineers interested in food development and processing technologies based on alternative proteins. Furthermore, scientific communities interested in the fundamental physicochemical properties of biopolymers and computational fluid dynamics for free surface flows will also benefit from this research. Findings from this project will be disseminated through peer-reviewed papers and presentations at scientific and professional meetings. Changes/Problems:
Nothing Reported
What opportunities for training and professional development has the project provided?One post-doc (senior scientist) was hired and joined the project in July 2022, the post-doc researcher has worked on the development of computational tools related to this project. In addition, a self-funded master's student participated the project and was involved in evaluating the physicochemical properties of bio-inks early on in this project. How have the results been disseminated to communities of interest?Part of the data-driven approach that evolved from this project was shared at a recent AOCS annual conference in an invited talk. What do you plan to do during the next reporting period to accomplish the goals?In the next phase, the optimized protein-polysaccharide system will be laminated using layer-by-layer printing - the instrument has been assembled in our lab. However, before up-scale production, there are still some key benchmarks to consider during the printing process, such as the time-resolved gelling behavior, internal structure, water and oil holding capacity, and the orientation change of fibrous structure. To this end, the appearance, texture, and cookability should also be considered to increase the printing accuracy and reliability in the following studies. More specifically, we will use post hoc strategies to refine the protein-polysaccharide formula during and after laminating by changing polymer concentration and mass ratio, as well as solution conditions (pH, ionic strength, and temperature). From the modeling side, we will incorporate more features to the current model to better assist the modification and optimization of the processing development. Lastly, and most importantly, we will start creating fish analogs on our newly assembled benchtop testing rig, and characterize the structure-to-texture relationship over a wide range of processing conditions and bio-inks.
Impacts
What was accomplished under these goals?
Towards Aim 1 To construct the bio inks using bottom-up strategy, the physicochemical properties of various plant-derived proteins and polysaccharides have been systematically investigated in our study. In particular, the solubility and zeta-potential of faba bean protein (M25010, AGT), pea protein (M22998, AGT), and lentil protein (M17399, AGT), as well as pectin, carrageenan, and xanthan gum were compared at different pH levels. Accordingly, pea protein (10 - 15 wt.%) and citrus pectin (0.1 - 1 wt.%) were chosen to formulate the phase-separated polymer mixture. Transglutaminase (0.1 - 2.5 wt.%) was also used to optimize the texture properties of protein-polysaccharide gels. The result from screening trials shows that the combination of 10 wt.% pea protein, 0.5 wt.% pectin, and 2 wt.% transglutaminase endowed the bio inks with the similar texture attributes of real salmon. Meanwhile, w-3 enriched flaxseed oil (0.5 - 1 wt.%) was successfully encapsulated in the protein-polysaccharide block structure. It should be noted that the hardness, springiness, and chewiness of pea protein-pectin gels can be harnessed by changing the temperature (40 - 55 ?) and ionic strength (e.g., 5 - 50 mM for CaCl2 and 50 - 300 mM for NaCl) of protein-pectin mixture. Towards Aim 2 and 3 We developed and successfully validated a computational model for slot coating, which was tested across a wide range of processing conditions to identify the optimal processing region for various bio-ink material properties. The model also incorporates a complex phase separation process based on the laws of mass conservation and thermodynamics, enabling accurate predictions of texture formation during the laminating process. As a result, this model will offer valuable insights into the interplay between processing conditions and material properties, facilitating the optimization of bio-ink formulations and the development of the proposed processing technology. Lastly, we have built the bench-top coating rig which is ready to test on various bio-inks from Aim 1.
Publications
- Type:
Conference Papers and Presentations
Status:
Published
Year Published:
2023
Citation:
Lu, J., Ubal, S., Corvalan, M. C., (2023, Apr. 30 - May 3) Using physics-informed neural networks on inversed problems in food materials. AOCS 2023 Annual Meeting & Expo, Denver, CO, United States
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