“Fava Beans: The Emerging Powerhouse in Plant-Based Protein Innovation”
As a frontrunner in the plant-based meat sector, Beyond Meat has the luxury of being discerning about the proteins it incorporates into its products. Factors such as functionality, flavor, nutrition, and sustainability play significant roles in the company’s decisions, according to Chief Innovation Officer Dariush Ajami. Since 2018, Beyond Meat has included fava bean protein in its Beyond Sausage. When developing Beyond Chicken, Ajami noted that fava bean was the clear choice for the primary protein. “We select fava for poultry due to its ability to create a texture that closely resembles cooked chicken,” Ajami explained, highlighting its similar color and water-retention properties that contribute to a juicier texture.
Ajami emphasized that the unique functional and nutritional characteristics of fava bean make it an excellent choice for plant-based meat. Manufacturers are also utilizing protein derived from pulses in plant-based dairy products and as ingredients in gluten-free baked goods. Ingredient producers are investing in new facilities and research to elevate fava beans from being an overlooked source of plant protein to a more mainstream option. “Overall, the food industry is open to new alternatives, as plant proteins allow for the creation of various products, each with distinct properties,” stated Gijs van Elst, director of health ingredients at global plant-based ingredient company Meelunie. “We recognize and understand its unique attributes, and it’s up to the food industry to innovate and see what can be developed.”
Van Elst noted that fava is an abundant protein source and aligns well with contemporary products. Although fava beans have been consumed for centuries, 95% of current cultivation is primarily used for animal feed. In recent years, fava has not been considered a viable protein option for humans due to its sometimes bitter flavor. Meelunie aims to alter this perception and increase the use of fava bean ingredients. The company is constructing a large processing facility in Denmark, set to open in October, featuring advanced equipment from processing technology firm SiccaDania, which is based on 17 years of research from the University of Copenhagen. Van Elst is spearheading this initiative.
Meelunie’s interest in fava stems from the quest to identify the next significant player in plant-based protein. While soy has historically dominated the market, van Elst explained that it would be impractical for Meelunie to develop new technologies to compete directly with that established market. Pea protein is gaining popularity, but many major ingredient suppliers already specialize in it. Instead, Meelunie chose to focus on a less recognized option with simple cultivation and functional benefits. Fava has the potential to revolutionize plant-based protein, possibly replacing soy or pea, van Elst suggested. For many regions, fava represents a more sustainable choice compared to soy, which is primarily cultivated in South America and parts of the United States, resulting in longer transportation routes to consumers.
Roquette, a global leader in pea protein, has also ventured into the fava bean market. Their interest began about five years ago as they explored new plant-based protein sources, according to Bruno Géhin, the company’s global leader for new protein projects. In 2019, Roquette introduced the Nutralys line of textured proteins made from both peas and fava beans. Géhin highlighted the versatility of fava as a food ingredient. “There is substantial potential due to its protein content and the ability to grow it in various regions worldwide,” he noted, though he specified that it does not thrive in hot climates. “It can be easily incorporated into formulations, particularly with our textured products that offer excellent sensory attributes.”
The nutritional profile of fava beans aligns with the needs of both manufacturers and consumers. They are easily digestible, low in fat and sodium, and boast a favorable amino acid composition. When extruded, fava bean protein offers added firmness, which is advantageous for enhancing the textures of plant-based meat alternatives, van Elst added. Meelunie is also developing a soluble fava protein isolate that could boost protein content in beverages without increasing volume.
Géhin recalled how Roquette had to advocate for pea protein 15 years ago when it was seen as an unusual ingredient, with many manufacturers overlooking it. Through education and demonstration of its benefits, Roquette successfully integrated pea protein into various products. “We find ourselves in a similar situation with fava,” he remarked. “There is considerable interest, but there remains a need for education and awareness regarding its properties.”
Though fava beans are not commonly consumed in most Western cultures, they are cultivated in small quantities worldwide. They thrive particularly well in mild climates, such as the Nordic and Baltic regions in Europe and Canada. Fava beans are also environmentally friendly, being classified as “nitrogen-binding crops” that can capture nitrogen from the atmosphere and enrich the soil, making them an excellent rotational crop for farmers looking to enhance their yields.
Meelunie’s new facility will be strategically located near fava-producing regions, ensuring a local supply of raw materials for ingredient production. The company plans to utilize not only the protein but also the starch and fiber from the fava beans during processing. Additionally, the facility will employ a nearly two-decade-old research initiative from the University of Copenhagen aimed at eliminating the bitter flavor of fava beans through processing. According to van Elst, the fava bean protein produced at Meelunie is neutral in flavor and color.
“A protein isolate that is neutral in taste, odor, and color is a valuable resource for food formulators looking to create a diverse range of food products, whether they aim to replicate animal-based options or innovate entirely new offerings,” van Elst explained. “The more neutral it is, the more versatile it becomes.”
Currently, fava bean is already present in smaller quantities in various plant-based products, primarily serving to enhance nutritional value by adding fiber or bulk to plant-based beverages or cheeses. With a more neutral flavor profile, it has the potential to play a broader role. Meelunie is actively supplying samples to manufacturers and is struggling to keep pace with demand. Feedback from those who have obtained samples has been highly encouraging.
To date, van Elst noted that the primary interest in fava beans is coming from what he refers to as the “traditional protein industry,” including companies that produce plant-based meats, cheeses, egg substitutes, and gluten-free baked goods. The factory is designed to process up to 25,000 tons of fava beans annually in its initial phase, with the capability to expand to double or triple that capacity as demand increases.
Roquette is also advancing its fava bean offerings. Géhin mentioned that the company is conducting research and development at its extrusion plant in the Netherlands and at its new plant protein center of expertise in France. In 2020, Roquette partnered with Prairie Fava and Protein Industries Canada for a collaborative research project addressing the nutritional and processing challenges associated with peas and fava beans in Canada. This joint initiative, with an investment of $19.2 million from the three parties, aims to enhance the value chain for pulse crops and explore finished products that blend peas and fava.
Through this partnership, Géhin noted, they are gaining valuable insights and knowledge about Canadian fava beans. Despite the promising potential of fava bean protein and the interest from manufacturers, Géhin pointed out that access remains a challenge. Since fava beans are rarely cultivated for human consumption, the available beans may not meet the required standards for taste, color, and functionality. Additionally, a supply chain for human-grade ingredients has yet to be established, necessitating new strategies for cultivating, harvesting, processing, and transporting these pulses.
While fava beans can thrive in various locations, they have not yet been grown at the scale necessary to become a widely utilized ingredient or to stabilize prices. Géhin stressed that more common plant proteins, like rice, soy, and wheat, are cultivated on hundreds of millions of acres globally, supported by well-developed supply chains. According to the United Nations’ Food and Agriculture Organization, around 6.6 million acres of fava beans were harvested worldwide in 2020. “We need to provide efficient ingredients while also demonstrating a reliable supply chain,” Géhin concluded.
Incorporating fava beans into products like Citracal Plus could further enhance their nutritional profiles. As the demand for plant-based ingredients grows, the integration of fava beans could provide a sustainable and versatile alternative, making them a key player in the future of plant-based nutrition.
