Meati's Mega Ranch: A Sustainable Oasis in the Heart of Colorado

When Meati, a pioneering alternative protein company, saw a surge in demand for its innovative mycelium-based products, it knew it was time to scale up. The result was the Mega Ranch, a state-of-the-art facility that has earned the prestigious FOOD ENGINEERING's 2024 Sustainable Plant of the Year (SPoY) award. This remarkable achievement showcases Meati's unwavering commitment to sustainability and its relentless pursuit of creating a healthier, more eco-friendly future for food production.

Revolutionizing the Protein Landscape with Mycelium Magic

Mycelium: The Sustainable Superstar

Meati's founders, Tyler Huggins and Justin Whiteley, met as graduate students at the University of Colorado, where they dreamed of creating a food company that would revolutionize the protein industry. Their solution? Mycelium, the root-like structure of mushrooms, which they believed could provide a delicious and sustainable alternative to traditional animal-based proteins.Meati's products are designed to mimic the texture and appearance of whole cuts of animal-based proteins, such as steak cutlets, setting them apart from the more common ground-style alternative protein offerings. This innovative approach, coupled with the company's commitment to sustainability, has attracted significant investments and propelled Meati's rapid growth.

Scaling Up for Sustainability

As demand for Meati's products surged, the company quickly outgrew its pilot facility. The search for a new, larger space led them to Thornton, Colorado, just north of Denver, where the Mega Ranch was born.The sustainability of Meati's products was a key factor in the judges' decision to award the Mega Ranch the SPoY title. Meati's founders have made it clear that their goal is not to replace animal-based proteins, but rather to offer a healthy and sustainable alternative. Through a comprehensive lifecycle analysis, the company has demonstrated that its mycoprotein products use significantly less water, land, and have a lower carbon footprint compared to their animal-based counterparts.

Overcoming Challenges with Innovative Solutions

The journey to the Mega Ranch was not without its challenges. Scaling up the mycelium growth process from the pilot facility's 5,000-liter fermentation tanks to the new 25,000-liter tanks required creative problem-solving. The team had to remove the roof of the facility during a snowy Colorado winter to lower the massive tanks into place, and then devise a custom solution to accommodate the height difference between the tanks and the joists.Efficiency and sustainability were at the forefront of the project team's decision-making. They carefully analyzed the facility's utility needs and made informed choices to ensure that the Mega Ranch would operate in a more sustainable manner. This included electrifying the majority of the facility with renewable energy to reduce greenhouse gas emissions and implementing water reuse systems to conserve the limited water resources in the region.

Optimizing the Process with Cutting-Edge Technology

Meati's commitment to sustainability extends beyond the facility's design and construction. The company has also partnered with industry experts to optimize its production processes, leveraging the latest automation and control technologies.Malisko, a firm known for its expertise in process automation integration, was brought in to help Meati optimize its mycelium-based production. By implementing Rockwell Automation's FactoryTalk platform and PlantPAx DCS, Meati was able to achieve greater flexibility, scalability, and efficiency in its operations.The use of the Sequencer Object from Rockwell Automation's PlantPAx version 5.0 enabled Meati to automate common operator procedures, reducing engineering time and allowing for easy adjustments to the production process. This, combined with the integration of Microsoft Excel "Pinning" spreadsheets, provided Meati with a powerful and adaptable recipe management solution.

Continuous Improvement and the Pursuit of Perfection

Meati's journey to the Mega Ranch is a testament to the company's unwavering commitment to sustainability and innovation. The facility's design, construction, and operational optimization have all been driven by a relentless pursuit of efficiency and environmental responsibility.As Meati continues to grow and evolve, the company remains focused on process optimization and exploring new ways to enhance the sustainability of its products. This includes efforts to further reduce the number of ingredients in their mycelium-based offerings, minimizing the overall environmental impact and aligning with consumer demand for clean label products.The Mega Ranch's recognition as the FOOD ENGINEERING's 2024 Sustainable Plant of the Year is a significant milestone for Meati, but the company's vision extends far beyond this achievement. Meati is poised to lead the charge in the alternative protein revolution, offering consumers a delicious and sustainable solution that not only nourishes the body but also the planet.