In a bold move that could significantly disrupt the plant-based meat industry, Seattle-based Rebellyous Foods is positioning itself as a game-changer with its innovative ‘Mock 2’ processing system. This technology promises to reduce production costs by a staggering 60% compared to traditional methods, potentially bringing plant-based meats to a cost parity with their animal-based counterparts. As the company invites proposals from food facilities to operate this groundbreaking system, the implications for the industry and consumer choice are profound.
Christie Lagally, the founder of Rebellyous Foods and a former Boeing engineer, has identified a growing demand for plant-based options, particularly in the foodservice sector. Despite a recent dip in retail sales of plant-based meats, Lagally notes a marked enthusiasm from schools and other foodservice accounts. Rebellyous Foods is currently supplying breaded soy-based nuggets, tenders, and patties to more than 200 school districts under the USDA National School Lunch Program. The surge in demand is attributed to a variety of factors: an increase in student populations identifying as vegans and vegetarians, dietary restrictions based on religious beliefs, the drive to meet climate targets, and simply a preference among many children for plant-based options over meat.
The company’s focus on the school market has been lucrative, with sales nearly doubling this year and projections to more than double the following year. The implementation of the Mock 2 system is expected to be a catalyst for Rebellyous Foods to approach profitability.
The Mock 2 system itself is a marvel of engineering, allowing for the production of 2,500 pounds of plant-based chicken per hour, with the potential to double that output. This level of efficiency is comparable to major conventional chicken processors and represents a significant leap from the current ‘mix and form’ batch production methods that are labor-intensive and not easily scalable. The system, which includes a continuous dough making system, integrated control system, and auxiliary equipment, is expected to be installed in a partner facility in early spring 2024.
The current batch processing methods used by many in the industry involve a cumbersome three-step process that limits scalability and increases costs. The mix and form approach requires manual intervention or costly temperature control measures to maintain quality, leading to significant waste and inefficiency.
By contrast, the continuous processing approach of the Mock 2 system addresses these challenges head-on. Automation reduces labor costs by up to 90%, energy costs are cut by 80% due to the elimination of the need for a chilled environment, sanitation costs are lowered, waste is reduced by an estimated 99%, and re-work is virtually eliminated. These advancements not only promise to revolutionize production efficiency but also have the potential to make plant-based meats more accessible and affordable for a wider range of consumers.
Rebellyous Foods is now seeking proposals from USDA or FDA food processing facilities to house the Mock 2 system, with a deadline for inquiries set for January 19. While Rebellyous will maintain ownership of the system, there is an opportunity for partners to use it to produce their own products, subject to licensing or tolling fees. This collaborative approach could benefit the entire sector, as other brands may leverage the technology to enhance their own production capabilities.
The move by Rebellyous Foods comes at a time when the plant-based meat industry is seeking ways to scale production and reduce costs to better compete with traditional meat products. With the Mock 2 system, Rebellyous is not only advancing its own competitive edge but also offering a pathway for the industry at large to innovate and grow. As the company prepares to roll out this technology, the landscape of plant-based meat production could be on the cusp of a significant transformation, one that promises to bring more sustainable and diverse food options to tables across the nation.