As discussed earlier, product development is achieved both by means of technological innovation and via the application of existing knowledge in new ways. Indeed, many new products in the market do not require new technologies per se but rather an upgrade in their nutritional content by adapting the ingredient list in existing products, such as adding a protein extract in powder form to granola bars. Nonetheless, there are a number of technological developments relevant for product development along the supply chain, from biotechnology and DNA modification for seed development to a complete set of practices and digital technologies used in primary production, including precision agriculture. These technological developments are also necessary in the secondary industrial production processes needed for the transformation of raw materials to produce more elaborate products, such as meat substitutes – or meat analogues and real in-vitro meat, also known as cultured meat and cultivated meat.
In the following sections, we will examine several ongoing developments leading to a diversification of the options available, ranging from production processes and industrial practices to different types of protein sources.
Product development of meat analogues
Meat analogues are products designed to simulate meat products and intended as meat substitutes, including both land and marine animal products. This differs from products such as bean burgers, which may serve as a direct replacement but do not simulate meat in the same way. Apart from replacing the source of protein, the central idea with meat analogues is to achieve a result that most closely replaces meat in terms of texture, flavour and function. The expectation is that by achieving these characteristics, consumers would pick analogues rather than the ‘real thing’, as this would not require major changes in people’s habits. The protein can be sourced from plants, fungi, microorganisms or insects, but they generally combine a mix of different ingredients, including fats, carbohydrates and fibre (Clayton et al., 2018).
The processes for producing meat analogues vary depending on the input factor used (e.g., soy) and specific company choices. A key part of the process, and a major challenge, is to achieve the desired texture – one most closely resembling real meat. Extrusion is the most common process to achieve Textured Vegetable Protein (TVP) ingredients in the form of chunks, flakes, mince or shreds. The result of this process is an intermediary product that needs further processing before becoming a meat analogue, such as burger patties or sausage-like products. However, since the 1960s discovery of extrusion technology for texturising soy protein, there have been no significant breakthroughs in the technology, but incremental innovations leading to improvements or refining existing techniques have been developed (Interview 5). Despite these advances, knowledge gaps still exist. According to one scientist working with product development, “even if manufacturers know how to set up extrusion to make fibrous high moisture meat analogues, nobody really knows what the mechanisms are for fibre formation” (Interview 5.8).
Despite extrusion being a well-proven technique, only a few companies use extrusion commercially in Europe (Interview 5.8). One example is Organic Plant Protein, a company producing TVP ingredients in Denmark, who apply a dry texturing process in which the dry protein concentrates from peas and fava beans are subjected to a series of physical processes, including mixing, hydration, kneading, heating and shaping.
The raw material or inputs used in extruders are either ‘protein concentrates’ with 55–65% protein content, high in dietary fibres, or ‘protein isolates’ with 80–90% protein content, low in dietary fibres (Interview 5.5). These can be wet or dry and have different advantages and disadvantages. Climate impact is one key advantage of using dry concentrates. Wet extrusion has emerged more recently in the past 10 to 15 years. Products made with wet extrusion are generally seen as performing better in terms of texture and taste, and there is a broader range of raw materials available for the process (Tzvia, Negro, Kalfagianni, & Hekkert, 2020). However, wet extrusion also poses challenges in terms of complexity, cost and sustainability. It requires more energy and yields different output characteristics, requiring freezing after processing (Interview 5.5).
TVP ingredients can then be utilised by food product manufacturers or chefs to produce the final product by adding other ingredients to achieve the desired flavour and result. Although this final step is the responsibility of the next company in the chain, Organic Plant Protein has taken the initiative to employ a chef who tests the usability of their TVP products and educates customers on how to cook with them. This shows that TVP products can still be considered a novelty for many actors in the food sector.
The primary production and extraction of the raw material (i.e., concentrates and isolates) is a whole different chapter, which depends on the input factors and their availability in different countries. Generally, this part of the process lies with other companies than those in charge of producing TVP products. For instance, Organic Plant Protein purchases the pea and fava bean concentrates as these are available in the Nordic and Baltic Region. The company is also exploring the potential of utilising concentrates extracted from other foods also common to the region, such as pumpkin seeds, sunflower seeds and rapeseed (Interview 5.5).
