Meat Analogue Extruder

The Bonnot Meat Analogue Extruder is a single-screw extrusion system engineered for medium- to high-moisture meat analogue (HMMA) production, used to make plant-based and hybrid poultry, beef, pork, and seafood products. It replaces traditional batch processing with continuous output, and it costs and operates significantly less than twin-screw extruder systems while integrating into existing meat and poultry processing lines. The system was developed by The Bonnot Company in collaboration with Ortiz Process Technologies LLC.

What the System Does

The Bonnot Meat Analogue Extruder produces high-moisture meat analogue (HMMA) — fibrous, layered protein products that mimic the texture of whole-muscle meat. The system uses a single-screw extruder (SSE) paired with a metering pump and a cooling die assembly. A hollow compression screw running a long L:D ratio induces mechanical shear through the formulation, while multiple jacketed barrels provide zoned temperature management. The result is a continuous process that can be run in place of a traditional batch operation. What the System Does The Bonnot Meat Analogue Extruder produces high-moisture meat analogue (HMMA) — fibrous, layered protein products that mimic the texture of whole-muscle meat. The system uses a single-screw extruder (SSE) paired with a metering pump and a cooling die assembly. A hollow compression screw running a long L:D ratio induces mechanical shear through the formulation, while multiple jacketed barrels provide zoned temperature management. The result is a continuous process that can be run in place of a traditional batch operation. The system has been validated in R&D testing with soy concentrate and wheat gluten formulations, achieving good fibrous texture at total liquid content up to 67% and oil addition up to 7%. Why Single Screw Instead of Twin Screw Most HMMA production today relies on twin-screw extruders. The Bonnot single-screw approach is built to deliver comparable product results at a fraction of the capital and operating cost. A twin-screw extruder system can cost roughly 4× the price of a single-screw extruder cooker. Beyond the purchase price, the single-screw system simplifies controls — one inlet and one outlet per cooling section — and can run on steam rather than the electrical energy that twin-screw systems typically require, which lowers energy cost in most regions where gas is cheaper than electricity. Because the SSE-and-pump combination can use existing cooling die assemblies, processors can free up their twin-screw capacity for other products rather than dedicating it to analogue runs. The single-screw design also opens up formulation flexibility that some existing processes can't accommodate, making it suitable for blended plant-and-animal protein and lipid systems as well as fully plant-based products. The system has been validated in R&D testing with soy concentrate and wheat gluten formulations, achieving good fibrous texture at total liquid content up to 67% and oil addition up to 7%.

How It Fits Into a Processing Line

The extruder is designed to be synergistic with existing meat and poultry facilities rather than requiring a purpose-built plant. Upstream, formulations must be pre-mixed before extrusion. Depending on the recipe, suitable mixers include slide-gate paddle mixers, slide-gate ribbon mixers, sigma blade mixers, or double-auger meat mixers. High-liquid or high-soluble-solid formulations tend toward a dough-like consistency, while non-soluble and lower-liquid formulations produce a crumbly, flowable mixture. Downstream, the extruded sheet can feed into standard protein-processing equipment: pricking conveyors (to penetrate the sheet for easier marination), vacuum tumblers or brine injectors, sear markers or continuous grilling lines, cutting systems, ovens for cooking or steaming, breading and par-frying lines, and IQF or refrigeration freezing.

The Meat Analogue Extruder is offered in three series spanning pilot-scale through high-volume production.

Available Sizes and Specifications

CO 2.25 Series

CO 2.25 Series
100 – 175
Approximate layout (L × H × W, in)
110 × 60 × 70
Hopper opening (in)
6 × 5
Extruder motor power (HP)
3/10
Metering pump capacity (cc/rev)
20
Metering pump output (lb/hr)
26 – 70
Metering pump motor power (HP)
3

Applications
The primary application is meat analogue production — plant-based and hybrid poultry, beef, pork, and seafood. The same single-screw platform also serves a broad range of other industries: bulk moulding compound, carbon, chemical catalyst, clay, cold forming, fire log, food forming, hydrocolloid, pet food and treats, rodenticide, rubber, and sealants.
The Sustainability Case
For processors evaluating analogue production on environmental grounds, plant proteins require less energy to produce, process, and transport than animal protein, and the production figures are substantial. Livestock production accounts for an estimated 18% of global greenhouse gas emissions — more than transportation. By comparison, published figures for a chicken analogue indicate 75–90% less water use and a 77–87% carbon reduction versus conventional chicken, with even larger differences for beef analogue versus beef. These reductions, combined with growing global protein demand, are central to the commercial case for HMMA capacity.

Frequently Asked Questions

What is a meat analogue extruder?
It is an extrusion system that converts protein formulations — typically soy concentrate, wheat gluten, and similar ingredients — into fibrous, layered products that replicate the texture of meat. The Bonnot version uses a single screw and is designed for medium- to high-moisture meat analogue (HMMA) production.
What is the difference between high-moisture and low-moisture meat analogue?
High-moisture meat analogue (HMMA) produces whole-cut, fibrous textures resembling intact muscle and is the focus of this system. Low-moisture extrusion typically produces dry textured vegetable protein (TVP) that is rehydrated later. The Bonnot system is built for medium- to high-moisture work, validated to total liquid content up to 67%.
How does a single-screw extruder compare to a twin-screw extruder for meat analogue?
A single-screw system is substantially less expensive — a twin-screw system can cost around 4× as much — and simpler to control, with one inlet and one outlet per cooling section. It can run on steam rather than electrical energy and can use existing cooling die assemblies, leaving any twin-screw capacity available for other products.
Can this integrate with my existing meat or poultry plant?
Yes. The system is designed to work alongside existing meat and poultry processing facilities and to feed standard downstream equipment such as tumblers, brine injectors, grilling lines, cutting systems, ovens, and freezers.
What throughput is available?
Three series cover 100–175 lbs/hr (CO 2.25), 600–1,000 lbs/hr (CO 4), and 1,500–2,500 lbs/hr (CO 6) at the extruder.
What formulations has the system been tested with?
R&D testing has demonstrated good texture using soy concentrate and wheat gluten, with oil addition up to 7% and total liquids tested to 67%.
Who developed this system?
The Meat Analogue Extruder was developed by The Bonnot Company in collaboration with Ortiz Process Technologies LLC.