While many of the ‘first wave’ products in this nascent field are likely to be hybrid products combining cell-cultured chicken or beef and textured plant-based proteins to provide texture and lower costs, BlueNalu intends to launch with whole muscle Bluefin Tuna Toro, a high-value product that typically commands a premium price.The firm – which has a 38,000sq ft pilot facility and innovation center – is currently in a back and forth with the FDA as it goes through a pre-market consultation process.This could take up to 18 months, at which point it plans to test market products in the foodservice arena and secure commitments that will help secure financing for a 140,000sq ft facility featuring multiple 100,000-liter bioreactors that can produce up to six million pounds of premium seafood products annually, the firm told FoodNavigator-USA.“We anticipate that we will select the site location for this facility in 2024, break ground in 2025 and that the facility will be operational in 2027. Once this facility is complete and optimized, we plan to replicate this around the globe so we have regional production centers.”Tech breakthroughsThe firm – which is working with partner Nutreco on bringing down the cost of animal-free growth media – says two key factors have been key to its latest cost projections: achieving single cell suspension (which mean it can grow large numbers of muscle cells without microcarriers in suspension); and ‘lipid-loading’ technology (prompting muscle cells to store a customized level of fat so BlueNalu doesn’t have to grow muscle and fat cells separately), CTO Dr Lauran Madden told us.No scaffolding or secondary bioreactors are needed, and the harvested cells are put through a cold extrusion process to create whole-muscle type products with the same amino acid and fatty acid profiles of regular bluefin tuna.Single cell suspension with non GMO cell lines: ‘It’s like if I put like a single marble in a vortex versus a beach ball’So how does it work?In the single cell suspension process, explained Madden, “We have all non GMO cell lines that we’ve been able to transition from the adherence state to the single cell suspension state.”BlueNalu’s myoblast cells (undifferentiated cells capable of giving rise to muscle cells) are ‘transitioned’ from an adherent state (where they need to be attached to something to grow and divide) to a non-adherent state such that they can proliferate in a large bioreactor and float around in single cell suspension without needing microcarriers (to attach to), which add expense, reduce cell densities, and then may become part the final product formulation.As the cells are in single cell suspension, rather than free-floating aggregates of cells, they are less vulnerable to shear forces that can damage cells in larger bioreactors (where the contents need to be agitated to ensure the nutrients get to all the cells), she added.“As you scale up you can be forced to have higher agitation and higher shear to get the proper mass transfer of nutrients [to the cells throughout the entire reactor].“It’s like if I put like a single marble in a vortex versus a beach ball or 10 marbles held together by bubble gum, they’re going to experience different types of shear, so you’re going to have shear impacts that can break apart the aggregates, you’re going to have diffusion limitations, because diffusion can only go so far into an aggregate, and so you begin having these inherent limitations of mass transfer, shear effects that really limit some of the scalability.”Lipid-loading: ‘We’re able to transition the muscle cells to store fats’As for the lipid-loading, she explained: “So Bluefin Tuna Toro has a combination of muscle and fat, typically 20 to 40% fat, which provides a lot of that flavor and mouthfeel and texture. Rather than having multiple cell types, a separate muscle cell type, a separate fat cell type [grown in different bioreactors and combined at the end], we’re actually able to transition the muscle cells to store fats, which is not typical of muscle, but creates the same nutritional profile as you would get in a fat loaded fat cell.”To achieve that, she said, “We have patent-pending technology, but essentially, we’re able to control the process to really be able to understand how much fat is going to be in the cell, and to also control the composition of fat to target the correct nutritional profile, which also gives you that proper flavor profile.”Nutritional equivalency – beyond macrosShe added: “We are using muscle cells, and when they turn on the gene expression and protein expression, we’re able to get the same protein that you have in fish meat to achieve nutritional equivalency at a molecular level [so not just the same macros – grams of fat, protein etc, but matching amino acid profiles, fatty acid profiles etc]. “So far, we have developed hundreds of cell lines for eight different finfish species, and we have initiated projects to expand into other premium seafood categories.” 
