Project background
Disappointment with plant-based meat alternatives is growing. Many consumers find them costly, overly processed, and lacking in flavour and texture. At the same time, there's increasing demand for nutritious, minimally processed foods made from familiar ingredients.
This project, funded by the South Australian Grain Industry Trust (SAGIT). aims to reimagine plant-based protein in the form of 'fancy baked beans' using locally grown pulses like faba beans, chickpeas, field peas and lentils. By tapping into existing domestic grain supply chains, the project supports more sustainable food production and reduces reliance on imported ingredients.
Objectives
- Develop a range of convenient, appealing and nutritious pre-cooked food products using local pulses—including faba beans, field peas, chickpeas and lentils—as single varieties and mixed combinations.
- Test a broad selection of international-style sauces that pair well with pasta, rice, corn chips, toast, potatoes and salads.
- Identify optimal commercial-scale processing methods for each pulse type (dehulling, splitting, soaking, for example), aiming to reduce handling and processing time while achieving desired texture and extended shelf-life in canned or pouch formats.
- Package proof-of-concept products in multiple formats—including cans, pouches and bulk cook-chill plastic bags—and assess their performance through testing with consumers, food manufacturers and retailers.
Research approach
Product development
A variety of locally grown pulses will be used to develop nutritious and convenient pre-cooked products. These will include both single and mixed pulse formats, served in tomato-based and internationally inspired sauces (like Indian and Mediterranean).
Each pulse type will undergo optimised processing steps—like dehulling and soaking—suitable for commercial-scale production. Efficient retort and cook-chill methods will be tested to ensure food safety, desirable texture and extended shelf life. Proof-of-concept products will be packaged in a range of formats to suit diverse market opportunities.
Sensory analysis
Products with higher preliminary sensory ratings will be selected for further evaluation. A larger panel of up to 30 participants will assess these using a validated consumer acceptance method in the SARDI sensory laboratory.
Microbial analysis
Prototype products will undergo microbial safety testing following packaging and the relevant retort or cook-chill process, in accordance with the Food Standards Code 1.6.1.
Expected outcomes
This project explores the potential of locally grown pulses to create value-added food products that resemble premium “baked beans”. While this may sound modest, the Australian baked bean market is valued at around $600 million per year (130,000 tonnes), with 3% annual growth, and is almost entirely based on imported navy beans.
The initial phase focused on identifying processing steps that optimise flavour and texture. Tests included soaking durations, stove-top cooking times, retort processing times, and timing of sauce integration. For example, unsoaked, dehulled split faba beans broke down during cooking and retorting, suggesting they are better suited as a natural sauce thickener, reducing the need for starch-based thickeners.
Whole hulled faba beans were trialled with different soaking, cooking and cooling times. Although chickpeas are softer in texture, they scored highest in sensory testing when processed under the same conditions as whole faba beans.
The second phase tested sauce compatibility. So far, yellow peas, green peas, lentils, and faba beans (including mixed varieties) have been paired with a range of tomato-based and Asian-inspired sauces. Participants generally accepted the pulse textures well. Some initially found whole faba beans firmer than expected but later appreciated their texture.
Feedback highlighted the importance of matching sauces and pulses. Participants preferred flavour pairings that were complementary but not overpowering. For example, Thai green curry and rogan josh were more popular than plainer sauces. The overall visual appeal of the dish also played a key role in consumer preference.
Nutritional panels have now been developed for each pulse-sauce combination. The project has entered its commercialisation phase, with ongoing discussions with industry partners. These conversations are helping to align product development with manufacturer needs and ensure a smooth transition to market. They are also shaping future product development work by focusing on commercially relevant questions.