The use of thickeners in plant protein beverages from laboratory to industrial production

Thickeners play a crucial role in Plant Protein Beverages by improving texture, stability, and shelf life. The global market for these beverages is expected to reach over USD 2,689.3 Million by 2035, growing at a 9.6% annual rate. Product developers face several challenges:

• Masking strong or unpleasant flavors and aftertastes
• Managing shelf life and product stability due to moisture absorption
• Preventing clumping and improving solubility
• Achieving a smooth mouthfeel without chalkiness

Understanding how to select and use thickeners from lab to industrial scale helps teams create beverages that meet consumer expectations.

Key Takeaways

• Thickeners improve plant protein beverages by creating a smooth texture, enhancing stability, and extending shelf life.
• Choosing the right thickener depends on the type of plant protein and the desired mouthfeel and stability.
• Proper mixing techniques and equipment are essential to prevent clumping and ensure even dispersion of thickeners.
• Scaling up production requires careful control of viscosity, consistency, and stability to maintain product quality.
• Using stabilizers, emulsifiers, and processing methods like extrusion and microgelation helps achieve a creamy, stable beverage.

Thickeners in Plant Protein Beverages

Texture and Mouthfeel

Thickeners play a vital role in shaping the sensory experience of Plant Protein Beverages. Many consumers expect these drinks to have a creamy, smooth texture similar to dairy milk. However, plant-based proteins often create a gritty or chalky mouthfeel. Food scientists use thickeners to address this challenge. Gums such as xanthan, guar, and acacia gum help create a smoother texture and improve mouthfeel. These ingredients increase viscosity, making the beverage feel richer and more satisfying.

Research shows that thickening agents change both the sensory and physical properties of plant-based milk alternatives. By increasing viscosity, thickeners enhance creaminess and help mimic the mouthfeel of dairy milk. For example, casein micelle aggregation in dairy and the use of κ-carrageenan demonstrate how protein-thickener interactions can influence perceived creaminess. In Plant Protein Beverages, the right combination of thickeners and processing methods, such as high-pressure homogenization or heat treatment, can further improve texture and sensory acceptance.

Tip: A balanced use of thickeners and processing techniques helps overcome the common challenges of plant-based drinks, which often have less stability and a less smooth mouthfeel than dairy-based options.

Stability and Shelf Life

Stability remains a major concern for Plant Protein Beverages. Without proper stabilization, these drinks can separate, form sediments, or develop an unappealing layer of fat on top. Several factors contribute to instability:

• Sedimentation of protein particles
• Fat separation and creaming
• Flocculation due to low saturated fat content
• Starch-related viscosity changes in cereal-based drinks

Thickeners such as carrageenan, gellan gum, and carboxymethyl cellulose (CMC) help address these issues. Carrageenan interacts with proteins to form a three-dimensional network that traps both protein and fat, reducing separation and sedimentation. Gellan gum forms a gel structure that suspends particles, even without protein interaction, which improves both mouthfeel and stability. CMC, derived from cellulose, also helps maintain uniformity by increasing viscosity and preventing particles from settling.

A well-chosen combination of thickeners and emulsifiers ensures that Plant Protein Beverages remain stable throughout their shelf life. Emulsifiers reduce the tendency of fat globules to merge, while thickeners keep particles suspended. This approach results in a beverage that looks appealing, pours smoothly, and maintains its quality over time.

Plant Protein Beverages benefit from these thickeners, which help manufacturers deliver products that meet consumer expectations for both taste and appearance.

Types of Plant Protein Beverages

Soy-Based

Soy-based beverages remain a staple in the plant-based market. Their protein content consists mainly of globular proteins, which differ from the casein found in dairy milk. This difference changes how thickeners interact with soy proteins. For example, kappa and kappa-2 carrageenan show minimal interaction with soy proteins, while iota and lambda carrageenan form stronger bonds. The choice of carrageenan type affects gel strength and stability. Cations such as potassium and calcium also influence the final texture. Product developers must consider these biochemical interactions to achieve the desired mouthfeel and suspension in soy-based drinks.

