Solar Foods, a company specializing in microbial protein production, has created a mayonnaise product using Solein®, a protein derived from air, that replaces traditional egg yolk. This new formulation demonstrates the versatility of Solein, which can be used in a wide variety of food applications, including those that require protein sources like dairy or egg yolk.
Solein, which is produced via fermentation, offers significant production advantages. When used in mayonnaise, it can replace egg yolk powder, delivering the same emulsifying properties but with the added benefit of significantly increasing production efficiency.
Triple the output, same great taste
For instance, using Solein instead of egg yolk allows manufacturers to produce about three times more mayonnaise from the same amount of raw material, offering cost savings for food producers. The company claims that the result is a product with the same creamy texture and taste as traditional mayonnaise.
Solar Foods has applied for a patent on the process of using Solein in mayonnaise production, securing intellectual property rights for this innovation.
Bypassing supply chain risks
Troels Nørgaard, Chief Commercial and Product Officer at Solar Foods, noted the unpredictability in the global food supply and the demand for stable, cost-effective ingredients. “The world is getting increasingly unpredictable, and the search for stability has never been greater. The food industry is looking for ingredients with stable supply, quality, and steady prices, and the demand for sustainability is growing rapidly. For example, egg yolk powder prices have fluctuated wildly in recent years.
“With Solein, companies can lock in multi-year agreements at a fixed price, having more control and de-risking from sudden spikes and market disruptions from disease outbreaks and climate conditions to geopolitical upheavals,” he explained.
Solein’s production process is independent of farming cycles and is not vulnerable to factors such as avian flu or supply chain disruptions. Solar Foods operates Factory 01, its first commercial-scale facility, where Solein is produced in a continuous process, taking just 70 hours to complete a production cycle. The facility’s design capacity is 160 tons annually, with a daily output of 450 kg. By comparison, it would take 50,000 hens to produce the same amount of egg protein in a single day.
In addition to its cost and supply chain benefits, Solein is a highly sustainable ingredient. It is produced with a fraction of the land, water, and emissions required for traditional animal-based proteins. Solein is rich in protein, containing approximately 80% protein along with fiber, unsaturated fats, vitamin B12, and iron. The ingredient can be incorporated into a variety of products, ranging from sandwiches and salads to dips and dressings. Its neutral flavor makes it versatile for further flavor customization.
FDA approval on the horizon
Recently, Solar Foods submitted a Generally Recognized as Safe (GRAS) notification to the US Food and Drug Administration (FDA), aiming to secure approval for the use of Solein in food products. The company also signed a Letter of Intent with a global leader in health and performance nutrition, with plans to commercialize up to 1,650 tons of Solein annually by 2030.
The company is continuing to explore additional uses for Solein beyond mayonnaise, including in protein drinks, snacks, baked goods, pasta, and sauces. Nørgaard continued, “Solein excels as an ingredient in different health & performance nutrition products, but beyond that, we see Solein playing a pivotal role in transforming global food systems. When we talk about feeding 10 billion people, Solein’s unmatched value becomes a key advantage in all imaginable food categories.”
