Process Optimization and Gelation Mechanism of Bangia fusco-purpurea-Based Vegetarian Sausages

To develop highly nutritious Bangia fusco-purpurea (BFP)-based vegetarian sausages, we investigated the effects of BFP, gluten, and complex gels (CG) on the gel strength and sensory quality of the sausages. The formulation process was optimized through single-factor and orthogonal tests, while the gel formation mechanism of the key factors was explored. The orthogonal test results showed that the optimal addition levels of BFP, gluten, and CG were 5%, 56%, and 37%, respectively. Variance analysis revealed that both gluten and CG significantly affected gel strength (p < 0.05), with gluten notably influencing the overall sensory quality (p < 0.05). Texture profile analysis (TPA) and rheological properties demonstrated that as gluten (33%–37%) and CG (52%–56%) concentrations increased, the gel strength and elastic modulus exhibited concentration-dependent enhancement. Further analysis of the sulfhydryl content, disulfide bonds, surface hydrophobicity, and microstructure revealed that higher gluten content promoted intermolecular disulfide crosslinking and hydrophobic group exposure, whereas CG contributed to physical filling via hydrogen and ionic bonds, resulting in a uniform and dense gel network structure. The synergistic effects of gluten and CG enhanced the gel properties of BFP-based vegetarian sausages. This study establishes a theoretical framework for the development of high-quality plant protein meat substitutes, presenting an opportunity to drive innovation in the food industry and address the increasing demand for environmentally sustainable dietary alternatives.