Protein extraction
There are several well-established methods for protein extraction from food sources, particularly plants, including alkaline extraction, isoelectric precipitation, salt-based extractions, ultrafiltration/ diafiltration and dry fractionation technologies (Hewage et al., 2022). However, these methods have many drawbacks, such as protein denaturation (alterations in the biological, chemical and physical properties) and generate significant amounts of wastewater, high usage of chemicals, high production costs and low yields (ibid.). This is particularly problematic for plant-based proteins, as the extraction methods can lead to a loss in their techno-functional properties, which are critical for food applications. Some of the key functionality traits include: “solubility, fat and water-binding capacity, foaming capacity and stability, emulsion capacity and stability, gelation, film-forming capacity and viscosity” (Hewage, et al., 2022). Some of the factors that impact the techno-functional properties of plant proteins are pH and ionic strength of the solvent, temperature, among others. For example, extremely high temperature and pH results in poor nutritional and functional properties (ibid.).
In addition, plants contain antinutritional factors (ANFs) that reduce protein digestibility, which again vary depending on the method employed for protein extraction. Wet extraction methods have the advantage that they result in higher protein concentration (>85%) and lower ANF content (75%–96% lower), whilst dry methods tend to result in lower protein concentration and higher accumulation of ANFs ( Amin, Petersen, Malmberg, & Orlien, 2022; Harvard T.C Chan School of Public Health, 2022). However, dry methods offer other benefits, not least their lower environmental impact (Interview 5.5) and efficacy in dissociating protein and other cellular compounds, i.e., starch, leaving no chemical residues, having minimal impact on the techno-functional properties and loss of insoluble protein (Hewage, et al., 2022). Novel technologies, although still in their infancy, show promise in overcoming some of these challenges, including enzyme-assisted extraction, deep eutectic solvent (DES) extraction, reverse micelles extraction, microwave-assisted extraction, ultrasonic-assisted extraction and subcritical water extraction (Hewage, et al., 2022).
Several of the companies observed in the Nordic countries apply dry methods, such as Ausumgaard, who extract protein from grass and Vestjyllands Andel, from plant and fish (i.e., starfish, shrimp waste), both located in Denmark. Vestjyllands Andel employs Spin Flash Dryers, which are widely used for a range of different applications, including agrochemicals, ceramics, food and feed products, inorganic and organic chemicals, pharmaceuticals, pigments and dyestuffs and waste products (SPXFLOW, n.d.). It is a patented process, offering a faster and highly energy-efficient alternative to, e.g., spray drying. The system is quite simple. There is a feed system in which the product is broken down by an agitator before it is sent to a drying chamber using a twin feed screw. The powder from the drying chamber is subsequentially collected in a filter bag.
Different processes of protein extraction occur following fermentation or when sourcing from microalgae, which mainly involves air drying. Furthermore, protein-rich foods can be consumed without the need to undergo significant transformational processes. Plants, meat, mushrooms, seaweeds and even insects can be consumed in their natural form with little or minimal transformation.
Fermentation
Fermentation is a versatile process that uses microorganisms to produce alternative proteins. It has been used for millennia to preserve food, create beverages and enhance nutritional value. There are three types of fermentation: traditional, biomass and precision fermentation. Traditional fermentation changes food through microbial digestion, while biomass fermentation efficiently produces protein-rich food using rapid-growing microorganisms. Precision fermentation programmes microorganisms to produce specific ingredients. Fermentation plays a vital role in the alternative protein landscape by optimising plant-based products and aiding cultivated meat production. It offers advantages such as efficiency, waste reduction and the creation of animal-free components. Advancing fermentation requires innovation in target selection, strain development, feedstock optimisation, bioprocess design and end-product formulation. Further exploration and optimisation of fermentation processes and bioreactor designs are essential for unlocking its full potential. Harvesting biomass or isolating specific target molecules can yield ingredients for alternative meat, egg, or dairy production (GFI 2023).
