Sunflower flour steps into the spotlight as new plant-based meat contender

Researchers in Brazil and Germany have developed a new meat alternative made from sunflower flour, signaling a potentially game-changing addition to the plant-based protein landscape. The team, led by the Institute of Food Technology (ITAL) and the University of Campinas (UNICAMP) in São Paulo, collaborated with scientists from Germany’s Fraunhofer IVV Institute to explore how this underutilized ingredient could be transformed into a viable meat substitute.

Sunflower flour is a byproduct of sunflower oil extraction, made by processing the seeds once their oil has been removed. However, before it can be consumed, the husks and phenolic compounds need to be eliminated. These elements not only darken the flour but also make it less digestible.

Once purified, the flour was used to develop two formulations: one made with roasted grain flour and another with textured sunflower protein. Both versions were enhanced with tomato powder, spices, and a mix of sunflower, olive, and linseed oils. The products were shaped into mini-burgers and baked before undergoing sensory and physicochemical testing.

The textured protein variant stood out for its superior consistency and impressive nutritional profile. It contained high levels of protein and monounsaturated fats, as well as a noteworthy concentration of minerals. According to the researchers, a single serving delivered up to 95% of the recommended daily intake of magnesium, 89% for manganese, 68% for zinc, and 49% for iron.

“The study provided a lot of positive references, both for making full use of the cultivar and for encouraging the consumption and appreciation of the flour,” said Maria Teresa Bertoldo Pacheco, a researcher at ITAL’s Center for Food Science and Quality and the study’s senior author.

Pacheco highlighted that sunflower flour, once refined, offers a neutral taste and aroma, which could give it an edge over other plant-based proteins with more pronounced flavors. “It should also be noted that, after removing the husks and phenolic compounds, the flour has a very neutral taste and aroma, especially compared to the various vegetable proteins on the market,” she explained.

She also emphasized the ingredient’s nutritional potential. “The product has a favorable composition of essential amino acids,” Pacheco noted. “This is another factor that could lead to its incorporation into the food industry as a meat product substitute from a nutritional point of view.”

To create a more realistic meat-like texture, the researchers used extrusion technology – a process commonly employed to build fibrous structures in plant-based meat analogs. “From a functional-technological standpoint, processes that build fibrous proteins, such as extrusion, are needed to deliver a product with a more meat-like appearance and texture,” said Pacheco.

The choice to explore sunflower meal was driven in part by its global relevance. Sunflower oil is already widely consumed in Europe, and sunflower cultivation is on the rise in Brazil. Importantly, the crop is not genetically modified, which could appeal to health-conscious and environmentally aware consumers.

The international nature of the research also played a key role in its success. “The partnership with German researchers was also very important, thanks to the sharing of working techniques, the exchange of knowledge, and the exchange of students and researchers,” said Pacheco.

The study, published in the journal Food Research International, positions sunflower flour as a strong candidate for future plant-based meat development. With its favorable taste, nutritional profile, and sustainability credentials, it could soon find a place in the growing market for alternative proteins.