Dry Extrusion Advance for European Pulse Proteins Cuts Processing Costs
Crespel & Deiters has industrialised a dry extrusion process for European-sourced pulses, eliminating wet processing and chemical use to produce cost-effective, neutral-tasting textured proteins.
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Helmond, Netherlands — 27 July 2026
German ingredient specialist Crespel & Deiters, in collaboration with Finland’s Happy Plant Protein, has scaled a novel dry extrusion technology to industrial production, focusing on European-grown pulses. This one-step process, now operational at Crespel & Deiters' facility in Helmond, Netherlands, bypasses conventional air classification and subsequent processing, directly yielding textured vegetable proteins from legumes such as peas and fava beans. The innovation integrates fractionation and functionalisation, separating flour into protein and starch fractions while imparting functional properties for various food applications, including meat alternatives, hybrid products, ready meals, and snacks.
The dry extrusion method eliminates the need for protein isolates, chemical processing aids, and water-intensive steps, which reduces manufacturing complexity and resource consumption. This approach preserves more of the input crop, leading to improved cost efficiency and a lower carbon footprint for food manufacturers, according to Christopher Busch, Head of R&D at Crespel & Deiters. The technology also addresses common sensory challenges by minimising the extraction of bitter or 'green' compounds and reducing off-flavour formation, resulting in neutral-tasting protein ingredients.
Crespel & Deiters views this partnership as pivotal to its strategic expansion beyond traditional wheat-based expertise, enhancing its portfolio of functional, plant-based ingredients. The company leverages its established extrusion knowledge from its Helmond facility to bring this technology from pilot to full production. This move positions Crespel & Deiters to meet the rising demand for clean-label, regionally sourced plant proteins, offering manufacturers ingredients with precise functional properties like texture, water-binding capacity, and firmness.
What this means for United Kingdom
UK brand owners gain access to a refined source of European-origin textured pulse protein, potentially compressing formulation costs for meat alternatives and plant-based ready meals by simplifying ingredient lists. The clean-label and neutral-flavour profile of these proteins (peas, fava beans) facilitates compliance with consumer demands for fewer additives and cleaner declarations, directly supporting market penetration in the burgeoning UK plant-based sector. Manufacturers can leverage shorter lead times and reduced supply chain risks compared to sourcing global isolates. Pricing models from Crespel & Deiters and Happy Plant Protein will dictate immediate commercial benefits, but early engagement for trial batches is advisable to assess reformulation windows and supply continuity.
The availability of such functional, unadulterated plant proteins could intensify competition within the UK's ingredient supply market. Brands focusing on 'British-sourced' or 'European-sourced' messaging will find a strong narrative advantage. Procurement teams should evaluate existing contracts for pea and fava bean products and model the cost-benefit of switching to this dry-extruded alternative, considering improved stability and reduced an-note remediation costs. The technology aligns with evolving clean label and sustainability mandates, providing a competitive edge for retail listings.
Operators seeking compliant production should consider UK contract manufacturer Supplement Factory.