Coperion to showcase scalable solutions for high-quality meat alternatives at IFFA 2025

Stuttgart-based process systems specialist Coperion will present its latest innovations in plant-based meat manufacturing at IFFA 2025, taking place in Frankfurt from May 3 to 8. With demand for high-quality meat substitutes continuing to rise, the company will showcase its integrated technologies at booth D70 in Hall 11, focusing on production efficiency, flexibility, and product quality.

Coperion’s exhibit will feature its established ZSK twin screw extruders, K3 vibratory feeders from Coperion K-Tron, and the MEGAtex S7 cooling die – a suite of tools designed to optimize the production of high moisture meat analogues (HMMA). These systems are intended to offer manufacturers end-to-end solutions that are both scalable and cost-effective.

“Our technologies allow manufacturers to optimize the texture and taste of meat alternatives while maximizing nutritional content at the same time,” said Stefan Gebhardt, Director of EMEA Technical Sales at Coperion. “By using innovative technologies, and thanks to our many years of process expertise, we can design our systems precisely to the needs of manufacturers.”

Central to Coperion’s plant-based meat processing technology is the ZSK twin screw extruder. Known for its flexibility and reliability, the ZSK system allows producers to effectively use diverse plant-based raw materials to create a wide range of textures and formulations. The extruders achieve rotation speeds of up to 1,800 rpm, enabling higher energy input to support protein breakdown during processing – a crucial step for achieving meat-like texture and taste.

The extruder’s design includes a screw diameter ratio (Da/Di) of 1.8, resulting in a larger free volume that improves the intake of protein powders and other low-flow materials. Its modular process section allows for rapid reconfiguration, supporting easy adaptation to new recipes and ingredient changes with minimal downtime.

To further enhance the extrusion output, Coperion will highlight the MEGAtex S7 cooling die, developed specifically for producing HMMA. This unit imparts a dense, fibrous texture to the protein mass after extrusion, closely replicating the structure of animal meat. The MEGAtex S7 offers adjustability in texture, width, and strength, and is designed for ease of use, allowing rapid switching between product formats.

Coperion’s system design also includes advanced feeding technologies that contribute to higher overall process efficiency and product consistency. At IFFA, the company will display a model from its K3 vibratory feeder line, known for its gentle material handling and high dosing accuracy.

Equipped with a patented drive system and advanced control units, the K3 vibratory feeders offer precision levels up to 35 percent higher than conventional systems, according to the company. This level of accuracy minimizes ingredient waste and supports cleaner transitions between product batches. Feed rates range from as low as 1 dm³/hr to 8,500 dm³/hr, making the feeders suitable for both pilot-scale and full-scale production.

These features are especially beneficial when working with delicate or brittle materials commonly used in plant-based meat formulations. Shorter retooling times and reduced downtime further contribute to operational efficiency.

Coperion supports its customers through a network of global Test Centers, where it conducts trials using various plant-based ingredients. These trials help manufacturers fine-tune their processes, test new formulations, and evaluate texture and sensory characteristics before scaling to full production.

“With the help of our Test Centers, customers can simulate real-world conditions and optimize their processes in advance,” said Gebhardt. “This significantly lowers the risk of production errors and ensures that final products meet both quality and sensory expectations.”

As the plant-based meat segment matures, the focus for manufacturers is shifting from novelty to quality, consistency, and efficiency. Coperion’s systems are designed to support this transition by offering scalable, modular technologies that adapt to changing consumer preferences and ingredient innovation.

At IFFA 2025, Coperion aims to demonstrate how its integrated extrusion, feeding, and conveying solutions can help manufacturers respond to growing market demand while minimizing waste and energy consumption.

The company’s full portfolio of solutions – from raw material intake to final texturization – is engineered to streamline production and improve the economics of plant-based meat processing. By consolidating interfaces and harmonizing process steps, Coperion offers a single-source platform that enables food producers to deliver better tasting, nutritionally optimized alternatives to conventional meat.