Precision fermentation is the use of microorganisms to produce commercial products.
At its core, precision fermentation enables the creation of complex and functionally distinct products. In green food processing, it brings an idealistic concept to reality.
Market insights
Precision fermentation continues to generate innovative breakthroughs. This is unsurprising, given the industry's $4.01 billion valuation in 2024[1].
With increasing awareness of the negatives associated with traditional methods, the following is expected:
- ~43.5% Compound Annual Growth Rate (CAGR) over the next 5 years[1].
- 2030 market size of ~$34.61 billion[1].
- Increase in consumer demand for eco-friendly alternatives.
Understanding the truth in precision fermentation
Precision fermentation vs. traditional
Traditional fermentation methods result in food products made up of the organisms themselves, including the product of interest. Beer and bread are classic examples, whereby the yeast, Saccharomyces cerevisiae, is itself part of the consumable product.
Precision fermentation methods instead engineer the host to produce compounds with specific desirable properties, which are then harvested by removing the production organism.
Green food processing is economically viable
Green food processing using microorganisms does require significant upfront costs, particularly when developing novel or unproven methodologies.
However, economies of scale mean that once developed, microbial solutions offer a significant return on investment.
Another consideration is intellectual property. Having full ownership of your strains and systems ensures no downstream royalties to external parties.
Scaling up production
Maintaining desirable and replicable conditions at the lab scale is relatively straightforward. During scale-up, replicating conditions such as temperature, pH, oxygen levels, and nutrient supply become much more challenging.
GMO and UPF: Overlap depends on industrial formulation
Precision fermentation uses organisms to produce single ingredients such as enzymes, proteins, and small molecules.
Most of these are produced within Genetically Modified Organisms (GMOs).
To be classified as an Ultra-Processed Food (UPF), these products must be combined with other industrially derived substances like additives and sweeteners.
How to start with precision fermentation: A step-by-step guide
If, after the ideation, customer segmentation, and product determination phases, you decide to use precision fermentation, the next step is considering outsourcing.
Why outsource?
Specialist microbiology labs are known to cost tens to hundreds of thousands of dollars, not to mention the expertise required to generate meaningful data.
Within the food and ingredients sector, companies often do not have a specialist lab or technical backgrounds, particularly start-ups. Additionally, most precision fermentation companies only need these resources for the early research phase, making outsourcing to a contract research organisation their only feasible option.
We have worked with companies, including those with little technical expertise, to align their food sector and consumer knowledge with what is technically viable.
What do typical precision fermentation projects look like?
Proof of concept
Here, the main focus is to determine an effective way to produce the end product.
Physical attributes, including quality as well as quantity, are often predefined and achieved through iterative experimentation.
Scale up production
Once a proof of concept has been achieved, next we move on to upstream process development and downstream process development. By undertaking these stages, we learn how to generate the product at scale and isolate it.
Regulatory compliance
Products derived from genetically modified organisms are subject to GMO regulations, which vary by country (FSA in England and Wales, FSS in Scotland, and HSENI for Northern Ireland).
GMP Manufacturing transfer
After developing the proof of concept and effectively scaling up, technology transfer from a CRO to a contract manufacturing organisation occurs.
Example food-based precision fermentation project
Overview: Co-founders with vast experience in the flavours industry approached us with a conceptual idea of using enzymes to enhance the palatability of a common healthy alternative food product.
Problem: Though highly experienced in the food sector, neither entrepreneur had a scientific background. Recommendations around using precision fermentation mainly came from investors, consultants, and research.
Solution: All sequences initially provided were found to be non-natural and inexpressible. As such, our scientists carried out a detailed scientific literature review to find previously employed enzymes.
We generated variants of these targets using our machine learning for enzyme engineering tool, EvoSelect®, and transferred these into our Pichia IsoChassis® expression host. After creating novel assays for this project, we discovered these enzymes had the desired properties outlined within the project scope. Our process innovation facility scaled production from a flask to 30 L. We then performed technology transfer to a GMP manufacturing site.
*In line with confidentiality agreements, we have kept names and specific details anonymous.
FAQs
Do you have a predefined workflow?
Yes, many projects in the food sector fit into our IsoZym® bioproduction platform.
My project is currently theoretical. Is there a way I can derisk before committing to working with a CRO?
We offer consultancy services where we perform background research on your project to identify the technical hurdles that lie ahead. Additionally, we can perform a technoeconomic analysis of your technologies to ensure that the current approach is commercially viable.
What's next?
In part 2 of this article, we delve into enzymes, one of the largest and fastest-growing markets not just in precision fermentation but in synthetic biology altogether. If you are interested in reading more about their application and advantages, you can read here.
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Do you have an idea or concept you'd like to develop a proof of concept for or scale? Contact us today to see how we use innovative approaches to simplify the commercialization process.