Source: PURDUE UNIVERSITY submitted to NRP
HARNESSING AGGREGATES OF HYDROLYZED PLANT PROTEINS AS GREENER AND EFFECTIVE FAT REPLACER IN FAT-FREE DAIRY FOODS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
ACTIVE
Funding Source
Reporting Frequency
Annual
Accession No.
1032463
Grant No.
2024-67017-42813
Cumulative Award Amt.
$299,657.00
Proposal No.
2023-10520
Multistate No.
(N/A)
Project Start Date
Aug 1, 2024
Project End Date
Jul 31, 2026
Grant Year
2024
Program Code
[A1364]- Novel Foods and Innovative Manufacturing Technologies
Recipient Organization
PURDUE UNIVERSITY
(N/A)
WEST LAFAYETTE,IN 47907
Performing Department
Food Science
Non Technical Summary
With increasing awareness of sustainability and healthy diets, the development of plant protein-based fat replacers to provide softness and lubricating effects to low-fat or fat-free products has gathered significant attention. However, the production of these fat replacers is energy-intensive due to prolonged heating at high temperatures, limiting their potential for food applications. Therefore, reducing energy consumption is essential to enhance their use in foods.In this project, plant protein is partially hydrolyzed by a protease, followed by gentle heating to form aggregates as fat replacers. The physicochemical properties of the protein hydrolysates and their aggregates are characterized to understand the increased aggregating capacity of the hydrolysates. The resulting fat replacer is then incorporated into skim milk to produce fat-free cream cheese. The quality attributes of the cream cheese, such as appearance, texture, and heat-melting behavior, will be tested. To scale up production, an extrusion processing is used. A techno-economic analysis of the process is conducted to calculate the energy consumption and production costs relative to traditional technologies. This project aligns with the program's priorities by enhancing sustainability and food quality attributes through advanced processing and bioprocessing technologies.
Animal Health Component
40%
Research Effort Categories
Basic
60%
Applied
40%
Developmental
(N/A)
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
5011412202060%
5023430200040%
Goals / Objectives
Our long-term goal is to efficiently produce aggregates of hydrolyzed plant proteins using industry-relevant processes for quality improvement of fat-free dairy products with less energy consumption. To achieve so, three specific goals are proposed. Goal 1: Optimize the condition to produce plant protein hydrolysates with maximized aggregating capacity. By changing the hydrolysis time and enzyme to substrate ratio, the degree of hydrolysis of plant protein varies. This further determines the surface chemistry and molecular weight of the hydrolysates, resulting in a distinct response towards heat. By controlling the degree of hydrolysis, protein hydrolysates with maximized aggregating capacity will be achieved under low to mild heating conditions. Goal 2: Identify the quality characteristics of fat-free cream cheese containing PPH aggregates. Aggregates of protein hydrolysates will be expected to deform and disassemble under shear force due to their high molecular flexibility. They could also interact with caseins to weaken or disrupt the intactness and continuity of casein-networks. Both contribute to a softer texture and smoother mouthful feelings of fat-free cream cheese. Goal 3: Determine the extrusion condition to large-scale production of PPH aggregates and its techno-economic analysis. The strong shear force provided within extruder will facilitate enzyme diffusion among protein matrix capable of conducting hydrolysis at high protein concentration. With controllable temperature in the extruder, PPH will be aggregated while the enzyme is inactivated. By adjusting the extrusion parameter and enzyme proportion, a process with more energy, time and cost efficiency will be achieved.
Project Methods
Aim 1: Optimize the condition to produce PPH aggregates under mild heat. Lab-extracted pea protein isolate will be suspended in water, mixed with protease, and hydrolyzed for a short duration at various enzyme to protein ratio. The produced hydrolysates with the highest aggregating capacity will be identified as the optimized condition based on the response surface methodology. The degree of hydrolysis, molecular weight, surface hydrophobicity, surface charge and available -SH group of the hydrolysates will be measured by TNBS method, SDS-PAGE, fluorescence spectroscopy, zeta sizer, and Ellman's reagent, respectively. The hydrolysates will be heated to form aggregates followed by examination of Morphology, size and molecular flexibility of the aggregates will be examined by SEM, Mastersizer, and relaxation solid­state NMR, respectively. Molecular forces that are involved in the aggregation of hydrolysates will be measured by using different solvents.Aim 2: Identify the quality characteristics of fat-free cream cheese with PPH aggregates. Skim milk containing plant protein hydrolysates or its aggregates will be used to form cream cheese. The proximate of cream cheese will be measured according to AOAC standards. The cheese microstructure will be characterized by using confocal microscopy SEM. Amplitude, frequency and temperature sweep will be conducted to measure the viscoelasticity and melt heating behavior. Firmness, spreadability and adhesiveness will be measured by using a textural analyzer with. Sensory analysis will also be conducted by quantitative descriptive analysis-QDA ™, using a randomized (full) block design. Judges (eight to ten) will be pre-screened and trained to determine the aroma, flavor, texture & mouthfeel attributes of the cream cheese samples.Aim 3: Determine the eREX condition for large-scale production of PPH aggregates and its techno-economic analysis (TEA). Commercial plant protein isolate will be mixed with water containing protease. They will be extruded under various moisture content, screw speed and feeding rate to identify the optimal condition with the highest cheese softening capacity. A system-level process simulation and economic analysis assuming the extrusion process are being scaled up to a commercial scale of 2,000 tons/yr. Material and energy balance, and flow rate will be quantified based on SuperPro Designer simulation of heat and mass balances. Quantified information will be used to calculate total chemical, energy, and enzyme consumption and thus variable operating costs. Fixed operating cost, including labor and various overhead items, will be quantified. The capital investment, total net profit, internal rate of return, and net present value as well as sensitivity analysis will also be calculated.

