Happy Plant Protein showcases game-changing tech at Protein Production Technology International webinar

The latest Protein Production Technology International webinar, From Tech to Table: Making Plant Protein Work for Real Food and Real Consumers, held 28 August 2025 in partnership with Happy Plant Protein, explored how the industry can deliver plant-based products that are both technically advanced and appealing to consumers.

The discussion brought together leaders across technology, research, and product development, including Jari Karlsson (CEO) and Pekka Lehtinen (CTO), Co-founders of Happy Plant Protein; Emilia Nordlund, Research Manager for Industrial Biotechnology & Food at Finland's VTT; Lukas Frei, Head of Market Segment for Protein & Ingredients at Bühler; and Lisa Zychowski, Head of Formulations & Strategic Procurement at Planted.

Happy Plant Protein, a one-year-old spin-off from Finland’s VTT, introduced its patented single-step dry extrusion technology. The process converts flours from crops such as peas, faba beans, and chickpeas into two valuable outputs: a high-protein texturized vegetable protein (TVP) and a carbohydrate flour branded as Happy Flour Plus.

“Our method combines traditional fractionation and texturization in a single step, without chemicals or waste streams,” explained Lehtinen. “Everything that goes into the machine comes out as either protein or carbohydrate ingredients.”

Karlsson added that the company’s TVP offers a protein content of 55-65% and delivers superior taste and texture compared to existing products, with fewer off-flavors. Beyond meat alternatives, the ingredients can be used in dairy-style products, spreads, and gluten-free baking.

In the panel discussion, watched by more than 350 international delegates, Karlsson acknowledged that early plant-based foods often struggled with poor taste, texture, and overly complex ingredient lists. While recent progress has improved sensory quality, he emphasized the importance of affordability. “If we’re talking about reaching ordinary consumers, affordability is critical,” he said. “And we need to move beyond black-and-white thinking – this isn’t about food ‘for vegans’ versus ‘for others.’ We should be preparing food for everyone.”

Zychowski agreed, noting that in markets such as Germany, price is the most decisive factor. “After taste, the next priority is the ingredient list. It has to be short and recognizable – what we call ‘kitchen ingredients’,” she said. She predicted that the “3.0 generation” of products will combine minimally processed ingredients with fermentation to further enhance quality.

Nordlund stressed that no single ingredient or approach can solve the protein transition. She presented a pyramid framework for ingredient production, encouraging greater use of less processed materials to preserve nutritional quality and reduce costs. “There’s no one-size-fits-all solution,” she said. “But if we can maximize resource use and retain natural nutrients, both industry and consumers benefit.”

Frei echoed the need for affordability and consistency, pointing to drying and rehydration as costly and energy-intensive steps that should be minimized. “Integrated processing is critical if we want to move forward,” he said. “Avoiding unnecessary intermediate steps has a huge impact on both sustainability and profitability.”

Fermentation emerged as a recurring theme across the panel. At Planted, Zychowski described it as “one of the pillars of the company,” enabling minimally processed ingredients to deliver improved digestibility, taste, and texture. Frei highlighted the potential of solid-state fermentation to upcycle side streams, adding value to both food and feed.

Nordlund highlighted the importance of long-term research in this area, particularly to diversify the limited range of crops currently used in plant-based production. “We need diversity in crops and in processing to make the protein transition truly sustainable,” she said.

Panelists were asked what kind of breakthrough could become the 'iPhone moment' for alternative proteins. Karlsson suggested it may come through combining multiple innovations to achieve a major shift, while Lehtinen saw hybrid meat-plant products as a route to mainstream acceptance.

Zychowski identified a minimally processed, consumer-friendly replacement for methylcellulose as the potential game changer: “That would make it much easier for producers even those with less R&D capability – to develop products with very short ingredient lists.” Frei agreed, saying such an innovation would reshape the industry.

Nordlund, meanwhile, envisioned combining plant proteins with fermentation-derived lipids to finally deliver the juiciness and mouthfeel consumers expect.

Across the session, the panel emphasized that no single company or technology can achieve the protein transition alone. Startups such as Happy Plant Protein are driving momentum, but partnerships with established food companies, equipment providers, and research institutions will be critical.

Importantly, Lehtinen revealed that Happy Plant Protein has already completed its first commercial production run. “We’re still at the beginning, but this milestone shows we’re truly on the way,” he said.

For those who missed the live discussion, a playback of the full webinar is now available to watch on demand. With perspectives from startups, multinationals, and researchers, the conversation offers rare insight into the next wave of plant protein innovation – and how to make it work for real food and real consumers.

Click here to register and watch the playback