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Este relatório é o resultado do estágio curricular realizado no âmbito do Mestrado em Engenharia Alimentar da Escola Superior de Biotecnologia da Universidade Católica Portuguesa no Porto, na empresa New Foods Company, na Maia, entre os dias 1 de fevereiro a 5 de julho de 2023. O estágio teve como principal objetivo investigar e aplicar conhecimentos relativos à produção de análogos de carne por extrusão húmida, melhorando o produto e tornando o processo mais eficiente com a redução e adaptação de tarefas. Foram realizadas pesquisas relativas à composição de um análogo de carne produzido por extrusão húmida, bem como sobre o funcionamento de uma extrusora, nomeadamente, no que diz respeito ao papel dos fusos, do cooling die e do processo de texturização. A extrusão húmida é um processo complexo visto ser necessário definir, controlar e adaptar diferentes variáveis intrínsecas ao processo e à formulação do produto. Ao longo do estágio, foram efetuados diversos ensaios com a alteração sistemática de variáveis do processo, tais como a temperatura de extrusão, a temperatura de arrefecimento do produto no cooling die, a velocidade de processamento e os caudais de entrada de matéria-prima no processo. Durante os ensaios surgiram, inevitavelmente, contratempos, tais como o entupimento do cooling die ou o rebentamento do tubo de admissão de óleo à extrusora, que exigiram sempre uma resolução rápida e eficiente. Produziram-se análogos de frango, aos quais foram realizadas análises à textura, cor, pH e atividade da água (aw). Após as análises, foi efetuada a comparação dos ensaios realizados na New Foods Company com um produto homólogo da concorrência e um bife de frango. Seguidamente, após a apresentação das conclusões obtidas, foram dadas sugestões com vista à resolução de problemas que surgiram com a alteração das variáveis.
This thesis is the result of the curricular internship carried out within the scope of the master’s degree in food engineering at the Escola Superior de Biotecnologia of the Universidade Católica Portuguesa in Porto at the company New Foods Company, in Maia, between February 1st and July 5th, 2023. The main objective of the internship was to investigate and apply knowledge related to the production of meat analogs through wet extrusion, improving the product and making the process more efficient by reducing and adapting tasks. Research was conducted on the composition of a meat analog produced by wet extrusion, as well as on the operation of an extruder, specifically regarding the role of screws, the cooling die, and the texturization process. Wet extrusion is a complex process as it requires defining, controlling, and adapting various variables inherent to the process and product formulation. Throughout the internship, various experiments were conducted with the systematic alteration of process variables, such as extrusion temperature, cooling temperature in the cooling die, processing speed, and raw material input flow rates. During the experiments, there were inevitably setbacks, such as clogging of the cooling die or bursting of the oil intake tube into the extruder, which always required a quick and efficient resolution. Chicken analogs were produced, and texture, color, pH, and water activity (aw) analyses were performed. After the analyses, a comparison was made between the experiments conducted at New Foods Company, a competing product, and a chicken steak. Following the presentation of the conclusions obtained, suggestions were given for resolving issues that arose with the alteration of variables.
This thesis is the result of the curricular internship carried out within the scope of the master’s degree in food engineering at the Escola Superior de Biotecnologia of the Universidade Católica Portuguesa in Porto at the company New Foods Company, in Maia, between February 1st and July 5th, 2023. The main objective of the internship was to investigate and apply knowledge related to the production of meat analogs through wet extrusion, improving the product and making the process more efficient by reducing and adapting tasks. Research was conducted on the composition of a meat analog produced by wet extrusion, as well as on the operation of an extruder, specifically regarding the role of screws, the cooling die, and the texturization process. Wet extrusion is a complex process as it requires defining, controlling, and adapting various variables inherent to the process and product formulation. Throughout the internship, various experiments were conducted with the systematic alteration of process variables, such as extrusion temperature, cooling temperature in the cooling die, processing speed, and raw material input flow rates. During the experiments, there were inevitably setbacks, such as clogging of the cooling die or bursting of the oil intake tube into the extruder, which always required a quick and efficient resolution. Chicken analogs were produced, and texture, color, pH, and water activity (aw) analyses were performed. After the analyses, a comparison was made between the experiments conducted at New Foods Company, a competing product, and a chicken steak. Following the presentation of the conclusions obtained, suggestions were given for resolving issues that arose with the alteration of variables.
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Extrusão húmida Análogos de carne Proteínas Textura Frango Wet extrusion Meat analogue Proteins Texture Chicken