Solein sets benchmark in protein innovation for food manufacturers

Solar Foods’ microbial protein Solein is emerging as one of the most disruptive ingredient innovations in the food industry — and its latest application in mayonnaise production could reshape how manufacturers think about cost, functionality, and sustainability.

The company has filed a patent for a novel use of Solein in mayonnaise, demonstrating its ability to fully replace egg yolk powder while delivering superior emulsification performance. For food processors, this means not only a plant-based alternative to a staple ingredient, but a direct production advantage: the same amount of Solein yields approximately three times more mayonnaise than dried egg yolk, unlocking significant cost efficiencies.

“Solein’s emulsifying properties are exceptional,” says Troels Nørgaard, chief commercial and product officer at Solar Foods. “It delivers the same creamy texture and mouthfeel as traditional mayonnaise, without compromising taste — and with far greater production efficiency.”

A game-changer for formulators
Mayonnaise is traditionally made by emulsifying oil with egg yolk, which acts as a natural binder. Solein replicates this function with precision, offering a neutral taste profile and smooth texture that supports both classic and flavoured formulations — from garlic aioli to spicy chili mayo.

For food manufacturers, Solein’s performance translates into reduced raw material usage, streamlined production, and lower costs. Its compatibility with existing processes makes it a plug-and-play solution for reformulation, especially in the fast-growing animal-free and flexitarian segments.

With the global mayonnaise market projected to reach nearly $13 billion in 2025, and demand for plant-based alternatives accelerating, Solein’s entry into this category is timely and strategic.

Stable supply, scalable production
Beyond functionality, Solein offers a reliable and scalable protein source. Produced via fermentation in Solar Foods’ Factory 01 — a commercial-scale facility with a design capacity of 160 tonnes annually — Solein is made in a continuous 70-hour cycle, independent of agricultural constraints.

To put this in perspective: producing 450 kg of Solein daily requires no farmland or livestock, whereas generating the same amount of egg protein would require 50,000 hens, according to Solar Foods. Solein’s production is unaffected by avian flu, climate volatility, or geopolitical disruptions — offering food companies long-term price stability and supply security.

“The world is getting increasingly unpredictable,” Nørgaard notes. “With Solein, manufacturers can lock in multi-year agreements at fixed prices, de-risking their operations from market shocks and ingredient volatility.”

Nutritional and regulatory versatility
With approximately 80% protein content, plus fibre, unsaturated fats, vitamin B12, and iron, Solein supports a wide range of health and wellness claims. It’s animal-free, gluten-free, cholesterol-free, and certified halal and kosher, making it suitable for diverse dietary needs and global markets.

Its neutral flavour and clean label credentials make it ideal for reformulating across categories, from sauces and dressings to baked goods, soups, snacks, and dairy alternatives.

A platform ingredient
Solar Foods sees Solein as a foundational ingredient for next-generation food systems. Its versatility spans health and performance nutrition, mainstream reformulation, and climate-resilient food innovation.

“Solein’s journey is just beginning,” says Nørgaard. “We’re exploring applications across every major food category — and the potential to feed 10 billion people sustainably. This isn’t just a new ingredient. It’s a new harvest for humankind.”