Introduction: Replacing animal with plant-based proteins in nutrition is in trend. Many plant-based food alternatives are available. However, final products raw materials are often highly processed, fortified with additives and nutrients for improving textural und nutritional properties. So-called hybrid products could be an alternative to increase sustainability while maintaining sensory and nutritional properties. In this study, we tested the effect of partial replacement of milk by lupine mass in semi-hard cheese analogue. Methods: Using the same starter culture, we developed a hybrid cheese analogue starting from micro-scale to pilot scale. With micro-scale in deep well plates (5ml) we evaluated the solubility and coagulation properties of different concentrations of milled lupin in milk. In mini-scale (250 ml) different alternatives to chymosin and the influence of CaCl2 were tested and optimized. At a pilot scale (30 L) 25% of raw milk was replaced by lupine mass. The production followed the traditional recipe of a semi-hard cheese. After ripening for two months, the samples were analyzed for chemical and biochemical properties. Hybrid cheese analogues with 5, 10 and 15% of lupine mass were tested for acceptance. Results: At micro scale level, a maximum of 25% lupine mass can be added while maintaining the original technology. At mini-cheese scale, Fromase was confirmed as optimal enzyme for coagulation visually by syneresis value. The addition of CaCl2 was necessary for improved coagulation. At pilot scale, control and hybrid cheese analogue with 25% lupine had similar lactic acids contents after 24h. Due to lower syneresis and additional water absorption during the salt bath, the hybrid products had higher water contents (53.6±1.7 g/100 g vs. 42.1±2.3 g/100g). Salt content in the samples with lupine (2.99±3.1 g NaCl/100g) was significantly (p=0.002) higher than without lupine (1.9±1.3g NaCl/100g), even though the bath time was reduced. These factors seemed to increase protein degradation and to intensify the formation of aroma active compounds. Consumer acceptance was not significantly different for products containing 5, 10 and 15% lupine mass compared to the control. Conclusions: The substitution of raw milk with up to 25% lupine mass allowed fermentation and ripening of a cheese-like product. Addition of compounds for textural and nutritional properties were not necessary. Nevertheless, technological adaptions are needed to optimize control of the process and to decrease salt content. Further research is needed to evaluate the impact on sustainability and food safety risk of the new raw materials.
