Key Takeaways
- Meati’s Mega Ranch facility in Thornton, Colorado, won FOOD ENGINEERING’s 2024 Sustainable Plant of the Year award.
- The company focuses on producing mycelium-based protein products, offering sustainable alternatives to animal protein.
- Innovative processes and renewable energy use help Meati minimize water and energy usage while scaling up production.
Expansion and Sustainability
Meati, a company specializing in mycelium-based alternative proteins, has expanded its operations due to increased demand for its products. The new facility, known as the Mega Ranch, has garnered recognition as FOOD ENGINEERING’s 2024 Sustainable Plant of the Year. Founders Tyler Huggins and Justin Whiteley envisioned creating flavorful and environmentally sustainable nutrition while they were graduate students at the University of Colorado.
Unlike typical ground-style alternatives, Meati’s products are designed to mimic whole cuts of meat, positioning the company distinctively in the alternative protein market. This unique approach has attracted significant investment since 2020, facilitating rapid growth and the need for larger production facilities.
To accommodate this growth, Meati relocated to a 100,000-square-foot converted warehouse in Thornton, Colorado. The project’s ambitions raised significant logistical challenges, particularly in installing larger fermentation tanks essential for scaling production. Meati upgraded from 5,000-liter to 25,000-liter fermentation tanks, requiring the removal of the roof for installation during a snowy winter. However, innovative engineering solutions ensured the project progressed efficiently despite these challenges.
Performance and Environmental Impact
The sustainability of Meati’s mycelium products significantly influenced the award decision. The company aims not to replace animal proteins but to provide healthier, more environmentally friendly options. According to Andrea Wombacher, Meati’s vice president of production, lifecycle analysis shows that their mycoprotein uses 89% less water, 96% less land, and has an 88% lower carbon footprint than conventional steak.
To further enhance sustainability, the construction of the Mega Ranch included systems for water reuse due to the water-intensive nature of mycelium cultivation. The facility is equipped with a 15,000-gallon storage system for consistent water supply and a 150,000-gallon equalization tank for wastewater management.
Meati emphasizes process optimization to improve efficiency and reduce energy consumption. Innovative production methods allow for more effective fermentation cycles, yielding higher output with lower energy inputs. The company’s approach includes smart automation solutions developed in collaboration with Rockwell Automation, enhancing operational efficiency and providing insights into the optimal conditions for mycelium growth.
Future Focus and Consumer Appeal
The Mega Ranch project faced numerous challenges, from installation timelines to permitting issues. Project Manager Chris Morse noted that flexibility and quick problem-solving from the construction team allowed the facility to open on schedule, despite weather conditions causing additional delays.
Consumer interest in sustainability continues to grow, and Meati is well-positioned to meet this demand. Wombacher highlighted the company’s commitment to optimizing their products for sustainability while ensuring clean labels with minimal ingredients. Their efforts resonate with consumers seeking healthier and more environmentally responsible food options.
As Meati continues to scale its operations and refine its processes, the company remains focused on developing products that are not just alternatives to meat but also healthier, sustainable choices that meet the evolving needs of the market. The goal is to establish a strong presence in the alternative protein landscape, driven by a commitment to quality, sustainability, and consumer preferences.
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