Revo Foods' new Taste Factory industrializes plant-based salmon filet production with 3D printing

Austrian food-tech startup, Revo Foods, has opened the world’s largest industrial facility for 3D food printing, known as the 'Taste Factory'. Located in Vienna, this new facility represents a significant step forward in the world of plant-based food production, utilizing innovative 3D structuring technology to create plant-based products with unique textures and enhanced functionality. According to CEO Robin Simsa, the opening of this facility marks an important milestone for the company and the broader alternative protein industry.

Revo Foods’ proprietary 3D structuring technology lies at the heart of their operation. The technology allows for the precise combination of fat and protein to replicate the complex textures of animal-based products like filets and steaks. The innovative approach creates layers that mimic muscle fibers, which results in a tender, juicy texture that consumers typically associate with traditional meat products. The first product to emerge from the Taste Factory is a plant-based filet made from mycoprotein, which will be available in European supermarkets from today (3 October).

According to Simsa, the integration of fat into protein fibers is critical for replicating the mouthfeel of meat, a sensory element that many plant-based alternatives struggle to achieve. "This is the first technology that allows the integration of fat into protein fibers, which is one of the essential sensory elements of meats. By combining two different ingredients in complex shapes, a completely new texture profile is enabled, resembling the anisotropic fibers of meat," he explained.

Scaling up 3D food printing technology to an industrial level has presented challenges, but Revo Foods is now capable of producing up to 60 tons of product per month at the Taste Factory. This makes it the first large-scale facility of its kind, operating a continuous process rather than the batch processes that typically constrain 3D food printing systems.

"We developed the first continuous process, thanks to our patented extrusion system and the implementation of multi-nozzle systems, which really increase the output by a large margin. We are now able to produce several tons of products per month," Simsa elaborated. This development has opened new doors for rapid product iterations and innovation, which is key in the evolving food tech landscape.

In addition to the textural advantages offered by 3D food printing, Revo Foods has placed a strong emphasis on maintaining the nutritional integrity of its products. Traditional food production methods, such as extrusion, often involve high temperatures and pressures, which can degrade nutrients like Omega-3 fatty acids. Revo Foods’ technology operates under much milder conditions, ensuring that more of the nutritional value remains intact in the final product.

Simsa highlights that this is a key advantage of the technology: "Our system operates at a low temperature and with low shear forces, therefore retaining more nutritional content inside the products," he said. This is particularly important given the company's focus on nutrient-dense ingredients such as mycoprotein.

Mycoprotein, a biomass derived from fermented mycelium, is widely recognized for its high nutritional value, boasting a complete amino acid profile, high fiber content, and greater bioavailability than beef. Its meat-like texture also makes it ideal for creating plant-based products without requiring extensive processing.

"It is very interesting because it is a fibrous biomass, meaning that it does not need to be highly processed to achieve fibrosity. This allows us to simply structure it in our process together with fats, which leads to this new texture dimension and enables flaky layers," Simsa noted.

One of the most exciting aspects of 3D food printing is its potential for flexibility in product iteration and mass customization. Traditional food production systems are often rigid, designed for high-volume output with little room for variation. In contrast, Revo Foods’ digital 3D structuring technology allows for rapid and seamless adjustments to product formulations, offering significant opportunities for product innovation and personalization.

"In our case, 3D food printing allows a completely flexible production system which can be digitally controlled. You can make product variations in an instant, simply by changing a software code," Simsa revealed. This flexibility could pave the way for personalized nutrition and mass customization, where products can be tailored to meet individual consumer preferences and dietary needs.

The company is already working with several large food producers to explore new applications of 3D structuring technology, with the aim of presenting joint product developments by early 2025. Simsa is particularly excited about the potential for personalized nutrition and small-batch production, which would allow for greater diversity in the plant-based food market.

"So far, food production is very standardized, meaning massive scale but little variation," he said. "This has advantages, but for many use cases such as small-batch production of specialty items, seasonal items, or varying items for different regions, a more flexible production system has a lot of advantages."

The opening of the Taste Factory in Vienna is just the beginning for Revo Foods. The company envisions replicating this model in other regions around the world, tailoring production to meet local consumer demands. The versatility of 3D food printing technology means that different ingredients can be used to create a wide range of products, offering exciting possibilities for the global food industry.

"The production setup we implemented now is based on our new 3D food printing technology, and this can be implemented anywhere in the world. With a simple adjustment of ingredients, many different types of products can be created," commented Simsa. While the initial focus has been on fish filets and meat alternatives, Revo Foods sees broader applications for the technology in various segments of the food industry.

Revo Foods’ first product, 'The Filet – Inspired by Salmon,' has a Nutri-Score 'A' rating, and is designed to appeal to health-conscious consumers looking for plant-based options without compromising on taste or texture. The product will initially launch in over 500 REWE Austria locations, one of Europe’s largest supermarket chains, and will also be available for purchase through Revo Foods’ online shop.

As Revo Foods continues to push the boundaries of food technology, the opening of the Taste Factory signals a new era in plant-based food production, one that prioritizes both sustainability and culinary innovation.

‍You can watch a video of the process here

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