Progress 08/01/24 to 07/31/25

Outputs
Target Audience:During this reporting period, our efforts reached multiple target audiences, including: (1) food industry professionals and product developers, (2) academic researchers and students, (3) science communicators and media outlets, and (4) high school students and educators. We engaged food industry professionals through the Spring Industrial Associates Meeting 2025 at Purdue University, where we participated in the Joint Poster Session and Networking Gathering to over 20 companies. This provided direct interaction with R&D personnel and decision-makers from food and ingredient companies, allowing us to share our progress and receive valuable industry feedback on the relevance and potential applications of our fat-free cream cheese innovation. Academic audiences were reached through ongoing mentorship of postdocs, graduate & undergraduate students, along with our participation in scholarly dissemination efforts and publication. We published one article in Food Hydrocolloids on Fat-free cream cheese, and submitted abstracts to the ACS Fall 2025 Meeting and the 6th International Electronic Conference on Foods and approved for oral presentation. We were also contacted by scientific writers from The New York Times and IFT's Food Technology magazine to discuss our innovation on high-protein foods and fat-free cream cheese, demonstrating strong interest in the societal and commercial impact of the research. Finally, we guided three high school students to develop fat-free cream cheese and presented to other high school students in the Summer College for high school students at Purdue University. This engagement helped promote STEM awareness and encouraged students to consider careers in food science and technology. Changes/Problems:There are no major changes to the overall research approach. Instead, we have expanded the research objectives to include the development of additional protein-based fat replacers derived from food byproducts, such as acid whey, to soften fat-free cream cheese. At the same time, we continue to pursue the original objectives focused on exploring the potential of limited proteolysis of pea proteins to reduce the hardness of fat-free cream cheese. What opportunities for training and professional development has the project provided?This project offered meaningful training and professional development opportunities for high school students, undergraduate students, graduate students, and postdoctoral researchers. Trainees received hands-on experience in laboratory techniques relevant to plant protein extraction, enzyme hydrolysis, cream cheese formulation, rheological measurements, functional property evaluation, and some other analytical methods. Under the guidance of the principal investigator, students were actively involved in experimental design, data analysis, and interpretation. Weekly lab meetings provided additional training in critical literature review, data presentation, and scientific communication. Graduate students and the postdoctoral researcher received individualized mentoring in manuscript preparation,research planning and conducting. They contributed as authors or co-authors to peer-reviewed journal articles and conference abstracts. Professional development activities included participation in the Agricultural Engineering networking event in Purdue, the Spring Industrial Associate Meeting, and the preparation and submission of abstracts for conferences such as the American Chemical Society (ACS) meeting and other online academic forums. The postdoctoral researcher also mentored two undergraduate students and three high school students, gaining valuable leadership and supervisory experience. Meanwhile, theundergraduate and high school students, gained hands on research experience and the awareness ofthe importance of developing low-fat and fat-free dairy products to promote human