Upscaling of Fermented Foods
From Laboratory Innovation to Industrial Production
For new fermented foods to reach consumers, promising laboratory processes must be successfully translated into industrial production. HealthFerm has demonstrated this crucial step by developing and validating pilot-scale fermentation protocols for key plant-based ingredients, proving that innovative fermentation processes can be reproduced reliably at larger production scales while maintaining product quality and functionality.
The project successfully upscaled two complementary fermentation processes based on faba bean: a fermented faba bean sourdough for high-protein bread applications and a fermented faba bean protein concentrate for use in plant-based meat alternatives. Both processes were optimised through close collaboration between research organisations and industrial partners, ensuring that laboratory discoveries could be transferred into realistic manufacturing conditions.
For the bread application, researchers scaled sourdough production from laboratory batches to 20 kg and subsequently 50 kg pilot-scale fermentations while maintaining the same fermentation performance, microbial growth and acidification characteristics. The resulting sourdough showed consistent quality, desirable flavour development and excellent storage stability, providing confidence that the process can be implemented in commercial bakery production.
For meat analogue applications, the project developed an industrial protocol for fermenting faba bean protein concentrate, followed by pH adjustment and drum drying to obtain an ingredient suitable for extrusion. Several pilot trials optimised fermentation conditions, neutralisation and drying, resulting in a robust process that delivers reproducible product characteristics while meeting the technical requirements of industrial food manufacturing.
These pilot-scale demonstrations bridge the gap between research and commercial application. By validating scalable production protocols, HealthFerm provides the food industry with practical pathways for manufacturing healthier and more sustainable fermented ingredients that retain the nutritional, sensory and functional benefits identified during laboratory research.
The successful upscaling of these fermentation processes represents an important milestone in bringing next-generation fermented plant-based foods closer to market and supports the wider transition towards sustainable, protein-rich food systems.