Plant-based protein manufacturer, Lovingly Made Ingredients, has entered the North American market by setting up a protein production facility in Calgary, Canada. 

The company – the ingredient manufacturing division of European plant-based key player, the Meatless Farm – is poised to meet the increasing demand for pea protein and other pulses, while sourcing raw ingredients from a local farmer network. 

The significant move is poised to help meet the increasing consumer demand for alternative proteins. Lovingly Made Ingredients forecasts an annual production capacity of 6,000 metric tons.

Sales manager Lindsay Sutton explains how Canada’s exceptional farming standards and investment in plant protein research drew the company to the North American market.

“Being that Canada is one of the top growers of the peas sold in the world, it made complete sense to build here. Canada also has some of the highest farming standards globally and has the consistency and quality we needed,” she tells FoodIngredientsFirst.

“We were built for growth. Canada is also well-positioned for shipping products all over North America, Asia as well as Europe. There is also research into plant proteins in Canada, an ecosystem of other plant-based innovations,” she continues.

“There’s also the skilled workforce. Calgary is seen as one of the best places to live/work, and that fits with the talent we want to attract.”

Sustainable sourcing 
The 33,000 square foot Calgary facility will begin with pea protein, but in a couple of months, fava beans and hemp will be key ingredients. The company will also investigate the potential use of novel proteins such as canola, mung beans, chickpeas and pumpkin.”

We will source as locally as possible to reduce the distance that raw materials need to travel to our facility. This year we will be working with Canadian farmers on supply contracts that provide mutual benefit. The farmer is the most vital part of this whole thing for us.”

“Our soil is one of our most important resources. We don’t want to sit on the sidelines and drive further issues here. If we can find a crop, a way of working, or a by-product, that means the farmer has the whole seed and even plant used, we lower our impact. If we can help innovate, help reduce pesticide/herbicide use and bring improved soil health, then we all win,” Sutton continues.

The textured proteins made from sustainably sourced pulses and other crops offer high-protein, clean-flavor ingredients that are ideal for a variety of food applications.

In dry form, textured protein appears as chunks or shreds, offering great texture plus protein in snacks, cereals, toppings and coatings.

When hydrated, textured proteins work well as plant-based meat analogs or alternatives because of the chewy texture. These versatile products also can add functional protein in bakery, snacks, soups, sauces and ready-meal formulations.

Technologies and processes 
The new facility will also use innovative equipment and processes.

“We have the largest twin-screw extruder in Canada. Our products start with quality Canadian pea proteins that are transformed through an extrusion process to create dry, crisp protein chunks or textured pea protein,” Sutton adds.

“Textured pea protein is a highly nutritious pea product, rich in protein and low in fat, making it an excellent alternative to meat,” she notes. “These textured proteins are made from pea proteins that have been cooked under pressure through the extrusion process and then dried.”

“Simply put, extrusion is akin to making bread: steam, pressure and the best Canadian prairie ingredients to make high functioning textured proteins.”

The process begins when pea proteins are mixed with water to create a wet mixture. This wet mixture is heated to allow the proteins to denature under pressure and time. At the end of the process, the wet protein solution exits the extruder, wher the sudden pressure change causes rapid expansion into a puffy solid that is then dried.

The shape, size and density of the texturized proteins can be changed depending on the application.

Lovingly Made Ingredients offers customized blends of plant proteins from size, source, content and application.

The new plant was designed and supplied by the Buhler group.

Lovingly Made Ingredients is also working toward certified B-Corporation status after 12 months of production and aims to offset its facilities’ carbon emissions to as close to zero as possible.

Key drivers for plant-based space
As underscored by Innova Market Insights’ Top Ten Trends 2021, the plant-based space is ever-evolving. The “Plant-Forward” trend highlights how the accelerated demand for new plant-based formats and more sophisticated alternatives drives successful launches.

It is largely agreed within the F&B industry that the sustainability and environmental impacts of feeding the world healthily and equitably will require seismic shifts in how food is produced.

Part of this focuses on reducing meat consumption and shifting diets toward plant-based eating while the commercialization of cultured meat. Poultry, seafood and fish are on the horizon. 

The shift toward plant-based diets has been driven strongly by consumer concern surrounding health, well-being and animal welfare. Plant-based meat analogs provide a meaningful way for consumers to positively impact their health, enhanced nutrition, weight management and overall health.

“Protein is a big challenge. Our world cannot sustain meat-centered diets and balance access and environmental degradation. Diversity in the types of protein types from plant, animal, insect is needed to feed our world. Plant-based meat alternatives have been shown to require less carbon, water and energy compared to red meats, for instance,” Sutton continues.

“Consumers have a huge role in this to make meaningful choices that can impact our globe. The reality of climate change and its impacts is becoming more tangible to consumers. For us, it’s not just about ‘talking the talk,’ but we are ‘walking the walk.’ We choose plant-based proteins to walk by.”

Lovingly Made ingredients is focused on its own impacts and making each step more sustainable from water and energy use.

“We are actively assessing our impact through life cycle assessments to find areas for improvement. It’s not enough for us to just say we are ‘sustainable.’ We need to measure it and show it then strive for more along the supply chain, from our farmers to our supplier to the end customer,” notes Sutton.

“This is real for us and is woven into everything we do. Our sister company, The Meatless Farm, started with this in the forefront by helping people make a big difference through small change. Focused on making delicious, healthy and sustainable options.”

Taste is king 
Sutton also notes that despite environmental and ethical concerns over food sourcing and production, taste remains the primary driver for consumers seeking plant-based products.

“Our facility is designed to do real and timely innovation and provide the next generation of textured proteins, snacks and cereals into the world,” she remarks.

“We are testing novel sources of protein from a variety of crops to push the limits on a possibility. We want to be part of the movement of providing dramatic improvements to taste, texture and functionality of plant-based analogs.”