health. Overall, this project strengthened participants' technical competencies, enhanced their scientific communication skills, and supported their preparation for future careers in food science and related disciplines. How have the results been disseminated to communities of interest?Project outcomes have been disseminated through peer-reviewed publications, scientific conferences, industry engagement, and community outreach. Key findings were published in Food Hydrocolloids, a leading journal in the field, detailing the mechanism behind the softening effect observed in fat-free cream cheese formulated with plant protein aggregates. Additional results, including the enhanced aggregation capacity of plant proteins through proteolysis, were presented at the Industrial Associates Meeting at Purdue University and submitted to Food Chemistry, the American Chemical Society (ACS) Fall 2025 Meeting, and the 6th International Electronic Conference on Foods. These efforts facilitated scientific exchange and fostered collaboration with academic and industry stakeholders. To engage non-academic audiences, the research team participated in high school outreach programs, providing hands-on demonstrations and discussions about fat-free cream cheese as an entry point to food science and STEM careers. The project also attracted interest from mainstream and professional media, including inquiries from The New York Times and IFT's Food Technology magazine, reflecting the broader societal relevance of innovations in high-protein and fat-free food products. What do you plan to do during the next reporting period to accomplish the goals? Complete remaining research activities under Goal 2, focusing on the microstructural characterization, interactions between casein and pea protein hydrolysates (PPH), and sensory evaluation of the resulting food products. Complete the activities under Goal 3, including large-scale production of PPH and its application in softening the texture of cream cheese. A techno-economic analysis will be conducted to assess the economic feasibility and scalability of the process. Synthesize and interpret findings from Goals 2 and 3 to prepare manuscripts for submission to peer-reviewed journals. Disseminate the results through academic conferences, including the ACS Fall Meeting, the Institute of Food Technologists (IFT) Annual Meeting, and the Conference of Food Engineering. Continue training undergraduate students, graduate students, and postdoctoral researchers involved in the project to enhance their research skills, scientific communication, and career development. Expand outreach through social media and public platforms to communicate key findings and their implications to a broader audience, thereby increasing public awareness and engagement with food science research.

Impacts
What was accomplished under these goals? Goal 1: We have completed the condition optimization using the RSM method and identify the optimal enzyme to substrate level, protein content and degree of hydrolysis that leads to the maximal increment of storage modulus. The molecular characteristics including the molecular weight, surface hydrophobicity,total sulfhydryl and disulfide bond contents of the hydrolysates and thermal properties were investigated. The microstructure and nanostructure of the aggregates of hydrolysates and their relation to the storage modulus were also explored. Goal 2: We have completed 50% of the proposed work, including development of fat-free cheese containing pea protein hydrolysates produced under optimal and non-optimal conditions and measured their rheological and tribological properties. The nanostructure of the cheese were investigated by synchtron X-ray scattering.

Publications

  • Type: Peer Reviewed Journal Articles Status: Published Year Published: 2025 Citation: 0
  • Type: Other Journal Articles Status: Submitted Year Published: 2026 Citation: N/A