External rendering of BlueNalu’s first large-scale facility with capability to produce up to six million pounds of premium seafood products annually. Image credit: BlueNaluTechno-economic analysisTo validate its commercialization pathway at its large-scale facility, BlueNalu commissioned a techno-economic analysis (TEA) performed in collaboration with a global engineering, procurement, and construction (EPC) firm and experts in bioprocess modeling, said co-founder, president and CEO Lou Cooperhouse.“This technology means we don’t have to blend; we’re developing a whole muscle high-value product that has the same nutritional and functional characteristics as conventional Bluefin tuna.”BlueNalu’s value proposition has attracted a number of strategic partners including multinational companies in Asia (Food & Life Companies, Mitsubishi Corporation, Pulmuone Corporation, Sumitomo Corporation, and Thai Union); Europe (Nomad Foods and Nutreco); and the U.S. (Griffith Foods and Rich Products), he added.Some construction could be debt-financedAsked about funding, he said: “We’ve raised $84.6m to date, and frankly what gets us very excited is our hope that we could get commitments on sales of a fair amount of the volume as we do market testing over the next few years. The goal is to get into the US but also other markets where per capita consumption of seafood is high and where our strategic partners can facilitate that and also where there’s regulatory approval.“So we feel not just that we can ideally sell a fair amount of the volume in advance of even construction occurring, but that this will also be very easily debt financed, because it is something that we’ll be able to demonstrate a very high level of demand for the time we put that shovel in the ground.”“Our projected 75% gross margin within the first year of production of our large-scale facility is unheard of in the food industry. This sets a very strong growth trajectory for the company, as we introduce additional products and establish new facilities around the globe.” Amir Feder, CFO, BlueNaluInterested in the future of meat?Check out our upcoming digital summit, Futureproofing the Food System (Nov 15-17), which will dedicated one of its six bite-sized sessions to The Future of Meat. REGISTER HERE (it’s free)!
FIRESIDE CHAT: Cell-cultured (a.k.a. ‘cultivated’) meat: Foodtech fantasy or the future of meat?Dr Elliot Swartz, lead scientist, cultivated meat, The Good Food Institute and Elaine Watson, senior editor, FoodNavigator-USAGrowing meat from cells in bioreactors instead of living breathing animals should logically be more efficient, as resources are spent on growing only the cells that make up the meat product rather than keeping an animal alive. So is cultivated meat a no brainer, or does the technology face ‘intractable’ problems at food scale?PANEL: Meat 2.0: With weakening sales in the alt-meat segment prompting some serious soul-searching, what does the future hold for meat alternatives, how do the available options stack up, what will distinguish the winners from the losers in the category, and how do consumers feel about the next generation of meat?
- Ethan Brown, co-founder and CEO, Beyond Meat
- Dr Lisa Dyson, founder and CEO, Air Protein
- Dr Tyler Huggins, co-founder, Meati Foods
- Abena Foli, head of regulatory affairs, Orbillion Bio
- MODERATOR: Elaine Watson, senior editor, FoodNavigator-USA
REGISTER HERE (it’s free)! .
Eat Real has broaden its appeal to flavour explorers with the addition of Sea Salt & Balsamic Vinegar to its hummus chip range.The leading UK free from brand – a pioneer in the plant-based snacking movement – is pushing to accelerate its growth with its bold flavours and better-for-you credentials. As such, its new variant is vegan and contains 30% less fat than regular potato chips. It is also free from gluten, artificial colours, flavours and ingredients. It joins other hero flavours in the range – like Tomato & Basil, Salted and Sour Cream & Chive – five of which are HFSS compliant, thanks to a reduction of their salt content by more than 50%.The launch coincides with Eat Real’s rebrand with new pack designs across its portfolio, which includes lentil chips, quinoa chips and veggie straws, among others.“Eat Real has become pioneers in better-for-you thanks to its unusual ingredients layered with bold, unexpected flavours inspired by the combinations you find in your own cooking,” said marketing director Helen Pomphrey.“We’ve found that Eat Real’s flavours are a key driver to consumer purchase, as more people opt for delicious, yet healthier alternatives.” Eat Real’s new packs are rolling out across the UK, in Sainsbury’s from September and other retailers including Tesco from October, in grab bags (45g) for an RRP of £1.20 and sharing bags (135g) for £2.00.Seasonal bestsellers
