Art meets science: PlantFusion balances sources to unlock complete vegan protein powders

Amid a booming demand for protein, there is a growing interest in plant-based protein powders for their sustainability prospects, compatibility with dietary restrictions, and appeal to flexitarian consumers. However, health-conscious consumers seek “complete” proteins to match animal-based sources, which can be challenging using plants.

Nutrition Insight meets with PlantFusion’s CEO, Phil Vigeant, to discuss how the company explores combinations of new, plant-based sources and occasionally supplements with vegan amino acids to create complete, sustainable protein powders with a taste and texture consumers expect.

“Honestly, it’s tough,” he admits. “When people talk about a truly complete protein, that typically comes from animal sources.”

“But we can get creative. We analyze the amino acid profiles of different plant proteins and do our best to balance them out, while also considering flavor and texture challenges.”

Vigeant says it’s a “mix of art and science.” For example, lentil or fava protein might complement pea protein and boost branched-chain amino acids. However, the taste or texture profile can be challenging to work with.

In addition, he explains that the company sometimes adds vegan-sourced amino acids to its products to fill any gaps in the profile while staying true to its vegan positioning. 

“It is extremely difficult to match animal protein exactly to make a complete protein or contain high levels of branched-chain amino acids consumers look for. But we can get very close with this combination of sources and supplementation.”

“And, of course, we’re always exploring new protein sources as they come to market.”

Legume protein sources

PlantFusion is exploring different sources for plant protein, such as legumes. “We’re looking at everything right now,” says Vigeant. 

He observes a confluence of alternative sources. “And because manufacturing of proteins like rice, soy, and pea has become so common, some of the same technologies and processes to extract proteins from those products are now being used on newer sources.”

In this recent interview, Phil Vigeant explains how PlantFusion develops new products.Vigeant highlights chickpea protein as a standout ingredient the company is interested in, though it hasn’t introduced it yet due to sourcing challenges. “Chickpea has been around for a while, but manufacturers struggle to create it commercially, sustainably, and consistently.”

Chickpea protein is relatively neutral in taste and contains “a lot of oil,” he details. “Depending on how it’s made, it tends to have a nice texture, and because it contains more fat and oil, it tends to have good food application properties. Therefore, it’s more functional in terms of applications.” 

For example, companies have used it in pasta or nutrition bars. 

New format developments

Vigeant observes two trends in animal proteins that may spill over to vegan alternatives: clear proteins and peptides. 

“Clear proteins are gaining momentum. We’re seeing strong online and retail trends — that delivery system is becoming very popular. As usual, animal proteins have led the way, but we’re exploring how to bring the same concept to plant-based proteins.”

“Instead of a traditional thick protein shake or smoothie — which many people, myself included, sometimes find too filling or causes bloating — clear proteins offer a lighter alternative.”

He says research indicates that many consumers, especially women, value such clear alternatives, as they want to feel satiated but not overly full or uncomfortable. 

PlantFusion blends diverse plant proteins and vegan amino acids to create powders that rival animal-based protein.“Another area is peptides,” Vigeant continues. “Most of the research on peptides has been in the animal protein space. But we see a big opportunity for plant-based peptides.”

He notes that various consumers — whether for vegan, religious, or allergen-related reasons — are left out of the peptide trend entirely. “We believe there’s a real unmet need for plant-based peptides, and in the past couple of years, we’ve seen several ingredient suppliers come to market with promising sources.” 

Balancing act

According to Vigeant, one of the significant issues when introducing alternative, vegan proteins to the market is their taste and texture. 

“Plant proteins are inherently tougher to work with from an organoleptic standpoint than whey protein or caseinates. Those are naturally sweet, they taste good, we’re used to the flavor systems, and they match with many other foods we eat.”

He says it’s a delicate balancing act to combine different sources for organoleptics and functionality while keeping cost in check. “We look at it like an open menu and explore how they balance themselves.’

“Another important factor is what manufacturers do with the other parts of the plant. For example, pea protein, fiber, and starches are used in other applications, such as noodles or fiber-based products. That balancing act often drives cost.”

Exploring algae

A vegan alternative Vigeant is excited to explore is algae protein, with its potential for environmentally friendly sourcing and “phenomenal nutritional properties” for human and animal health. 

However, algae organoleptics is a crucial challenge to overcome in successful algae protein powders. “When you say algae, people immediately think of the sea, fish, and smell.” 

“Years ago, I was working on a product where we tried to add more algae. We could mask the smell in the early stages of the product. But over time, especially if the product sits in a jar or is exposed to heat, the smell and flavor intensify — even if the product itself hasn’t gone bad.”

Algae protein offers exceptional nutritional potential, yet overcoming its intense flavor and aroma remains a key hurdle for product development.“I believe we’ll eventually find a great source of algae protein,” he notes. “It has enormous potential — not just nutritionally, but across the entire supply chain. From production to the consumer, it could provide functional and nutritional benefits.”

Finding market gaps

PlantFusion starts its product development process by determining if a new ingredient is better or different on the market. It examines whether it delivers meaningful value. 

“Products don’t always have to be revolutionary, but they need to be either among the first of their kind or significantly improved versions of what’s already out there,” says Vigeant.

“We stay on top of new ingredients, with new ones coming to the market weekly. Suppliers often approach us with new options. Sometimes these are traditional ingredients and a commodity on the market, but an ingredient supplier determines how to make them more bioavailable or improve the taste.” 

He says the company evaluates many ingredients and occasionally discovers something that fills a gap in the market, where consumers don’t know they want something until they see it. 

“We could sit here for hours talking about the number of brands and products in the supplement and functional food space where somebody created something that met an unmet need.” 

Plant protein is an excellent example of this, underscores Vigeant. “Twenty years ago, the options were primarily animal/whey-based or soy. Many people had allergies, dietary restrictions, or personal preferences that made those options unappealing. Pea protein entered the market and filled that gap, eventually creating a whole new category.”

“That’s how we look at innovation: is there an unmet need that we can solve, either by making something better or creating something entirely new?”