Project
Exploring a new protein production facility in Lithuania for Cosun Ingredients
Cosun Ingredients is investigating greenfield opportunities for a new production facility in Lithuania to support the growing demand for plant-based protein. NIRAS is helping to examine how a new factory could translate a proven process into efficient, reliable, commercial production at industrial scale.
October 1, 2026
- Sector: Food & Beverage
Turning a plant-based protein developed at laboratory scale into a robust industrial process is rarely a straightforward affair, according to Jeroen van den Boezem, Senior Marketing Director at NIRAS in the Netherlands. “Producers – from start-ups to established manufacturers – know their products and processes better than anyone. However, designing an entirely new production environment requires a broader view: From the behaviour of raw materials and process selection to utilities, hygiene, logistics and future expansion. With ‘new’ raw materials such as plant-based proteins, the details of scale-up are decisive.
"Scaling up requires specialist expertise."
A new production facility
Cosun Ingredients extracts its proteins from fava beans using specialised extraction and purification technology. To prepare for growing demand for Tendra®, the name of the finished fava bean product, the company is investigating a greenfield project for a new production facility in Lithuania, where substantial quantities of fava beans are grown.
NIRAS is supporting the development by examining the requirements and opportunities for a purpose-built factory. Van den Boezem explains: “A greenfield project allows the process, building, utilities and internal logistics to be developed as one integrated concept. It also creates the opportunity to plan for efficient resource use, operational reliability and future expansion from the outset.”
“The origin of proteins is becoming increasingly important. European food manufacturers are increasingly looking for locally produced raw materials and greater security in their supply chains.”
Michiel Pronk, Sales Lead Protein at Cosun Ingredients
Why a greenfield approach?
This is one of several questions NIRAS helps food manufacturers address. For this project, local production is a key factor in determining the plant’s location, while the objective of scaling up the production process also supports the case for a purpose-built facility.
Michiel Pronk, Sales Lead Protein at Cosun Ingredients explains: “The origin of proteins is becoming increasingly important. European food manufacturers are increasingly looking for locally produced raw materials and greater security in their supply chains. Therefore, a site in Lithuania is a logical scenario to investigate.”
“Clients come to us when they want to scale up, broaden their product range or optimise production, for example. They may also need to resolve challenges relating to hygiene, logistics, water, energy or other resources. We assess whether a new factory, a new production line or an expansion of existing facilities or lines offers the strongest solution, and we map the costs, advantages and disadvantages of each option.”
Van den Boezem adds: “Producers often quickly assume that CapEx is unavoidable. But when we take a critical look at the challenges, we regularly conclude a smaller investment may be sufficient, or that optimising what is already there is a good option. Our independence in a process like this is extremely important; we consistently look for the solution that best fits the situation.”
Investing in process knowledge
A greenfield project creates freedom to design an efficient facility from the ground up, but it also makes early technical choices especially important. Van den Boezem adds: “NIRAS invests in knowledge about plant-based proteins and their use in hybrid products. There is still a great deal to be developed for the scale-up phase of plant-based protein production. It all starts with extracting proteins from raw materials, but the facility design must also account for product behaviour, yields, quality, cleanability, utilities and future capacity.”
Pronk adds: “The greatest impact is achieved when producers (of hybrid products) can make improvements without having to compromise. That makes meeting a better sustainability standard not only desirable, but commercially viable as well.”
Designing value into the new facility
The greenfield investigation for Cosun Ingredients also creates an opportunity to consider the whole fava bean and the full production system from the outset. Van den Boezem explains: “Fava beans are used primarily for their proteins, but other components of the bean can also be highly valuable as raw materials. There is a business case there too, one we are keen to contribute to.” NIRAS draws on knowledge gained in other industries, including dairy, where manufacturers have spent generations optimising the use of raw materials, energy and water. “Many of the techniques used to produce plant-based and hybrid products are based on proven principles in engineering, logistics and hygiene. However, the 10% that differ is crucial to success. By addressing that difference early, a new facility can be designed to support efficient production, valuable side streams and long-term flexibility.”
“Many of the techniques used to produce plant-based and hybrid products are based on proven principles in engineering, logistics and hygiene. However, the 10% that differ is crucial to success. By addressing that difference early, a new facility can be designed to support efficient production, valuable side streams and long-term flexibility.”
Jeroen van den Boezem, Senior Market Director NIRAS
Building for the next generation of proteins
“Tendra® (the protein ingredient) was developed with functionality as the starting point. Producers want proteins that behave predictably in their processes, have a neutral taste and are easy to use,” says Pronk.
NIRAS has gained first-hand experience through clients producing hybrid products, including Farm Dairy and Van Loon Group (see below). Jeroen: “Several years ago, we helped Farm Dairy draw up a master plan for expanding dairy production at its current site. They later incorporated hybrid dairy into their plans as well – a very forward-looking step at the time.” Both Farm Dairy and Van Loon Group use Tendra® for their hybrid solutions, a plant-based protein from Cosun Ingredients, part of Royal Cosun. This practical market experience provides valuable context for the proposed facility.
Van den Boezem adds: “Plant-based proteins can offer a less environmental impactful choice and often more affordable alternative to animal protein, as well as a neutral-tasting ingredient for enriching hybrid products.”
Farm Dairy
Farm Dairy focuses on hybrid dairy products as part of its mission to produce better dairy. It does this by combining milk with plant-based ingredients. In collaboration with PlanetDairy, Farm Dairy scaled up a recipe to commercial production, containing 30% plant-based ingredients in the semi-skimmed version and 40% in the full-fat version. Taste was the guiding principle: The product had to remain close to conventional milk.
The dairy processor considers hybrid dairy important because it combines the nutritional value of dairy with the benefits of plant-based ingredients. As fully plant-based alternatives are not yet an obvious choice for everyone, hybrid dairy can help consumers make more sustainable choices step by step.
Van Loon Group
Van Loon Group had already comfortably exceeded its 2024 ambition of 7.5% by 2025: 11.1% of its total meat production volume had been converted to a hybrid product. By partially combining meat with plant-based ingredients based on fava beans and peas, the proportion of plant-based ingredients in the product increases. This step can reduce the climate impact of meat products. The development is in line with themes such as food availability, changing legislation and increasing pressure on both livestock farming and plant-based supply chains.
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