Dutch Structuring Technologies enhances precision in plant-based protein production

Dutch Structuring Technologies (DST), a Netherlands-based innovator in plant-based protein structuring, has integrated Rockwell Automation’s Kinetix servo solution into its production process. This advanced system enables DST to achieve the high-precision micro-dosing necessary for its new continuous meat-replacement technology, helping manufacturers create more realistic meat and fish substitutes while lowering energy consumption and increasing flexibility.

DST, headquartered in Wageningen, specializes in developing next-generation plant-based and hybrid protein solutions that closely mimic the texture and taste of conventional meat. The company’s new process, co-developed with mixing system specialist Sobatech and supported by Rockwell Automation distributor Routeco Netherlands, represents a departure from traditional extrusion-based methods. Instead, DST’s SHEARTEX technology utilizes precision-controlled continuous shearing and mixing to transform plant proteins and water into structured meat alternatives.

“Our focus is helping developers make new plant-based and hybrid products that are as close as possible to the meat-based ones they replace,” commented Julian Lekner, Co-founder of DST. “Food producers have been looking for the next big technology, and we believe that our SHEARTEX process answers their call. What's more, flavors and colors can be added directly, removing the need for post-processing steps.”

The continuous nature of the SHEARTEX process demands accurate control over mixing, dosing, and operational parameters to achieve the desired texture and structural integrity. Rockwell Automation’s Kinetix system provides the necessary precision to maintain these demanding conditions.

“The continuous method of operation demands incredibly accurate mixing, dosing, and parameter control to deliver the perfect texture,” explained Clint op den Buijsch, Sales Engineer at Routeco Netherlands. “This level of precision ensures that the final product consistently meets consumer expectations in terms of texture and mouthfeel.”

The adoption of DST’s SHEARTEX process is expected to lower production costs to levels comparable with animal-based proteins, a significant milestone in making plant-based alternatives more accessible to the mainstream market. Additionally, the ability to produce a wider variety of structured plant-based proteins could accelerate innovation in the sector, allowing food producers to diversify their offerings.

“The meat- and plant-protein markets are developing at a staggering pace,” said Roger Gaemperle, head of industry strategy and marketing, CPG and life sciences, EMEA, at Rockwell Automation. “New technologies and digitalization are expanding what is possible in terms of processing, control, and management. Meat replacement is seeing huge growth, but until now, extrusion has been the only widely available technology. This new shearing process will introduce a paradigm shift in terms of what is now achievable.”