Plant-Based Meat Alternatives: Manufacturing Food Safety Considerations

Younes Jellal, Head of Supply Quality & Product Safety, Impossible Foods

The plant-based meat alternatives “PBMAs” market has experienced significant growth and evolution. Traditional options such as tofu and tempeh have existed for thousands of years. The plant-based meat industry in the United States has a history dating back to the 19th century, with several leading companies established in the 1970s–90s. Until recently, this category remained relatively small and was primarily consumed by vegans and vegetarians. However, there has been a notable expansion in the market in the past several years. This is due mostly to the emergence of plant-based products mimicking animal counterparts, such as burgers and nuggets that closely resemble conventional meat. Impossible Burger and Beyond Burger (2016) are notable examples that have gained popularity in mainstream fast-food outlets and then retail (2020).

With such rapid growth come new challenges to ensuring the safety of these products. Manufacturing food safety considerations for plant-based meat alternatives are crucial to the production of safe and high-quality products: 

Ingredient Sourcing and Supply Chain Visibility: Rigorous evaluation and approval of suppliers are essential to guarantee that the raw materials and ingredients sourced for plant-based products meet the required safety standards. These ingredients need strong traceability systems to ensure each ingredient can be traced back to its source to facilitate quick and effective responses in case of safety concerns. 

It is critical to seek transparency in the supply chain to monitor and control potential risks from raw material sourcing to the final product. Manufacturers must work closely with suppliers to address safety concerns and ensure alignment with food safety practices. 

Working together with suppliers enables manufacturers to establish a comprehensive approach to risk assessment, considering various factors that could impact the safety of the final product. An example of a unique risk consideration to PBMAs is potentially hidden Animal Derivative Materials. Conducting thorough risk assessments is vital, especially in identifying and addressing potential points of contact and/or introduction of animal derivatives. This includes scrutinizing raw materials, processing methods, and facilities. Another important consideration is assessing and managing risks specific to bio-manufacturing processes. Bio-manufacturing could inadvertently introduce hidden hazards such as gluten from growth media that may be used and microbial concerns that may arise from lengthy fermentation processes under “warm” conditions.  

Testing Protocols: Implementing testing protocols, such as test and hold procedures, are strongly recommended for PBMAs due to the lack of relevant scientific evidence pertinent to some novel plant-based products and processes. This ensures products are thoroughly examined before being released to the market. This helps catch any potential safety issues before they reach consumers. In addition, conducting challenge studies where contaminants or stressors are intentionally introduced to assess how well the product and the manufacturing process can withstand such challenges could be key to preventing food safety and spoilage concerns.

"For individuals involved in plant-based food safety, professional development should be encouraged to remain adaptive and resilient in the face of evolving challenges."

Training and Awareness: Personnel involved in plant-based product manufacturing should receive adequate training on food safety practices. This includes understanding the unique considerations related to plant-based ingredients and production processes. It is crucial to establish awareness programs that help keep employees informed about the specific challenges and requirements associated with maintaining the food safety of PBMAs, especially when manufactured in shared facilities with animal proteins. 

Audits (GFSI, Supplier, and Internal Audits): It is critical to develop specific auditing criteria based on risk assessments and to conduct regular audits. This is important for evaluating and verifying the effectiveness of the food safety management system, which involves systematic inspections and assessments of all relevant processes and documentation. Audits provide opportunities for continuous improvement by identifying areas that can be enhanced to further ensure product safety. Some GFSI schemes now offer plant-based certification programs such as BRCGS Plant-Based Standard, which can be added to any GFSI benchmarked Food Standard.  

Product and Marketing Claims: Product and marketing claims should align with regulations to prevent misleading information about plant-based products' safety or nutritional aspects. It’s essential to provide accurate and transparent information to consumers to build trust and help them make informed decisions regarding the safety and authenticity of plant-based alternatives.

Global Market Nuances: Acknowledging and navigating international market nuances involves staying informed about different regions' diverse regulations, standards, and cultural expectations. Subsequently, adapting the food safety management system components to align with those variations ensures that plant-based product offerings meet the specific safety requirements of each market. An area of focus is the fortification of PBMAs with added micronutrients. It’s important to check for the mandatory inclusion of certain nutrients in some destination markets or the lack of approval for using the same nutrients in PBMAs in other markets. 

Continuous education is necessary to navigate the dynamic landscape of food safety. This involves staying updated on emerging risks, technological advancements, and industry best practices. For individuals involved in plant-based food safety, professional development should be encouraged to remain adaptive and resilient in the face of evolving challenges. By integrating these considerations into the manufacturing process, PBMA producers can uphold the highest food safety standards, meeting both regulatory requirements and consumer expectations.