DSM-Firmenich scales yeast protein to replace fishmeal and whey

DSM-Firmenich is preparing to take Protopia, its single-cell yeast protein, into industrial-scale production, with a 120,000-liter fermentation run planned for later this year and a larger European facility expected to follow in 2027. According to information reported by AgFunderNews, the company aims to position the ingredient as an alternative to fishmeal in aquaculture and whey protein in human nutrition, while developing a licensing model for production partners in different markets.

The technology is based on a highly optimized torula yeast strain that can use multiple feedstocks, including ethanol, methanol, acetate, sugar and molasses. DSM-Firmenich says this flexibility, combined with higher yields and productivity, could allow Protopia to compete with established protein ingredients.

The company has already produced Protopia in a 15,000-liter fermenter for customer trials. The next step will be a 120,000-liter run designed to validate the process at larger scale and provide sufficient quantities for market testing.

According to Karim Kurmaly, DSM-Firmenich's director of single-cell protein, the company is planning to move into a facility, most likely in Eastern Europe, with access to bioethanol and beet sugar. The target production capacity is between 2,000 and 10,000 tons per year.

The company expects to produce approximately 400 to 500 tons from the middle of next year to support customer trials while it works on licensing agreements in three countries.

Protopia contains a minimum of 70% protein and has a PDCAAS digestibility score of approximately 0.94 to 0.96, close to that of animal proteins. Its applications include aquaculture, pet food and human food.

DSM-Firmenich says the ingredient can be incorporated into human foods at levels of up to 10% to 12% without negatively affecting taste, while inclusion rates of up to 20% have been tested in salmon diets.

The aquaculture market is one of the company's main targets. Protopia is being positioned as a potential 1:1 replacement for fishmeal, an ingredient whose price and availability have become concerns for salmon producers.

“Today 65% high-quality fish meal is around €3,000/ton and we can compete at those levels. Providing it doesn’t drop below €2,000/ton, we’re okay,” Kurmaly told AgFunderNews.

For human nutrition, the company sees an opportunity in products ranging from snacks and meat alternatives to smoothies and milk alternatives. The ingredient is supplied as a fine, off-white powder with a slight savory note and can provide functional properties such as gelling and emulsification.

The company is also looking at India as a potentially important market. Raman Chandrasekar, managing director of UK-based Sustein Ltd, told AgFunderNews that India's combination of protein demand and underutilized ethanol capacity could create an opportunity for local Protopia production.

The proposed model would integrate fermentation units with existing ethanol or sugar plants, allowing producers to use existing feedstocks, utilities and effluent infrastructure.

According to Chandrasekar, a Protopia facility consuming 100,000 liters of ethanol per day could potentially produce around 16,000 tons of protein annually.

“Protopia can utilize this ethanol as feedstock but also has the flexibility to use any source of sugars, methanol, acetate or any carbon source, really. So it’s a magical technology.”

DSM-Firmenich does not plan to build and operate a large network of Protopia plants itself. Instead, its strategy centers on licensing the technology to local partners.

Under this model, the company would provide the yeast strain, process technology, know-how and technical support, while licensees would manufacture and market the protein. DSM-Firmenich would receive royalties and support partners with applications and market development.

The company's intellectual property portfolio currently includes more than 18 patents covering the strain, fermentation process and applications.

The broader strategy is to replicate the model in regions where companies have access to low-cost feedstocks, existing fermentation infrastructure or inexpensive renewable energy. Beyond Europe and India, DSM-Firmenich identifies Brazil, China and the United States as potential markets.

According to AgFunderNews, the industrial-scale expansion represents a significant test for single-cell protein technology, as many companies in the sector have faced difficulties translating laboratory-scale performance into competitive industrial economics. DSM-Firmenich is betting that its strain, process technology and flexible feedstock strategy can overcome that challenge.