ACI Group: Reformulating everyday meat products could unlock major environmental gains

Ingredient distributor and supply chain specialist ACI Group has published a new whitepaper examining how reformulating everyday meat products with plant-based proteins could help reduce the environmental impact of food production while supporting growing global demand for protein.

Titled Hybrid Meat & the Future of Sustainable Protein, the report argues that widespread, partial replacement of animal protein could deliver greater system-wide environmental benefits than relying exclusively on consumers adopting entirely plant-based diets.

The report draws on ACI Group’s experience working with food manufacturers across the protein market and its relationship with IFF, a global leader in food ingredients and solutions. ACI’s expertise spans protein sourcing, formulation and supply across applications including meat, culinary products, bakery and bars, giving the company insights into both the technical and commercial challenges involved in bringing reformulated products to market.

The whitepaper highlights research suggesting that replacing approximately 30% of meat content with plant-based protein can meaningfully reduce greenhouse gas emissions and land use while maintaining the nutritional quality and sensory characteristics consumers expect.

It also cites World Resources Institute (WRI) research illustrating the potential impact of reformulation at scale. WRI estimates that replacing 30% of beef in the approximately 10 billion burgers consumed annually in the US with mushrooms could reduce agricultural production-related emissions comparable to taking two million cars off the road.

Dr Briony Sayers, Food and Nutrition Scientist at ACI Group, said: “The protein transition doesn't have to mean taking meat off the menu. Reformulating products that millions of people already buy could offer a more immediate and accessible route to reducing environmental impact. But this will only work commercially if manufacturers can preserve taste, texture, nutrition and affordability.”

The report identifies an opportunity among consumers already moderating their meat intake. Citing Mintel research, it notes that 34% of UK consumers who regularly ate red meat or poultry reported taking regular meat-free days, rising to 38% among those aged 25 to 34.

However, ACI Group emphasises that successful hybrid meat development requires more than simply replacing animal protein with plant-based ingredients.

Manufacturers also need to consider the commercial implications of reformulation. Reducing the proportion of meat can help bring down cost per use, but the plant-based protein selected must deliver the functionality needed to protect the eating experience. Protein quality and functionality can influence flavour, texture, moisture retention and cooking performance, making ingredient selection critical to the success of the final product.

Supply chain resilience is another consideration as manufacturers scale hybrid formulations. Sourcing strategies need to account for availability, consistency and geographic risk rather than relying on supply chains concentrated in a small number of higher-risk markets.

ACI Group’s protein portfolio includes isolated pea protein, texturised pea protein flakes, soy proteins and specialist plant-based blends selected to support protein enrichment, texture development, moisture management and partial meat replacement. Its technical and supply chain expertise enables manufacturers to assess ingredient choices against the specific requirements of the finished product, from sensory performance and nutrition through to cost and supply chain resilience.

With market projections cited in the report estimating that the global hybrid meat category could grow from approximately US$540.6 million in 2025 to US$1.31 billion by 2035, ACI Group believes hybrid formulations represent a significant commercial opportunity for food manufacturers seeking to improve the nutritional and environmental performance of established products. 

Manufacturers can download the full whitepaper, Hybrid Meat & the Future of Sustainable Protein, from ACI Group to explore the formulation and commercial considerations in more detail. ACI Group can also provide ingredient information and samples to manufacturers looking to investigate hybrid meat applications. Download the whitepaper here or visit www.acigroup.biz for more information.