Formulation, Texture, and Sensory Assessment of Novel Vegan Savory Protein Snacks

The present study describes the exploratory development of a refrigerated, vegan, clean-label, high-protein savory snack bar based on mycoprotein (Fusarium venenatum) and pea protein fractions, produced without E-number additives, conducted at Revo Foods GmbH, Vienna, Austria. A market gap analysis of ten commercially available products confirmed the absence of any directly comparable product in the European market combining a refrigerated bar format, mycoprotein-based primary protein, vegan composition, allergen-free ingredient declaration, and E-number-free positioning. A two-phase, one-variable-at-a-time (OVAT) screening approach was applied across ten pilot-scale formulation Development batches (Dev 1.1–Dev 3.2; Dev 4.1–Dev 4.4; 300 g wet weight). Phase 1 (binder screening, Development batches Dev 1.1–Dev 3.2) evaluated Bambu Fiber and Psyllium Husk Powder individually at inclusion levels of 2% and 5% (w/w), and Bambu Fiber in binary combinations with Psyllium Husk and Tapioka Starch. Bambu Fiber at 2% (w/w) was selected as the optimal binder (hardness: 880.6 ± 51.2 g; overall acceptability: 5.75 ± 0.96). Phase 2 (protein source screening) evaluated four secondary protein sources; Textured Pea Protein at 25% produced the highest hardness (3725.8 ± 635.9 g) but lowest juiciness (2.60 ± 1.82), while Pea Protein Isolate at 20% showed the most favorable combination of sensory acceptability and instrumental TPA (hardness: 3059.2 ± 803.4 g; overall acceptability: 5.60 ± 1.14; chewiness: 486.9 ± 72.4 g). No single protein source provided the optimal combination of firmness, juiciness, colour acceptability, and sensory quality, supporting further investigation of multi-protein formulations. The recommended formulation combines Mycoprotein (30%), Textured Pea Protein, and Pea Protein Isolate with Bambu Fiber at 2% (w/w) as binder. All batches were produced by high-shear mixing, manual shaping (8 × 4 × 1 cm), vacuum packaging, and steam pasteurisation at 100°C for 30 minutes (internal temperature >74°C; CCP satisfied). Sensory evaluation used a nine-point hedonic scale (n = 5, twelve attributes). The study establishes a feasible pilot-scale process, confirms Bambu Fiber as an effective clean-label binder, and provides a foundational formulation framework for this novel product category.