Oat and Cereal-Based

Oat and cereal-based beverages present unique challenges for thickener functionality. Pectin, a common thickener, interacts with oat components and lactic acid bacteria starter cultures, leading to variable effects on texture. Most starter cultures are designed for dairy, not plant-based fermentation, which complicates consistency. Oat proteins have limited thickening ability due to their denatured state and low content. Manufacturers often add oat protein isolates or concentrates to improve texture. Chemical or enzymatic modifications further enhance gelling and water-holding properties. These steps help overcome the natural limitations of oat proteins in Plant Protein Beverages.

Note: Achieving consistent texture in oat and cereal-based beverages requires careful selection of thickeners and processing methods.

Nut and Seed-Based

Nut and seed-based beverages rely on hydrocolloids such as locust bean gum, gellan gum, xanthan gum, and acacia gum to improve stability and mouthfeel. These thickeners suspend plant particles and reduce sedimentation. The interaction depends on concentration, pH, and the presence of minerals and sugars. Emulsifiers like lecithin enhance creaminess by stabilizing air bubbles and reducing oxidation. Processing methods such as homogenization and ultra-high pressure homogenization reduce particle size, creating a smoother, creamier drink. The combination of thickeners and emulsifiers is essential for achieving a uniform texture and preventing separation during storage.

Pea and Legume-Based

Pea and legume-based beverages often face issues with sedimentation and phase separation. Guar gum stands out as the most effective thickener, providing rapid hydration and maintaining stability. Locust bean gum and pectin also offer benefits, such as improved color and texture. The choice of thickener influences not only stability but also the sensory qualities of the beverage, helping to replicate the properties of cow’s milk.

Common Thickeners

Gums and Polysaccharides

Gums and polysaccharides serve as essential thickeners in many plant-based drinks. These ingredients, such as xanthan gum, guar gum, gellan gum, and tara gum, help improve viscosity, stabilize emulsions, and prevent sedimentation. They come from renewable, plant-based sources and support clean label claims. Many manufacturers choose these thickeners for their multifunctional roles and natural origin.

Natural thickeners like citrus fiber, tapioca starch, and lecithin also support clean label trends. These ingredients often come from non-GMO and organic sources, meeting consumer demand for transparency and sustainability.

Cellulose Derivatives

Cellulose derivatives, such as carboxymethyl cellulose (CMC), offer excellent solubility and stability in Plant Protein Beverages. CMC, derived from cellulose, interacts with proteins to enhance viscosity and prevent sedimentation. It works by creating electrostatic repulsion and steric hindrance, which keeps particles suspended and improves shelf life.

These cellulose-based thickeners provide reliable performance and are widely accepted in food applications.

Microbial Exopolysaccharides

Microbial exopolysaccharides, such as xanthan gum and gellan gum, are produced by fermentation. They deliver consistent thickening, gelling, and stabilizing properties. These ingredients help manufacturers achieve uniform texture and stability in plant-based drinks. Many of these thickeners are considered natural and align with clean label requirements.

Tip: Companies continue to innovate with natural and clean label thickeners, offering new solutions that improve texture, stability, and nutritional value in plant-based beverages.

Lab-Scale Incorporation

Selection and Screening

Scientists begin by selecting thickeners based on the desired texture, stability, and compatibility with plant proteins. They often review guide formulations from similar products to predict how a thickener will behave. Screening involves testing different types and concentrations of thickeners in small batches. This process helps identify which ingredients deliver the best mouthfeel and stability. Researchers also consider how thickeners interact with other ingredients, such as sweeteners or minerals. They may use technical case studies to compare performance and select the most promising options.

Mixing and Hydration

Proper mixing and hydration are essential for achieving consistent results. The way a thickener is added can affect its performance. Scientists follow these best practices:

• Add thickener powders slowly onto the liquid surface when using conventional agitators. This step helps prevent lumps and fisheyes.
• Use high shear mixers to add the powder all at once, but quickly and in a controlled manner. This method ensures rapid dispersion and hydration before the mixture thickens.
• Prepare premixes or suspensions for some thickeners to improve spreading and compatibility.
• Add gums and thickeners last in the formulation. This approach allows other powders to disperse easily while viscosity remains low.
• Investigate hydration conditions, such as water hardness and shear forces, to optimize thickener performance.

