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Meati Foods Grows Sustainability with Innovation

Mushroom-root protein producer collaborates with Gold System Integrator Cybertrol Engineering to put efficient commercial production on the fast track

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Not Your Typical Meat Alternative

When Justin Whiteley and Tyler Huggins met as Ph.D. students on the University of Colorado-Boulder campus, they recognized a shared passion for nature-driven, sustainable food systems. And a complementary skill set.

“Tyler is an environmental scientist who has focused on biology throughout his career,” said Justin Whiteley, CSO and co-founder, Meati Foods. “And my focus is mechanical engineering – with a Ph.D. skewed towards materials science.”

While still students, the men built a biomanufacturing roadmap that took advantage of both disciplines – and set the course for Meati Foods, the producer of a meat alternative based on mushroom root. Unlike many other meat alternatives, Meati is a complete protein and nutritional powerhouse that provides significant B vitamins, fiber and zinc. 

“Meati also delivers a familiar meat texture, which is lacking in other options,” Whiteley said. “And it can be made with a fraction of the land and water required to grow animal protein – plus the process emits substantially less greenhouse gas.” 

Innovative Proprietary Process

Using novel food processing techniques, Meati developed a system for producing mushroom root – known as mycelium – consistently and efficiently. Much like beer brewing, Meati grows its mycelium in fermentation tanks.

In brewing, yeast fungi convert carbohydrates or sugar molecules into alcohol. In the Meati process, fungi, in this case mycelium spores, convert sugar and nitrogen into protein-rich mycelium.

“Mycelium consists of tiny fibers,” Whiteley explained. “Our technology takes advantage of those fibers to turn mycelium into advanced muscle structures that create a pleasing texture.” 

Published July 26, 2023


 

"The proprietary process is rapid. In just three days, one Meati batch yields as much meat as five cows."

 


The Critical Role of Data

While Meati continued to refine their process at their pilot and research facility in Boulder, they laid the foundation for commercial production in Thornton, Colorado. The production facility or “Mega Ranch” is vertically integrated – and includes all processes required to grow, harvest, process and package the product.

To support the transition to commercial scale, Meati called on Cybertrol Engineering, an industry-leading control and information system integrator. Cybertrol is a Gold-level System Integrator partner company in the Rockwell Automation PartnerNetwork™ program.

“We knew automation and access to the right data was critical to improving our process – and key to a successful scale-up,” Whiteley said.

Cybertrol built the solution on a Rockwell Automation platform based on PlantPAx®, a modern distributed control system (DCS) and Allen-Bradley® ControlLogix® controllers. The system includes a FactoryTalk® View SE HMI, with FactoryTalk Historian collecting and managing process data and FactoryTalk VantagePoint® for self-serve analytics. The system runs on an EtherNet/IP™ network.

“While our typical food manufacturing solutions historize and track maybe 500 to 2000 tags, the Meati team asked us to track 5000 to 10,000 data points at any given time,” said Craig Moeller, senior business development manager, Cybertrol Engineering.

As a result, the solution allows for deeper and continuous visibility into the data required to maintain product quality – and optimize water and energy usage within the processes.

“We made conscious decisions early on to use renewable energy to electrify the facility and to implement a large water reuse system,” Whiteley said. “Data will provide the information we to need to become even more efficient in the future.”

A Need for Speed

“From a sustainability perspective, we felt it was important to introduce this product to the market as quickly as possible,” said Whiteley. “We believe the world simply cannot wait for this type of alternative.”


 

"To speed time to market, Cybertrol established an aggressive 10-month timeline - about 25% to 50% faster than comparable projects."

 


And because the Mega Ranch was a first-of-its-kind facility, there were more changes throughout development than a typical system. 

“Despite the variability, this was one of the fastest paced projects we’ve worked on at this scale,” said Moeller. “Time to market was a top priority, and we were able to accelerate our process because Meati made decisions quickly.”

Successful Launch. Continued Expansion.

The Mega Ranch began production on schedule, and Meati Foods launched their product nationwide in March 2023. Ultimately, the company plans to produce tens of millions of pounds of Meati annually.

“To reach those numbers, we will be going through a pretty rigorous expansion of our Mega Ranch over the next few years,” Whiteley said. “Also, we are constantly running a lifecycle assessment (LCA) in the background to benchmark water and land use, greenhouse gas emissions and other metrics per pound.”

Based on their collaboration with Meati Foods, Cybertrol received the 2023 Rockwell Automation PartnerNetwork Award for Sustainability.  

Learn more about our PartnerNetwork Program.

 

 

The PartnerNetwork Sustainability Award recognizes the partner that has shown exceptional efforts, initiatives, and programs in  this area and aligns with our mission to integrate control and information across the enterprise to help industrial companies and their people be more productive and sustainable.

Topics: Food & Beverage PlantPAx ControlLogix FactoryTalk Analytics FactoryTalk View ME FactoryTalk View SE FactoryTalk View FactoryTalk ViewPoint
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