Abstract The aim of this study was to find the optimum extrusion process conditions for texturized soybean meal as a meat analogue for food formulations using genetic algorithm. The defatted soybean meal was replaced with whole soybean meal at 10% and extruded in the temperature range of 150–200 .C, screw speed of 270–300 rpm and 20–25% feed moisture content based on the Box–Behnken design. The barrel temperature effect was markedly greater than those of the feed moisture content and screw speed on the product functional properties and appearance. Higher temperatures led to a higher rehydration capacity, water and oil absorption capacity, however, it had a negative effect on the product brightness. It was found that the extrusion at lower moisture content improved soy protein functionality. Genetic algorithm technique was applied to find the best process conditions. The optimized process conditions were found to be the temperature of 198.8 .C, screw speed of 291 rpm and feed moisture content of 20.2%. Overall, the whole soybean treatment was applicable to overcome the oil separation issue during extrusion and the process was optimized to produce texturized soy protein with the maximum attainable functionality.

Keywords