Tip: High shear mixing can perform several tasks at once, such as dissolving, emulsifying, and homogenizing, which saves time and improves consistency.

Evaluation Methods

After mixing, scientists evaluate the samples using both sensory and analytical methods. They measure viscosity at different shear rates to understand how the beverage will behave during pouring and drinking. They also check for sedimentation, phase separation, and overall appearance. Sensory panels may taste the samples to assess mouthfeel and creaminess. Researchers use these results to refine the formulation and select the best thickener for further development.

Scale-Up Challenges

Dispersion Issues

Scaling up from laboratory to industrial production introduces new challenges in dispersing thickeners. Larger batch sizes often lead to bigger particle sizes and uneven mixing. Standard mixing equipment may not fully disperse thickening agents. This can cause oil separation, clumping, and waste from undissolved materials. Many facilities face these problems:

• Inadequate reduction of particle size in soy, seed, coconut, and grain-based drinks
• Agglomerate formation due to poor mixing
• Equipment that is hard to clean and does not meet sanitation standards
• Difficulty forming stable emulsions with simple agitators

Specialized high-shear mixers, such as Silverson mixers, help solve these issues. These machines use suction, milling, and hydraulic shear to break down particles and create stable emulsions. Advanced mixing technology ensures thorough dispersion and reduces waste.

Viscosity Control

Controlling viscosity during scale-up requires careful attention. Processing conditions must be optimized to maintain the desired texture. Stabilizing agents play a key role in managing viscosity and functional challenges. Plant protein fluids often show complex, non-Newtonian behavior, which means their thickness changes under different conditions. Using pilot-scale steps before full industrial production helps avoid sudden changes in viscosity. Selecting scalable mixing equipment and controlling both mechanical action and temperature are important. These strategies help keep product texture and viscosity consistent as production increases.

Consistency and Stability

Maintaining consistency and stability in large-scale production depends on the right use of stabilizers. These additives prevent sedimentation, protein aggregation, and unwanted changes in viscosity. Hydrocolloids like xanthan gum, carrageenan, and guar gum provide gelling, thickening, and emulsifying properties. Leading companies develop custom stabilizer blends for different plant protein bases and clean-label needs. Stabilizers help keep mouthfeel and sensory appeal uniform throughout shelf life. They also support ready-to-drink products by ensuring proteins and nutrients stay evenly mixed. The use of natural stabilizers meets consumer demand for clean-label products and supports regulatory compliance.

Note: Planning for future expansion, ensuring proper facility utilities, and designing for food safety are also critical steps in successful scale-up.

Industrial Production

Mixing Technologies

Industrial-scale production of plant-based beverages requires advanced mixing equipment to ensure product consistency and quality. Manufacturers often face challenges such as powder clumping, long batch times, and buildup on mixing equipment when incorporating thickeners like gums and starches. Specialized mixing technologies help solve these problems by dispersing powders efficiently and preparing uniform pre-emulsions.

These technologies allow manufacturers to add powders beside the tank, minimize the number of passes through homogenizers, and reduce downtime. As a result, batch times decrease, and product quality improves. High shear mixers and inline systems also support continuous production, which is essential for meeting large-scale demand.

Tip: Choosing the right mixing technology can prevent common issues like “fish eyes” (clumps of undispersed powder) and ensure a smooth, stable beverage.

Extrusion Processing

Extrusion processing has become an important step in the production of plant-based beverages. This method uses high temperature and strong shear forces to change the structure of plant proteins. During extrusion, proteins unfold, and their bonds break and reform, leading to protein aggregation. These changes affect how proteins dissolve and form gels, which are key factors for thickening and stabilizing beverages.

When extrusion modifies protein structure, it can improve or reduce the effectiveness of thickeners. For example, better solubility can help proteins blend more easily with thickeners, creating a smoother texture. However, too much aggregation may lower the ability of proteins to hold water or form stable gels. Manufacturers must carefully control extrusion conditions to achieve the desired texture and viscosity in Plant Protein Beverages.

Note: Adjusting extrusion parameters allows producers to fine-tune the mouthfeel and stability of their beverages.

