Revo Foods releases EL BLANCO, a fungi-based black cod alternative using 3D extrusion

Revo Foods, the Vienna, Austria-based food technology company, has announced the launch of 'EL BLANCO – Inspired by Black Cod', its latest structured fish alternative made using fungi-derived mycoprotein and microalgae oils. Designed with the help of the company’s patented 3D extrusion process, the product is intended to replicate the rich, flaky texture of black cod – a species widely consumed in high-end restaurants but increasingly under pressure from overfishing and ecological decline.

Black cod, also known as sablefish, has become a prized ingredient in international cuisine, especially across North America, Japan, and parts of Europe. With its buttery mouthfeel and high oil content, it’s a staple of popular dishes such as blackened cod and miso-glazed sablefish – both known for their seared surfaces and delicate flake. But like many wild-caught species, black cod is not immune to sustainability concerns. Although some fisheries are well-managed, demand often outpaces responsible sourcing, leading to strain on natural stocks and growing interest in alternative options.

Revo Foods saw the opportunity to reimagine this species as part of its broader mission to develop structured seafood alternatives with nutritional and environmental advantages. “Black cod is known for its rich flavor and distinct flaky texture, making it an exciting next target for showcasing our innovative 3D extrusion tech,” commented Robin Simsa, CEO. “Mycoprotein remains our hero ingredient because of its superb nutritional qualities – amino acid profile, fibers, low processed.”

EL BLANCO follows Revo’s 2023 launch of THE FILET – Inspired by Salmon, and further demonstrates the potential of 3D structuring in alt-protein applications. The product is manufactured at The Taste Factory, Revo’s production site in Vienna, which began scaled operations in 2024 and serves as the company’s hub for R&D and commercial production.

Using its 3D extrusion process, Revo transforms unstructured mycoprotein – produced via fermentation – into a layered, aligned structure that mimics animal muscle. “Our 3D extrusion technology precisely arranges mycoprotein fibers in structured, aligned layers,” continued Simsa. “This leads to anisotropic fiber formation similar to animal meats.”

To recreate the juicy, fatty quality associated with dishes like blackened cod, Revo Foods also developed an emulsion of microalgae oil that melts slowly during cooking. “The microalgae oil is part of an emulsion that was designed to slowly melt during the cooking process, recreating the behavior of animal fats for a juicy texture,” Simsa explained.

Unlike conventional extrusion technologies, which typically rely on high pressure and high heat, Revo’s approach preserves nutritional integrity by avoiding harsh processing. “Our process doesn’t require high temperature or pressure, and our starting material is a natural, non-processed biomass (mycoprotein),” said Simsa. “It’s about as natural as it gets. We just make the product small in a mixer and align it in layers in our 3D process. No magic, no fancy ingredients – it’s pretty plain and simple.”

Mycoprotein, made from fermented fungi, also offers significant efficiency advantages from a production standpoint. “Mycoprotein doubles its biomass roughly every five hours, making it incredibly efficient for large-scale production,” Simsa noted. “Its naturally fibrous structure is ideal for creating meat-like textures. Maybe most importantly, it is a natural biomass: It does not require any processing, but is just grown and harvested – compared to soy protein for example, which has additional processing steps such as protein isolation and extrusion, where nutrients also get lost.”

With EL BLANCO, Revo is not just aiming to provide a plant-based product – it’s aiming to match the aesthetic and sensory qualities of whole-cut fish. The company holds three patents covering its extrusion method, and its technology is designed to allow for adaptations beyond seafood.

“Our 3D extrusion technology is highly modular and adaptable, allowing for diverse applications beyond fish,” Simsa said. “We will actually release a new product in two weeks which is our most ambitious development yet, which shows the potential of this technology.”

While the structuring and extrusion stages at The Taste Factory are largely automated, downstream operations such as packaging remain more labor-intensive. “The Taste Factory is heavily automated, especially in the extrusion and structuring processes,” Simsa said. “Current bottlenecks are mostly found downstream, such as in packaging and vacuuming, where manual work remains important – but continuous automation improvements are underway.”

Production volumes currently stand at several tons per month, supported by partnerships across the supply chain. “The technology is really our own development that we pride us with,” said Simsa. “Other than that, we work with trusted ingredient suppliers and logistic partners – without this would be impossible.”

Despite the innovation behind its methods, Revo Foods takes a restrained approach to marketing its technology. “We do not use our production technology as part of our communication and marketing, even though it actually brings advantages compared to other methods,” Simsa said. “People do not care about the technology, they only care what the product can do for them in terms of taste, nutrition, etc. This is where we want to lead!”

Simsa believes that providing recognizable, versatile formats – like a whitefish filet suitable for grilling, pan-searing, or baking – is key to helping more consumers make the shift toward alternative proteins. EL BLANCO will be available in supermarkets in Austria and Germany from April 2025, alongside Revo’s existing product range in retailers including REWE, EDEKA, SPAR, and BILLA.

“Our approach is not to tell consumers they need to change everything they eat – it’s about offering options that are familiar, practical, and better for the environment,” Simsa said. “That’s what makes the biggest difference in the long run.”