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Industrial solutions tailored for plant-based alternative production

Diversifying protein sources has become a global challenge. Driven by growing expectations around health, sustainability, and cost control, plant-based alternatives have established a lasting presence in fresh and frozen aisles as well as in food service. 

The market is now entering a phase of maturity: consumers are no longer satisfied with the plant-based argument alone and assess products against the demanding criteria of taste, texture, and appearance. The diversity and complexity of plant-based formulations therefore require perfectly controlled processes that can reproduce the organoleptic and dimensional characteristics validated in the R&D laboratory at an industrial scale. 

To achieve this, manufacturers need flexible production lines that are capable of consistently meeting the product quality, industrial performance, and sanitary requirements specific to plant-based preparations. Automated pan-based lines provide a particularly well-suited answer to overcome these challenges. 

Flexibility and innovation: Supporting a growing product offering 

Plant-based product ranges no longer stop at meat imitation. New recipes are constantly emerging: nuggets and breaded products, balls and patties made from pulses or cereals, mushroom-based preparations, fish alternatives, and hybrid products combining plant and animal proteins. The growing variety of preparations, formats, and supports is often produced on the same industrial line, making recipe changeover and cleaning times increasingly important. 

Several features of the pan-based line assist with this: 

  • The M-DAN oven adapts temperatures quickly from one recipe to the next. 
  • Each module of the M-UB vertical handling system used in coolers and freezers can be bypassed to absorb process time variations without any output loss. 
  • The line is compatible with a large range of supports: flat pans, indented pans, and moulds in various formats. 
  • Product supports are cleaned continuously, so there is no need to stop production between two recipes. 

Control over organoleptic characteristics 

The baking process must reach the targeted product characteristics precisely: 

  • Effective pasteurization of the preparation 
  • Coagulation of the plant-based matrix without forming a surface skin 
  • Even or contrasted internal and external coloring 
  • Achievement of the desired texture and taste  

These objectives call for steam input at the start of baking, independently controlled energy inputs above and below the product, the use of radiation to limit drying, and precise hygrometry control. 

The M-DAN oven delivers all of this thanks to its compact, independent heating zones (under 25 m²) which provide a precise temperature curve. Each zone offers three combinations of heat transfer modes with fine control over intensity and hygrometry for a perfectly dosed energy input. 

Preserving the integrity of the product 

The plant-based preparation, whether liquid or pasty in consistency, is moulded into the desired shape and remains fragile from dosing to demoulding. To preserve its integrity and quality, it must stay on the same support throughout the entire process. 

Conveying on supports avoids product transfers, minimizes handling, and prevents marks on the product.The shock-free M-UB vertical handling system ensures smooth pan transfer through rotating movements when used in a pre-dryer, cooler, or freezer. 

Meeting the strictest sanitary requirements 

Rich in protein and water, plant-based preparations provide a favorable environment for microbiological growth, and chilled or frozen distribution leaves little margin for error. Pasteurization and cooling to below 10°C in less than two hours are the first pillars of food safety for this category, but their effectiveness depends on a flawless production environment. Pan conveying reduces cross-contamination risks, while the stainless steel equipment designed to minimize retention areas makes daily cleaning in accordance with HACCP requirements easier.  

Consistent quality, flexibility, food safety, and sustainable production: in a plant-based market that is still taking shape, MECATHERM’s industrial solutions provide a complete answer to these challenges while supporting manufacturers from the earliest stages of project design. 

Boost your performance and sustainability with our automated pan-based line.