quorn - steve finn · 2018. 8. 3. · brief history of quorn • early 1960s experts predicted...
TRANSCRIPT
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Quorn FoodsA Fifty Year Overnight Success Story
Steve Finn
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Who is Steve Finn?Married with four children, one Daughter‐in‐law, and one Grandson
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Leisure
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Work• NHS – Biomedical Scientist• ICI – Analytical Chemist• ICI ‐ Process Technologist/Microbiologist• ICI/Quorn – Shift Manager• AZ/Quorn – Operations Manager• Quorn – General Manager
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How Did Quorn Begin?
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The 1960s was a time of huge achievement...
Once Upon a Time, 50 years ago
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....And growing concerns
Quorn in context
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A man with a big idea
Quorn story
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Brief History of Quorn
• Early 1960s experts predicted worldwide protein famine by 1980s
• Lord Rank started the ‘Starch to Protein’ project• Search began in 1967 – requirements were delicious,
nutritious and safe to eat food• >3000 soil samples from all over the world were screened• Fusarium venenatum A3/5 was eventually found in a garden
in Marlow, Buckinghamshire• 20 year research/scale‐up programme• JV with ICI in 1984• Approved by MAFF in 1985 as the ‘first new food since the
potato’• Marlow Foods formed in 1986 and first product on sale 1987
after RHM/ICI joint venture
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Why Billingham?
‘Belasis Site’ 35 years ago‘Food from Fuel’Belasis Site was first developed by ICI in the early 1980’s to make an animal feed single‐cell protein ‐called Pruteen
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Technical Success
However, Commercial Failure
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The time for Mycoproteinis now!
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+ a large number of ducks, rabbits, horses, turkeys…
..3 camels and one unfortunate mule
Chickens 110,000Pigs 2,630Sheep 922Goats 781Cows 557
The scale of livestock production is driven by our desire for cheaper and more plentiful meat, but there are damaging consequences,
which at the moment are forecast only to intensify
The current context…
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Challenge Consequence
To feed 9bn in 2050 FAO say we need 70% more food available
some of the true costs of cheap and plentiful animal protein
Challenges for a scalable, meat-based sustainable, food future
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Global Greenhouse Gas Producers
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Mishka Henner
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Quorn Environmental Footprint
Key Comparisons vs Quorn
GHG LAND WATER
Beef Mixedx9 more GHG
x9 more land
x10more water
Beef Grazed
x36 more GHG
x12 more land
x11 more water
Chickenx3 more GHG
x2 more land
x2 more water
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No other protein can create the meat like textures achieved by Quorn
Unique textural attributes
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Additional InterestSCFA productionFibre (chitin and ẞ‐glucans)
Mycoprotein: protein and fibre
Physical Properties (shape)
BENEFITS
Texture creation• Authentic meat‐like texture• Creation of fibrosity through fibre assembly
General Nutrition• High quality protein• Low fat content (membranephospho‐lipids)
• High fibre (cell wall)• Low energy density
Clinical Research Programmes• Lowering serum cholesterol• Satiety• Insulinemia and glycemia in diabetics
Composition
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Quorn fits easily into everyday life and makes meat reduction simple…
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Quorn Foods UK Supply Chain BillinghamFermentation
Mycoprotein Production
StokesleyForming and Frozen
Manufacture and Packing
MethwoldTertiary Manufacture
Chilled Packing
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Billingham ProcessEfficiently Converts Glucose to Protein
Fermentation
To grow the organism
RNA Reduction
To meet specification
Centrifuge
Separate solids and liquid
Chillers
Harvesting of Mycoprotein
paste
Despatch
Chilled to Stokesley for
onward processing
MycoproteinGrowth Medium
Utilities
Deep shaft fermenter
to process waste
Clarifier
to separate
Clean Water
To River Tees
Sludge
to land injection
400,000t of Mycoprotein produced to date (>4bn
meals)Exported to 20 countries
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Paste Volume Growth 1994 - 2016
Paste volume doubled 2001 – 2014.
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Paste Volume Growth Projected to 2026
Paste volume has doubled 2010 –
2018.
It will then double again 2018 ‐2022
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Building a ‘Billion Dollar’ Business by 2027
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Existing 3 x Fermenters1994, 1996, 2015480,000 litres total
capacity
BF1 Harvesting/FormingAug 2018
Mince & Pieces
BF2 Harvesting/FormingOct 2021
Fillets, Nuggets Goujons etc
BQ5 FermenterJuly 2020
170,000 litres
BQ6 FermenterJan 2022
170,000 litres
Wastewater TreatmentAug 2018
R&D Pilot PlantJan 2019
Combined Investment >£120mGenerating ~100 new Jobs
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• Pilot plant under construction– Cost estimate‐ £2M– Build start – Q2 2018– Commissioning – Q1 2019– Capacity ~200 litres– New science based employment on site for graduate level scientists– Next generation IP development
• Development facility to optimise production
• Biotech centre for strain improvement
• Process Design centre for next generation fermentation– collaboration with CPI Wilton
Global Centre of Excellence for Fermentation science
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An easy way to remember this…….
Member of the FUNGI familyThat’s grown by FERMENTATIONAnd is FILAMENTOUSThat helps us to create FIBROSITYWhich we achieve through FREEZING
The Eight F’s
And creates nutritious new FOODWith a low environmental FOOTPRINTPart of a Sustainable Food Future
Easy Way to Remember:
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THANK YOU