Latest / The Manufacturing Podcast with Fexingo: Factories, Supply Chains, and Industrial Business / How a Danish Factory Is Making Protein from Methane
Transcript
- Lucas: You know how we talk a lot on this show about turning waste into something valuable — food waste, plastic waste, even CO2. But I came across a factory in Denmark that starts with something you'd never guess could become food. Luna: Oh, I'm curious. What is it? Lucas: Methane. Natural gas. The company is called Unibio, and they've built a facility in Kalundborg, Denmark, that grows protein from methane gas using bacteria. Not from plants or animals — from gas. Luna: So they're feeding bacteria methane and then harvesting the bacteria as protein? Is that the basic idea? Lucas: Exactly. The technical term is 'single-cell protein.' They use a specific strain of bacteria called Methylococcus capsulatus, which naturally consumes methane as its energy source. The bacteria are grown in large fermenters — think giant stainless steel tanks — and they multiply rapidly, producing a high-protein biomass. Luna: And that biomass becomes, what, a powder? A meal? Lucas: It's dried into a fine powder that's about 70 percent protein, with a full amino acid profile. Right now it's primarily used as animal feed — for salmon, for chickens, for pigs. It's a replacement for fishmeal or soy protein concentrate. Luna: And the methane itself — where does it come from? Are they using pipeline natural gas? Lucas: They can use both. The Kalundborg plant is located at a Statoil facility, so they're using natural gas from the grid. But the beauty is, they can also use biogas from landfills or agricultural waste. In fact, Unibio has a pilot project in Russia using associated petroleum gas — the methane that gets flared off at oil wells. Luna: So instead of flaring that gas and wasting it, you're making protein. That's a nice double benefit. Lucas: Right. Flaring releases CO2 and wastes a resource. Unibio's process actually captures that methane and turns it into something valuable. And the land footprint is radically smaller than soy or even algae. They claim their production requires about one-fifth the land area of soy farming per kilogram of protein, and virtually no water. Luna: But there's an energy cost, right? Fermentation tanks need heating and mixing, and you have to dry the product. How does the overall energy balance compare? Lucas: That's the key question. Unibio says their process uses about 2.5 kilowatt-hours of energy per kilogram of protein, which they say is competitive with soy protein concentrate when you factor in agricultural energy use. But critics point out that if you're using fossil methane, the carbon footprint depends on whether the methane would have been released anyway. The best case is using captured methane that would otherwise be flared. Luna: And consumer acceptance? I mean, 'protein grown on natural gas' doesn't exactly roll off the tongue. Are people going to eat this? Lucas: For animal feed, it's a much easier sell. Farmers care about cost and performance, not provenance. And Unibio has been selling to feed companies for years. For human food, there's more of a hurdle, but it's not unprecedented. There's a company called Calysta in the US making a similar product, and another called FeedKind. The science is solid. It's really about branding and regulatory approval. Luna: So where is Unibio today in terms of scale? Are we talking pilot plant or commercial production? Lucas: They have a commercial-scale plant in Kalundborg that's been operating since 2018, producing about 200 tons of protein per year. They're now building a larger facility in Denmark that should produce 10,000 tons annually by 2028. And they have licensing deals with partners in Russia and China. Luna: Ten thousand tons — that's still tiny compared to global soy production, which is around 350 million tons. But it's a start. Lucas: Absolutely. The argument is that this technology can complement traditional agriculture, not replace it. In a world where we need to feed 10 billion people while reducing deforestation and emissions, having an alternative that uses less land and water is valuable. And methane is abundant — there are thousands of landfills and oil wells flaring gas right now that could be feeding these fermenters. Luna: What about the cost per kilogram? Is it price-competitive with soy? Lucas: Unibio claims their protein costs around $1.50 to $2 per kilogram, which is in the ballpark of soy protein concentrate. But that depends on methane prices and scale. As they build bigger plants, costs should come down. And if carbon pricing ever becomes widespread, using captured methane instead of flaring could give them an additional cost advantage. Luna: It's interesting to think about — we've seen how fermentation can make everything from insulin to rennet. This is just another application of that same core technology. Lucas: Exactly. And the companies that are doing this — Unibio, Calysta, others — they're essentially industrializing photosynthesis without the plant. Instead of sunlight and CO2, they use methane and oxygen. It's a different metabolic pathway, but the end result is the same: protein. Luna: Speaking of industrial processes, it reminds me of something you mentioned earlier about turning waste into value. And I know our listeners are often people working in manufacturing or supply chain — folks who are always looking for more efficient ways to do things. If you've found value in these conversations, whether it's a new idea for your own plant or just a better understanding of industrial innovation, we want to let you know that listener support is what keeps this show ad-free and independent. Lucas: Yeah, it's a small way to give back if the show has helped you. You can support us at buy me a coffee dot com slash fexingo. No pressure at all — just if you feel like it. Luna: And it genuinely helps us keep bringing you stories like this one. Now, back to Unibio — you mentioned they're expanding. What's the next big milestone for them? Lucas: The big one is the new 10,000-ton plant in Denmark. But they're also working on getting their protein approved for human consumption in Europe and the US. That would open up a much larger market. If they can get that approval, you might start seeing 'methane protein' in protein bars or plant-based meat products within the next five years. Luna: Would you eat it? Lucas: I would. The bacteria are killed during processing, the protein is highly refined, and it's been tested for safety. It's not that different from eating yeast or bacteria-based probiotics. In fact, Quorn is made from a fungus — this is just another microorganism. So yeah, I'd try it. Luna: I think I would too, as long as it tastes neutral. I don't want my protein bar to taste like natural gas. Lucas: Fair point. From what I've read, the final product is flavourless and odourless, so it should blend right in. The question is whether consumers will accept the idea. That's always the wildcard with novel foods. Luna: Well, it's a fascinating angle on the protein transition. I'll be watching to see if Unibio's new plant comes online on schedule. Lucas: Me too. It's one of those technologies that seems futuristic but is already happening. And if it scales, it could make a real dent in the environmental footprint of animal feed. Luna: Alright, that's the story of protein from methane. Thanks for listening — we'll be back next time with another look inside the factories changing how we make things.