New food tipping point

July 21, 2025

One example is Novonesis, a global company working with enzymes and microorganisms. In Nebraska, GEA delivered the bioprocessing systems behind a new site for plant-based protein production which is designed for efficiency, hygiene and continuous operation.
 
Another example is Solar Foods, which produces Solein – a microbial protein made using air and renewable electricity. The company has successfully scaled up its unique gas fermentation production, supported by process design and downstream technology integration from GEA.

Better bioreactors: The perfusion breakthrough

As companies work to scale cultivated meat production, one challenge remains central: how to increase cell yield while ensuring processes are stable and cost-effective? Bioreactor functionality is at the heart of that equation.

At GEA, a team of engineers is advancing perfusion-based processing – an alternative to batch and fed-batch methods that allows for higher cell densities and productivity and continuous cell harvesting. “Our studies and modeling show that perfusion is the path to reach production capacity,” says Tatjana Krampitz, Head of Technology Management at GEA’s New Food unit. “To achieve continuous operation, we combine smart process control with optimal perfusion performance, enabling well-timed (partial or continuous) harvesting and feeding strategies.”
 
These insights led GEA to launch an entry-level perfusion platform for aseptic pilot projects in 2024, including the Axenic P bioreactor and Kytero single-use separator. This unique combination enables high-density cell cultivation, while the centrifuge also streamlines continuous cell harvesting and reduces cleaning and sterilization efforts.

GEA’s R&D in new food is also advancing areas like process control (improved mixing for example), machine learning (to enhancing yields through efficient planning and scheduling) and operational efficiency improvements (by reducing downtime and ensuring the availability of production media).

Circular new food processes are the next innovation

With engineering expertise across the entire production chain, GEA brings a holistic view to new food. The company goes beyond reconsidering how food is made – to challenging producers to (re)structure their production for long-term efficiency and sustainability.

This holistic approach draws on GEA’s deep knowledge in heating, refrigeration, bioprocessing and plant optimization. Rather than scaling up by default, GEA helps food and biotech companies design smarter factories – built for energy efficiency, circularity and real-world performance.

“Efficiency is not just about output,” says Tatjana Krampitz. “It’s about building systems that work smarter from the start – with energy recovery, automation and flexible platforms that adapt as the market evolves. That also means using resources wisely, without compromising on quality or yield.”

One example of this holistic approach: GEA’s collaboration with innocent drinks, the world’s first carbon-neutral juice and smoothie production factory in Rotterdam, Netherlands. Instead of designing the plant first and calculating energy demand later, GEA’s team engineered the factory around its energy requirements from day one. The result is a fully renewable facility powered by green electricity, where waste heat from refrigeration is captured and reused elsewhere in the process.

Another example of decarbonizing the beverage world: In 2026, a major beverage company will create its first brew at what will become Europe’s first carbon-neutral brewery – also powered by circular energy systems from GEA. Despite brewing’s heavy heating and cooling demands, GEA heat pumps and mechanical vapor re-compression systems cut thermal energy use by up to 90% by recovering waste heat from refrigeration and wort boiling.

Applying brewery logic to new food

Adam Mincher, GEA’s Technical Director Engineering for Beer & Alcoholic Beverages, sees the same logic translating to alternative proteins. “New foods offer an alternative to what many consider unsustainable industrial agriculture,” he says. “But there are still questions about how much climate benefit they deliver – especially given the energy needed to run these plants. If we design them to be energy self-sufficient and circular from the start, we unlock a whole new layer of efficiency. So, if we can get breweries to net zero, we can do the same for precision fermentation.”

He adds that unlike breweries, new food systems often operate with a steadier energy load, making them even better suited for heat recovery.

Nature-inspired engineering

For GEA engineers, the goal is not only to shrink food’s footprint, but also to shift food manufacturing closer to utilizing nature’s own logic. As Morten Holm Christensen, Application Manager for Biotechnology, explains: “Microbial metabolism produces product; but it also releases water and CO2 – and both can be captured and reused. That might sound like science fiction, but it’s exactly how nature has always worked.”

Rethinking scale: Why process beats size

Just a few years ago, the excitement around alternative proteins focused primarily on scale – moving from lab experiments to industrial output. Scale still matters. But today, many experts argue that process efficiency may matter more: continuous operation, smart energy use and better bioreactor design are proving more powerful than size alone.

“In established manufacturing sectors, fine-tuning process efficiency often has a far greater impact on cost and sustainability than simply building bigger facilities,” explains Christensen. “New food needs more than just steel. It needs smarter systems.” 

A recent McKinsey analysis supports this shift in thinking. According to their findings, process improvements can improve the cost of goods sold for fermented ingredients more than scaling alone – by up to 60 percent. While doubling plant scale can reduce unit costs by 20 to 50 percent, improving process parameters – such as product concentration, fermentation performance, and strain stability – can cut unit costs by up to 60 percent.

For precision fermentation, Christensen points to three areas where smarter processes are essential: 

One bioreactor or 25,000 cows

As performance improves across these three dimensions, productivity could grow exponentially. “Today, one large bioreactor might replace 2,500 dairy cows in terms of protein production capability. But if strain engineering, stability and bioreactor tech progress in paralell – as we expect – those synergies could allow that same reactor to replace 25,000 cows.”

What fuels Christensen’s optimism is that much of the infrastructure for commercial-scale precision fermentation is already in place. “Whether it’s media prep, sterilization, separation, filtration, purification, spray drying or powder handling – GEA’s portfolio already covers what’s needed, especially on the downstream side,” he explains. “And bioreactors are net heat producers. Add GEA’s energy recovery systems to the mix, and the case becomes even stronger.”

The tipping point is coming

Technology, economics and social urgency are aligning. For Christensen, a new food tipping point is within reach – and with it, a shift in industry power. “The final bottlenecks are being solved. The companies that control robust production strains will lead. Especially those with scale-ready, stable strains – they have a major head start.”

His message isn’t about caution. It’s about timing. “The new food train hasn’t left the station yet. But when it does, it’ll be moving fast.”