Pladis has unveiled its 2022 Christmas ranges from Jacob’s and Carr’s, which includes returning favourites and non-HFSS (high in fat, sugar and salt) treats.Jacob’s has refreshed its line-up of ever-popular Christmas Caddies (£2.79), with 50% HFSS-compliant. This year, Jacob’s Mini Cheddars Original and Treeselets are joined by two lighter options – Mini Cheddars Nibblies Cheddar & Smoked Paprika – which contain 30% less fat. Jacob’s Mini Twiglets is also returning with a non-HFSS recipe, which is both 60% lower in salt and high in fibre.Jacob’s Festive Selection (300g £3.25; 450g £4.40; 900g £7) dials up its longstanding baking heritage and expertise. Ready for topping, dipping, or sandwiching – the selection includes big sellers like the signature Cream Cracker.Jacob’s Heritage Tin (£6) taps into the trend towards togetherness with a seasonal sharing selection of crackers – including Jacob’s Cream Crackers and Jacob’s Digestives.Also returning is Carr’s Melts Warm Chilli (£1.69), crisp wheaten biscuits that embody Carr’s signature light, melting texture with a gentle heat.Carr’s Melts Selection Pack (£5) includes a trio of treats, namely Melts Original, Melts Cheese and Warm Chilli, great for the post-dinner cheeseboard.Carr’s Selection (200 £3; 400g £4.50) offers a variety of nine savoury biscuits and crackers.“As always, we’ve focused heavily on offering shoppers quality and choice with our 2022 savoury Christmas range,” said Cassie French, marketing director, Seasonal & Cake.“We’ve no doubt our portfolio of cracker selection boxes – whether family favourites from Jacob’s, or our extra special offerings from Carr’s – will be particularly popular this year. As Brits tuck into cheese boards and gather together with friends and family in larger groups, products which are perfectly placed for sharing will perform well.” The Jacob’s and Carr’s Christmas products are rolling out various UK grocery retailers – including Tesco, Sainsbury’s, Asda, Morrisons, Amazon and Ocado – as well as discounters.Pizza perfect
Schwan’s Company has launched the Hearth & Fire pizza line: pre-fired frozen pizzas that delivers pizzeria-quality craftmanship.Hearth & Fire begins with a minimum 20 hour-fermented dough (a process that took three years to perfect) that is flame-fired at 1,000°F (537°C) to add crunch and char to the crust. Every pizza is then finished with a selection of artisan toppings and vacuum-packed to ensure the craft quality is preserved from freezer to oven to table.There are four variants in the line: The Margherita (mozz, basil, red sauce and a dash of olive oil); The Pepperoni (pepperoni, mozz, spicy red sauce and a parmesan herb sprinkle); The Bianca (mozz, Fontina, cheddar, goat cheese, asiago, a parmesan garlic cream sauce and oregano); and The Mushroom (gouda, portabella mushrooms, caramelised onions, roasted shiitake and cremini mushrooms, goat cheese, asiago and thyme).Available at Kroger stores and online in select US states for an RRP of $11.99-$12.99.Biscuit perfection
Mason Dixie Foods has recently revamped its e-comm platform so consumers will have easier access to its best-selling baked goods.Demand for its clean label Buttermilk Biscuit Sandwich continues to grow, completely selling out of Whole Foods each week. As such, the brand has made the scratch-made sandwiches available online – with free shipping – so fans won’t miss out.The buttermilk sandwiches are made with real ingredients like nitrate-free sausage and 100% egg, and is available in two options: 8 single-serve sandwiches or 12 sandwiches that come in a 2-pack packaging.Mason Dixie is also offering 15% off the buttermilk sandwiches, which use only real ingredients like nitrate-free sausage and 100% real egg, with code BACKTOSCHOOL.Cereal snacker
General Mills has continued to expand its bestselling cereals into the snacking aisle.Trix Popcorn joins Cinnamon Toast Crunch and Cocoa Puffs in General Mills’ line-up of indulgent popcorns, as a perfectly balanced sweet and salty snack.Featuring a Trix-flavoured fruity glaze, along with bits of the cereal itself, the popcorn offers a nostalgic crunchy bite ideal for any snacking occasion.Trix Popcorn is available at Sam’s Club for an RRP of $6.48 for a 20oz bag, while a 7oz pack will be available at Walmart stores for $3.69 from October.Scotland at its finest