One company applying precision fermentation is Solar Foods, based in Finland. Solein, the company’s key product, is produced by fermenting a single-cell organism, a microbe, utilising air and electricity as the primary resources. The result is a protein-rich powder that can be further utilised in food product development. With a protein content of 65–70%, Solein’s macronutrient composition resembles that of dried soy or algae. It contains essential nutrients such as iron, fibre, B vitamins and all nine essential amino acids required by the human body. The bioprocess of Solar Foods is twenty times more efficient than photosynthesis and 200 times more efficient than meat production. This opens a wide range of possibilities for the food industry, offering nutritious and sustainable options for the future. (Solar Foods, n.d.).
Macroalgae
In Europe, seaweed biomass is a flexible and multi-purpose resource utilised across several sectors, including the food and feed industries (Kuech, Breuer, & Popescu, 2023). To some extent, seaweed is used for its protein content, but it is also found in food supplements due to the high concentration of antioxidants in the form of vitamins and Omega-3. Seaweed is also indirectly relevant in the protein shift in the form of feed supplements, which have shown promising results, both in facilitating growth and reducing methane emissions from cattle (Katz-Rosene et al., 2023). While the aim here is mainly to reduce emissions rather than provide alternative proteins to cattle, the innovation is primarily considered a method for reducing the environmental footprint of conventional animal-based products. The Swedish start-up company Volta Greentech has recently established the first on-land commercial scale production of Asparagopsis seaweed specifically for this purpose (Giacometti, 2021). In 2022, the company launched the world's first ‘methane-reduced beef’ to the market in collaboration with retail giant Coop and food company Protos and in summer 2023, the product became available in selected stores in the Stockholm area. According to tests conducted by the company, the algae-based supplement reduces methane emissions from animals by approximately 70–90% (Volta Greentech, 2023).
Microalgae
Microalgae are versatile microorganisms with immense potential for various industries and applications. In Europe, many companies employ microalgae biomass in the food and feed industries (Kuech, Breuer, & Popescu, 2023). The use of microalgae as a nutritional source has long been recognised and widely utilised in animal nutrition, particularly in aquaculture. Fishmeal, a protein ingredient commonly used in aquaculture feed, plays a crucial role in production costs. However, the declining availability and increasing price of fishmeal pose sustainability and growth challenges to the aquaculture industry (Roy & Pal, 2015). Consequently, there is a need to partially or completely substitute fishmeal with alternative protein sources. Currently, microalgae are being successfully employed worldwide as a viable alternative protein source in place of fishmeal (Roy & Pal, 2015).
Fungi-based
Mycoprotein, or fungi, are another protein alternative. Their filamentous structure, similar to muscle tissue, offers a texture that, to some extent, resembles meat (Food Business News, 2020). Fungi provide significant environmental advantages compared to meat production, including the ability to use agri-food waste as a substrate (Chezan, Flannery, & Patel, 2022), although the EU Novel Foods directive may impose restrictions on using inputs predefined as ‘waste’ (Wøien Meijer, 2023). Fungal protein also has a favourable nutritional profile with high fibre content and low saturated fat levels, making it a relatively appealing choice compared to meat (Chezan, Flannery, & Patel, 2022).
One example of a mycoprotein-based Swedish company is Mycrorena in Gothenburg. Mycelium, which is the underground network of roots found beneath mushrooms, serves as the foundation for Mycorena's flagship products and has a neutral taste and texture that resembles that of meat. Mycelium presents a whole new ballgame in protein production, reducing the amount of space, water and time needed. The fungi grow to 10,000 times its size in approximately 48 hours when cultivated.
