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), aimed 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 supported more sustainable food production and reduced 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
A variety of locally grown pulses were used to develop nutritious and convenient pre-cooked products. These included both single and mixed pulse formats, served in tomato-based and internationally inspired sauces (like Indian and Mediterranean).
Each pulse type underwent optimised processing steps – like dehulling and soaking – suitable for commercial-scale production. Efficient retort and cook-chill methods were tested to ensure food safety, desirable texture and extended shelf life. Proof-of-concept products were be packaged in a range of formats to suit diverse market opportunities.
Products with higher preliminary sensory ratings were selected for further sensory evaluation.
Prototype products also underwent microbial safety testing following packaging and the relevant retort or cook-chill process, in accordance with Standard 1.6.1 of the Australia New Zealand Food Standards Code.
Outcomes
This project explored 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.
- This project showed that Australian-grown faba beans, green peas and yellow peas can be used to make canned and Ready-To-Eat products that are appealing to customers.
- Soaking whole faba beans, green peas and yellow peas in water for 18 hours improved water absorption, reduced cooking time, and helped achieve the desired texture. Split faba beans did not require soaking and could be processed with shorter cooking times.
- The sensory results showed that texture and sauces selection are important for consumer acceptance. Consumers preferred pulses with a firm texture rather than mushy texture. The appearance of the pulse and sauce combination was also important. Cherry tomato, Moroccan and Rogan Josh sauces were accepted across multiple pulse types.
- All three processing formats tested (canning, hot filling, and Modified Atmosphere Packaging or MAP ready-to-eat meals) were suitable. Hot-filled and MAP products showed good microbiological stability during shelf-life testing. Canned products also showed good potential, however, some further work under commercial processing conditions is still needed.
- Overall, the value-added products had good taste, texture, and appearance, and the project showed that Australian grown pulses can be used to create appealing and safe food products.
