Fermenting the Future: Solar Foods Confirms Solein Can Scale Sustainably

Courtesy: Solar Foods

In a critical milestone for food tech and climate-resilient nutrition, Finnish biotech company Solar Foods has successfully scaled its novel gas fermentation process from pilot to industrial scale. The company announced today that the production parameters achieved at its commercial facility, Factory 01, have verified the scalability of its core technology—unlocking profitability for its next facility, Factory 02, and enabling the commercial launch of Solein® in the United States.

Factory 01, which began operations in April 2024, marks the world’s first full-scale facility producing Solein—a microbial protein made from a previously unknown microorganism discovered in Finnish nature. Unlike conventional agriculture, the production process requires no arable land, animals, or sunlight. Instead, Solein is cultivated using carbon dioxide, hydrogen, and renewable electricity in a 20,000-liter bioreactor through a continuous gas fermentation process entirely operated in-house by Solar Foods.

“Factory 01 is a one-of-a-kind production facility unlike anything ever built before,” said Petri Tervasmäki, Chief Technology Officer at Solar Foods. “Successfully scaling up production is a significant milestone in the development of our technology and the commercialisation of Solein. We have demonstrated that the results achieved in our pilot facility are replicable and scalable.”

Over an uninterrupted eight-month period leading up to a scheduled maintenance break in May, Factory 01 operated continuously and validated industrial-scale output metrics. The facility reached a productivity level of 0.8 grams per liter per hour and an energy efficiency ratio (O2/CO2) of 2.7—an impressive outcome that gives the company confidence in the economic viability of its second commercial plant, now entering the pre-engineering phase. With the current performance benchmarks met, Factory 02 is expected to be profitable upon commissioning.

The company is not stopping there. Efforts are underway to match or exceed the pilot plant’s best productivity figures—up to 1.6 g/l/h—with Factory 01’s industrial-scale systems. These improvements are central to Solar Foods’ plan to reach a 160-ton annual production capacity by the end of 2025. Enhanced energy efficiency and yield will further drive down production costs, strengthening Solein’s competitiveness as a climate-friendly protein ingredient.

The commercialisation of Solein has already begun. Solar Foods has started fulfilling supply agreements and shipping product to U.S. customers. Solein’s shelf life has been extended from one to two years, and new product concepts have been developed to better demonstrate its versatility in consumer foods. The company reports overwhelmingly positive customer feedback, with particular praise for Solein’s nutritional profile, neutral taste, and functionality.

“We were able to start commercialisation activities for Solein in the United States at the very end of last year,” said Juan Manuel Benitez-Garcia, Chief Sales Officer. “The feedback from customers has been bewilderingly positive. Solein receives constant praise for its excellent nutritional values, great taste and functionality.”

In parallel with commercial roll-out, Solar Foods has signed a Memorandum of Understanding with two international customers to explore future deliveries totalling 6,000 tonnes of Solein per year. If the agreements are finalised, they would account for roughly half the output of Factory 02, securing a strong commercial foundation before construction begins.

Solar Foods’ model offers a radical departure from conventional protein production, promising a resilient, scalable solution to feed a growing population within planetary boundaries. With Solein now proven at scale and U.S. commercialisation underway, the company appears poised to enter its next growth phase—one that could reshape how and where we make food.