Scale-Up Economics for Cultured Meat: Techno-Economic Analysis and Due Diligence

Abstract

“Cultured meat” technologies aim to replace conventional meat with analogous or alternative bioproducts from animal cell culture. Developers of these technologies claim their products, also known as “cell-based” or “cultivated” meat, will be safer and more environmentally friendly than conventional meat while offering improved farm-animal welfare. To these ends, Open Philanthropy commissioned this assessment of cultured meat’s potential to measurably displace the consumption of conventional meat.Recognizing that the scalability of any cultured-meat products must in turn depend on the scale and process intensity of animal cell production, this study draws on techno-economic analysis and due-diligence perspectives in industrial fermentation and upstream biopharmaceuticals to assess the extent to which animal cell culture could be scaled like a fermentation process.The analysis identifies a number of significant barriers to the scale-up of animal cell culture. Bioreactor design principles indicate a variety of issues associated with bulk cell growth in culture: Low growth rate, metabolic inefficiency, catabolite and CO2 inhibition, and bubble-induced cell damage will all limit practical bioreactor volume and attainable cell density. With existing bioreactor designs and animal cell lines, a significant engineering effort would be required to address even one of these issues.Economic challenges are further examined. Equipment and facilities with adequate microbial contamination safeguards are expected to have high capital costs. Suitable formulations of amino acids and protein growth factors are not currently produced at scales consistent with food production, and their projected costs at scale are likewise high. The replacement of amino-acid media with plant protein hydrolysates is discussed and requires further study.Capital- and operating-cost analyses of conceptual cell-mass production facilities indicate production economics that would likely preclude the affordability of their products as food. The analysis concludes that metabolic efficiency enhancements and the development of low-cost media from plant hydrolysates are both necessary but insufficient conditions for the measurable displacement of conventional meat by cultured meat.

How Cellular Agriculture Systems Can Promote Food Security

“…Cellular agriculture does not yet produce a significant amount of food, and there remains uncertainty on what amount of food could be possible to produce. Recent techno-economic analyses of cultured meat production have estimated different potential costs per kilogram ranging by several orders of magnitude (Humbird, 2020;Risner et al, 2021;Vergeer et al, 2021;Zhang and Dullaghan, 2021). Animal cell cultures also have several technical challenges and biological limits that affect the maximum possible cell density and bioreactor size.…”

“…Animal cell cultures also have several technical challenges and biological limits that affect the maximum possible cell density and bioreactor size. This may limit the amount of food it is feasible to produce from animal cell cultures, and therefore the extent to which cultured meat may contribute to food supply (Humbird, 2020;Risner et al, 2021;Vergeer et al, 2021). Several microbial cell culture technologies, however, have been previously scaled to extremely large production volumes (e.g., fuel ethanol, baker's yeast, lysine for animal feed, wastewater treatment) (Humbird, 2020).…”

Scale‐up economics for cultured meat

“…These technical and economic aspects are explored in a recent assessment of cultured meat's potential to measurably displace the human consumption of conventional meat (Humbird, 2020 ). Its methods and findings are summarized in the present article.…”

Simple and effective serum-free medium for sustained expansion of bovine satellite cells for cell cultured meat

“…Here, cell culture media is a particularly problematic hurdle for several reasons. First, cell culture media comprises the majority (>99%) of the cost of current production systems [7][8][9] . Second, the culture of meat-relevant cells (e.g., bovine satellite cells) has traditionally relied on fetal bovine serum (FBS), a notoriously expensive, unsustainable, and inconsistent component, which is inherently antithetical to the aims of cultured meat 4 .…”

“…At the same time, cultured meat could improve animal welfare, food security, and human health outcomes [4][5][6] . The challenges that face the successful technological transition of cultured meat to the marketplace stem from the need for production systems that are low-cost, scalable, food-safe, and free of animal-derived inputs 4,7,8 . Here, cell culture media is a particularly problematic hurdle for several reasons.…”