Walker’s is exclusively unveiling its newly curated four-strong Premium Festive Travel Retail Range, decked out in seasonal World of Walker’s livery, at the TFWA World Exhibition and Conference (2-6 October in Cannes, France).The range consists of a 200g Christmas Spiced Shortbread Tube, a 200g Cranberry and Clementine Shortbread Tube, a 460g All Butter Festive Shortbread Assortment Gift Box and a Premium Six Mince Pies Gift Box.Reflecting the brands recent rebrand, the World of Walker’s sports playful illustrations of iconic global landmarks, along with a fresh take on the brand’s Scottish heritage. It has been reimagined for today’s traveller, and highlights its focus across sustainability and digitisation, including the first fully recyclable paper Sharing Bags and Gifting Tubes.“This year has seen several milestones for Walker’s across global travel retail as we continue to celebrate our heritage and expertise,” said MD Nicky Walker.“We remain committed to strengthening the opportunities across premium travel retail and bringing our shortbread to consumers and customers around the world. We are excited to be coming back to Cannes to showcase the ‘World of Walker’s’ and our products to both long established and new customers”. Visitors will be treated to an immersive experience for all the senses with freshly warmed samples, enabling them to taste Scotland at its finest first hand.Four times winner of the Queen’s Award for Export Achievement, Walker’s exports its distinctively packaged luxury shortbreads, biscuits, cakes and oatcakes to over 100 countries worldwide. In 2017, Walker’s Shortbread was granted a Royal Warrant of Appointment from Her Majesty the Queen for the supply of shortbread to the Royal Household, following a similar granting by the Queen and Queen Mother in 2002 for oatcakes.All Walker’s products are free from artificial colours, flavourings and preservatives. They are certified Kosher (OUD) and are suitable for vegetarians.Spook-tacular
This Halloween, Post Consumer Brands is rolling out Limited edition Fruity Pebbles cereal.The cereal will sport the same fruity taste that brand loyalists love, but with a mixture of orange and purple flakes to join in on the fall festivities. The box also features Fred Flintstone and the cereal’s namesake character, Pebbles, dressed in costumes for the holiday.The Limited-Edition Fruity Pebbles cereal will be available at retailers across the US in 10oz packs, along with an 18.5oz pack for die-hard fans.Ready or not…
… limited time RXBar flavours are coming in hot.Chocolate Cinnamon Brownie will be joined by three seasonal favourites – Pumpkin Spice, Gingerbread and Pecan – available until the end of the year.Each is inspired by nostalgia – like the smell of warm pecan pie, cinnamon and spice – but made with wholesome ingredients for a better-for-you treat.The trio also boast the brand’s simple ingredient list – egg whites (punching in 12g of protein), dates (to bind), nuts (texture) and 0g added sugar.“These bars are anything but basic, and we hope each nostalgic flavour helps eliminate any added stress or drama the season might bring along,” said senior associate brand manager Carly Smith.These are accompanied by limited time Chocolate Cinnamon Brownie, packed with whole almonds, chocolate chunks and cinnamon, a nod to homemade brownies straight from the oven.The bars are available online and in selected retail stores across the US for an RRP of $2.79/bar, $9.99/4-pack and $25.99/12-pack. Additionally, new bite-sized RXBar Pumpkin Spice and Chocolate Sea Salt Minis will be available exclusively at Target beginning mid-August.Let’s twist again
Gourmand Pastries is hopping onto the vegan trend, getting into a twist and showcasing all-butter-tasting croissants that are actually made from a butter/marg blend at SIAL Paris 2022 (15-19 October).Vegan is one of the biggest trends of the last few years. That’s not new news, but what is, is that Gourmand Pastries – which specialises in frozen viennoiserie for the B2B sector – is joining the movement. Its vegan viennoiserie range comprises croissants, pains au chocolate, praliné croissants and maple pecan plaits. The range is made from 100% plant-based ingredients, including certified sustainable palm oil (RSPO).Getting into a twist, but doing it in style, the Pretzel Triangle by Gourmand Pastries uses a variety of pastries to create a treat somewhere between a croissant and a pretzel. A crisp start is followed by soft texture and slightly salty tones. This new-fangled vennoiserie is perfect on its own, or as a richly filled sandwich-carrier.Finally, the Belgian bakery manufacturer is showcasing Superblend, a clean label combo of butter and margarine, which flawlessly matches the buttery flavour of a real butter croissant. .
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