New Micro-extrusion Advanced Technology for plant-based whole-cut meat substitutes

Información del proyecto

NewMEAT

Identificador del acuerdo de subvención: 190112238

DOI

10.3030/190112238

Proyecto cerrado

Fecha de la firma de la CE 4 Julio 2022

Fecha de inicio 1 Enero 2022

Fecha de finalización 31 Diciembre 2023

Financiado con arreglo a

• The European Innovation Council (EIC)

Coste total

€ 2 658 178,75

Aportación de la UE

€ 1 860 725,00

Coordinado por

NOVAMEAT TECH SL
Spain

Periodic Reporting for period 2 - NewMEAT (New Micro-extrusion Advanced Technology for plant-based whole-cut meat substitutes)

Período documentado: 2023-01-01 hasta 2023-12-31

Resumen del contexto y de los objetivos generales del proyecto

Humanity is currently facing two grave unprecedented problems in its history: global warming and a broad loss of biodiversity. Challenges that if not faced and reverted with maximum urgency might seal the fate of the next generations.
It is known and scientifically proven that animal farming is one of the main drivers of this global crisis and that switching to plant-based diets is the best single solution and most impactful investment to revert this situation.
Novameat has been working on developing a technology that will help shift away from the consumption of animal-originated protein to plant-based products which are more sustainable, healthier, and economically competitive with animal meat but that don't offer a compromise on taste and mouthfeel as current products in the market do.
After years of perfecting its patent-pending microextrusion technology with 3D printers, using tissue engineering strategies, Novameat started working to scale up this technology through the invention and adaptation of industrial machinery. This industrial-scale technology will be capable of achieving the same whole-cuts meat analogues composed of a natural-origin wide range of different vegetable proteins, fibers, oils, and aromas that were produced at laboratory-scale with the 3D printers. This is the core objective of Novameat's project, with the ultimate goal of taking unique and superior plant-based meat alternatives to market in an economically efficient way, thus pushing forward the growth of the sustainable alternative protein sector and helping fight our current humanitarian crisis.The ultimate results of the NewMEAT’s project were the successful achievement of four incredible plant-based meat alternatives, the shredded “beef”, the shredded “chicken”, “chicken” fillets and the “turkey” pastrami. These products have been tested wbyfoodservice professionals, chefs, and consumers and have been regarded as high-quality, unique innovations in the plant-based landscape and are ready for commercialization.

Trabajo realizado desde el comienzo del proyecto hasta el final del período abarcado por el informe y los principales resultados hasta la fecha

Novameat has been working with plant-based formulations to achieve the correct requirements on viscosity, texture, taste, nutritional elements, and other characteristics. The work both on the technological process and on formulation development needs to go hand-in-hand as one is directly dependent on the other.
In 2022 Novameat built and inaugurated the first-of-its-kind R&D facility for micro-extrusion in Barcelona, where its headquarters are located.
There, the micro-extrusion process was scaled-up from the 3D printers, limited to production speeds of less than 1 kilogram per hour, to industrial-scale equipment; proving that the micro-extrusion process can work at speeds of hundreds of kilograms per hour.
This was achieved by repurposing widely-used food industry equipment to micro-extruding our proprietary formulation to produce our plant-based analogues, through the design of prototypes, devices and equipment, the reformulation of the micro-extrudable dough and parameters, and testing and iterating.
The micro-extruding process and downstream has been developed and refined, in order to increase production capacity, extend shelf-life, improve nutritional profile, and reduce both carbon footprint and costs.
This resulted into the creation of four market-ready products, including the following of all health and food safety standards, packaging, logistics and marketing. The product lineup includes chicken-mimicking filets, turkey-esque pastrami and two shredded options that simulate beef and chicken.
Additionally, the Novameat R&D team is working on other meats and cuts such as pork or lamb, all with positive feedback from renowned culinary chefs, meat experts, potential consumers, and foodservice professionals.

Avances que van más allá del estado de la técnica e impacto potencial esperado (incluida la repercusión socioeconómica y las implicaciones sociales más amplias del proyecto hasta la fecha)

Current technologies to develop plant-based meat alternatives focus on individual aspects such as flavour, appearance, or texture of meat. NOVAMEAT's micro-extrusion technology is the only one that can simultaneously mimic the texture, appearance, flavour and nutritional properties of meat whole-cuts by using plant-based proteins of different origins. This unique technology works at industrial scale by low-temperature processes, with a low environmental impact and carbon footprint, using a wide range of proteins and ingredients, moving beyond the need of soy or gluten, and with a short list of ingredients. Besides this, it uses widely-used commercially available equipment, reducing the CAPEX risk and speeding up its implementation in new locations.
This proprietary technology has been patented and already granted in the US (U.S. Pat 11,779,033), Chile (PCT 2021000275), Europe and Japan (both in process of being published). The company anticipates further approvals in numerous other countries throughout 2024.
The products obtained by this technology have received widespread acclaim from both consumers and chefs. They stand out as preferred choices due to their exceptional texture, taste and versatility. Notably, one of the products, the Nova-T*rkey pastrami, was awarded as the best plant-based deli product at the Plant Based World Expo. This recognition further underscores the positive reception and excellence of the products created through this innovative technology.

Award given to our Nova T*urkey deli slices at a conference in 2023

Plant-based meat tacos

Plant-based chicken

Large part of NEWMEAT team in December 2023

Plant-based meat, Reinvented

Pulled plant-based meat