Rebellyous Foods introduces Mock 2 technology to advance plant-based meat production

Rebellyous Foods has introduced its innovative Mock 2 Production System, designed to enhance the scalability and efficiency of plant-based meat production. Now operational at RMS Foods' state-of-the-art facility in New Mexico, this system is set to produce plant-based meat at volumes between 2,500 and 5,000 pounds per hour, making it one of the most efficient production methods in the alternative protein industry.

Founded by former Boeing engineer Christie Lagally, Rebellyous Foods has been on a mission to make plant-based meats price-competitive with traditional animal meat, without sacrificing quality. The Mock 2 technology, which automates labor-intensive processes, offers a way to significantly lower production costs while delivering consistent, high-quality products.

“Our mission has been to develop a system that efficiently and affordably produces our high-quality plant-based chicken nuggets, tenders, and patties,” said Lagally. “The Mock 2 system allows us to scale up production and make plant-based eating more accessible to consumers.”

The Mock 2 system represents a shift in plant-based meat production by replacing traditional batch processing with a fully continuous, automated system. This approach not only increases production efficiency but also ensures consistent product quality across large volumes.

In an exclusive interview, Lagally explained how the system achieves this: “The Mock 2 system includes a novel progressive hydrator and emulsification system. It integrates temperature control and automated recipe management, which ensures precise hydration, emulsification, and mixing of ingredients. This level of automation enables high-volume, consistent output with minimal human involvement, ensuring accurate recipes and food safety.”

One of the most important aspects of the Mock 2 system is its chilled dough substrate processing. This process, according to Lagally, is key to maintaining the texture and flavor of the plant-based meat. “Chilling the dough during processing enhances the overall quality by ensuring a highly viscous dough and preserving flavor, which are critical for plant-based meat products. The chilled environment helps maintain ingredient integrity and consistency, allowing for better emulsification and reduced risk of contamination.”

Moving from traditional batch processes to continuous production posed a number of challenges for Rebellyous Foods. “The main design challenge for this system was determining how to turn traditionally batch processes into continuous ones,” Lagally said. “This included developing just-in-time hydration that moves material while simultaneously hydrating, and determining a continuous mixing system that didn’t degrade the textured protein. Among many other challenges, moving a system from batch to continuous is the most challenging.”

Despite these challenges, the team at Rebellyous Foods succeeded in creating a system that not only produces plant-based meat efficiently but also does so in a way that reduces material waste and energy consumption. "The Mock 2 system minimizes material waste by using precise recipe management and continuous, fully contained production, which ensures consistent product quality and reduces the chances of errors or the need for rework. This level of automation also results in less downtime and waste during changeovers," Lagally explained.

The cost of plant-based meat has been a significant barrier to wider adoption. Rebellyous Foods’ Mock 2 system is designed to tackle this issue by lowering production costs in several key areas. “The most significant cost reductions come from automating labor-intensive processes, reducing energy consumption, minimizing the physical space needed, and eliminating the need for a chilled working environment for staff,” Lagally noted.

Energy efficiency is another key benefit of the Mock 2 system. Traditional plant-based meat production methods often require significant amounts of energy for chilling and processing. However, the Mock 2 system operates at a fraction of the energy cost. “By running internal chilling systems at the equipment level, we avoid the use of CO2 and ice, which further reduces costs,” Lagally shared. “The continuous production model also helps lower costs by improving production consistency, reducing waste, and enhancing food safety.”

In addition to cost savings, the system is designed to have a lower environmental footprint compared to both traditional meat production and existing plant-based production methods. “The Mock 2 system is designed to be energy-efficient and to operate with a smaller physical footprint,” said Lagally. “Its automation minimizes labor, energy, and material waste, all of which contribute to a lower environmental impact compared to traditional methods.”

Although a formal life cycle assessment (LCA) of the Mock 2 system is yet to be completed, Rebellyous Foods anticipates that the energy and material efficiencies it offers will lead to significant reductions in its environmental impact.

Another important aspect of the Mock 2 system is its impact on worker safety and ergonomics. “Current plant-based meat manufacturing is incredibly labor-intensive, involving lifting heavy loads, scraping dough, and moving around large, heavy pieces of equipment,” Lagally explained. “The Mock 2 system improves safety by reducing workers' exposure to dust, repetitive motion, lifting injuries, and strenuous manual labor. The automated nature of the system minimizes human involvement, creating a safer, more ergonomic environment with fewer risks.”

The system is also designed for flexibility, allowing it to accommodate different formulations and product types without significant downtime or reconfiguration. “The Rebellyous recipe for ‘dough’ is the same for all of our SKUs; to produce different product types simply involves a change in forming plates,” said Lagally. “The Mock 2’s automated recipe management and precise control mechanisms ensure the system can shift between products efficiently while maintaining quality.”

Rebellyous Foods is optimistic about the future of the Mock 2 system and its potential to scale across new geographic markets and product lines. Lagally shared that Rebellyous plans to continue refining the system and adapting it for use in various regions, with the goal of further lowering the environmental footprint and making plant-based products even more competitive with traditional meats.

“We are considering localizing production by building Mock 2 systems closer to the markets we serve. This approach reduces the energy costs of transportation and distribution, which would further lower the environmental footprint and ensure competitive pricing in different regions,” she said.

With plans for future expansions and optimizations, Rebellyous Foods’ Mock 2 technology could play a central role in making plant-based meat production more sustainable and efficient, helping to meet the growing global demand for alternative proteins.

By focusing on cost reductions, energy efficiency, and worker safety, Rebellyous Foods is taking practical steps to address the challenges of plant-based meat production, ensuring a more sustainable future for protein consumption.