Quality Control

Quality control ensures that every batch of plant-based beverage meets safety and sensory standards. Production teams monitor several factors during and after processing:

• Viscosity: Regular checks confirm that the beverage has the right thickness and mouthfeel.
• Particle Size: Teams use instruments to measure and control the size of suspended particles, which affects smoothness and stability.
• Homogeneity: Visual inspections and laboratory tests help detect separation or sedimentation.
• Microbial Safety: Routine testing prevents contamination and ensures shelf life.
• Batch Consistency: Automated systems track ingredient addition, mixing times, and temperatures to maintain uniformity.

Manufacturers often use inline sensors and automated sampling to monitor these parameters in real time. This approach helps catch problems early and reduces waste. Continuous improvement and strict quality control help companies deliver Plant Protein Beverages that meet consumer expectations for taste, texture, and safety.

Best Practices

Formulation Tips

• Manage viscosity and mouthfeel by understanding how plant proteins aggregate. This step helps prevent gritty or overly thick textures.
• Use stabilizers and emulsifiers to stop sedimentation and phase separation. These ingredients keep the beverage smooth and stable during storage.
• Choose pea protein for its strong emulsifying properties. It forms protective layers around oil droplets, which improves stability.
• Adjust pH and use enzymatic treatments to boost protein solubility. These methods help thickeners work better and create a more uniform drink.
• Select proteins with low viscosity and high heat stability, such as Vivitein™ BLG. These proteins support a creamy texture and prevent unwanted changes during processing.
• Consider how proteins behave under different pH and heat conditions. This approach ensures both microbial safety and shelf stability.

Tip: Always test small batches first to see how new ingredients affect texture and stability.

Process Optimization

• Apply microgelation to crosslink plant proteins into tiny, stable microgels. This process gives better control over viscosity and improves stability.
• Use microgels to enhance lubrication, which reduces friction and astringency. This change leads to a smoother mouthfeel.
• Adjust protein concentration and crosslinking density to fine-tune the properties of microgels. This flexibility helps match consumer preferences for texture.
• Perform tribological testing to measure lubrication and predict mouthfeel. This step supports product development and quality control.
• Use thermal gelation followed by controlled shearing to create microgels. This method mimics the smoothness of oil-in-water emulsions without adding extra fat.

Note: Microgels behave more like Newtonian fluids, which means they stay stable and resist clumping during processing.

Troubleshooting

• If the beverage feels gritty, check for incomplete hydration or protein aggregation. Increase mixing time or adjust the order of ingredient addition.
• When sedimentation occurs, review the type and amount of stabilizer. Try increasing the dosage or switching to a more effective gum.
• If viscosity changes after storage, monitor temperature and pH during processing. Use proteins with better heat stability to prevent thickening or thinning.
• For phase separation, ensure proper emulsifier use and verify that all powders are fully dispersed before thickening agents are added.

Tip: Keep detailed records of each batch. This practice makes it easier to identify and fix problems quickly.

Thickeners help manufacturers create Plant Protein Beverages with smooth texture and long shelf life. Scale-up brings challenges like mixing and stability. Teams should apply best practices and keep improving their process. For more on advanced formulation and processing, industry journals and technical workshops offer valuable insights.

FAQ

What is the main purpose of thickeners in plant protein beverages?

Thickeners improve texture and stability. They help the beverage feel creamy and smooth. Thickeners also prevent particles from settling at the bottom. This keeps the drink looking and tasting good.

Are all thickeners considered clean label ingredients?

Not all thickeners meet clean label standards. Some, like acacia gum and citrus fiber, come from natural sources and support clean label claims. Others may require chemical processing. Manufacturers should check ingredient origins for clean label status.

How do manufacturers prevent clumping when adding thickeners?

Manufacturers use high shear mixers and add powders slowly. This method helps thickeners dissolve evenly. Premixing thickeners with other dry ingredients also reduces clumping.

Can thickeners affect the taste of plant protein beverages?

Yes, some thickeners can change the taste. Most have little flavor, but high amounts may cause off-notes. Product developers test different levels to keep the taste neutral.

Which thickener works best for soy-based drinks?

Carrageenan and xanthan gum both work well in soy-based beverages. They help create a smooth, stable drink.