The use of fungi as a base for alternative protein products is not a recent development. The British company Quorn has been using fungi in their products for decades. The expiration of Quorn’s extensive list of patents in 2015 opened up new opportunities for fungi-based businesses across Europe. However, it is worth noting that Quorn never marketed its products explicitly as fungi-based. Therefore, there is much work ahead to promote or raise awareness of fungi-based foods to overcome prejudice about their safety. In contrast to Quorn’s approach, Mycorena focuses on developing a food ingredient rather than exclusively offering products based exclusively on fungi for direct sale to the consumer. They believe that by positioning themselves as an input factor provider in the food chain, they can have a more significant impact in a long-term perspective in diversifying the food market (Wøien Meijer, 2023).
Insect-based protein
Insects have gained attention as a novel ingredient in high-value food products. In the last ten years, researchers have been investigating the potential of edible insects as an innovative ingredient in high-value products as a substitute for conventional protein sources (Gravel & Doyen, 2020). Food experts who speculate about the future acknowledge that as society becomes more focused on sustainability, insects will be increasingly embraced as an alternative source of protein. However, it is important to note that the insects that have been extensively studied and are easily raised may not necessarily be the most sustainable, widely accepted, or enjoyable options in terms of taste (Wang & Shelomi, 2017). According to Gravel and Doyen (2020), insect proteins can serve as functional ingredients in food preparation. To integrate insect proteins into large-scale industries, further research is required to optimise processing techniques and achieve the best balance between cost-effectiveness, functionality, taste and sustainability, all while ensuring consumer safety.
According to a review undertaken by Wang and Shelomi (2017), the black soldier fly (hermetia illucens) is a highly efficient converter of various organic materials, including food waste and manure, into insect biomass. This review highlights the advantages of black soldier flies, such as their ability to grow and be harvested without dedicated facilities, their low pest potential and their good nutritional composition (42% crude protein and 29% fat). However, the review also discusses their higher saturated fat content compared to other insects and the challenges posed by social stigmas and legal restrictions surrounding their consumption as human food, as it is primarily currently used in animal feed. There are several companies in the Nordic Region working with black soldier flies, including Danish ENORM and Norwegian companies Invertapro and Ecoprot (Wøien Meijer, 2023).
Cellular agriculture: Cultivated meat
A whole different field of research and industrial development is focused on cellular agriculture, which is a biotechnological process used for growing meats (i.e., beef, pork, poultry and seafood) and other animal products (i.e., milk and egg white protein) from cell cultures instead of using livestock (Khan, 2022). Unlike meat analogues, cultivated meat, also known as cultured, in-vitro, or clean meat, is real meat that is made from the same animal cells grown artificially through cellular agriculture instead of a living animal (Clayton et al., 2018). “Cultivated meat is made of the same cell types that can be arranged in the same or similar structure as animal tissues, thus replicating the sensory and nutritional profiles of conventional meat” (Swartz & Bomkamp, n.d.). Cellular agriculture is a resource-efficient process that reduces inputs to a fraction, in comparison to animal-grown meat, reduces waste and eliminates the need for vast pasture lands and crops devoted to feeding animals (Clayton et al., 2018). Nonetheless, it is important to note that cell-cultured meat production still requires some contact with animals, where living or even extinct animals can be involved in the process. These products mainly target meat-eaters and flexitarians, offering an alternative to conventional meat.
The process of producing cultivated meat consists of three key steps: stem cell extraction, proliferation and differentiation (Interview 5.4). Figure 8 provides a visualisation of this process. First, biopsies are carried out to extract stem cells from the animal. Then, the stem cells proliferate inside a bioreactor, also known as a cultivator, which is a vessel or tank that provides the controlled conditions that enable cells to grow and replicate. Replacing the function of the animal’s body, the bioreactors provide the environment with the correct temperature and oxygen levels and is where cells are fed with “an oxygen-rich cell culture medium made up of basic nutrients such as amino acids, glucose, vitamins and inorganic salts and supplemented with growth factors and other proteins” (Swartz & Bomkamp, n.d.). Finally, differentiation consists of shaping and providing a structure to the mush of cells by means of scaffolds, to achieve a similar structure to animal tissue (Interview 5.4). Similar processes are now being developed to create milk and other animal products (Swartz & Bomkamp, n.d.).