Äio scales up yeast-based oil production with first 1-tonne run
The product delivers natural umami flavour and a versatile texture, making it suitable for a wide variety of applications, including plant-based meats and confectionery.
ESTONIA – Food-tech start-up Äio has reached a significant milestone with the successful completion of its first full-scale production run of yeast-based oil, achieving a volume of 1 tonne.
The breakthrough represents a 300-fold increase from its initial laboratory capacity, demonstrating the company’s ability to scale beyond pilot settings.
The production run, which took place between late 2024 and mid-2025, is a critical step in Äio’s mission to provide natural, sustainable alternatives to environmentally damaging food ingredients.
Äio uses biomass and precision fermentation to turn industrial side streams into nutrient-rich oils and fats.
Its encapsulated yeast oil is high in protein, fibre and functional lipids, offering a sustainable replacement for ingredients such as palm oil, coconut oil, eggs and even cocoa powder.
The product delivers natural umami flavour and a versatile texture, making it suitable for a wide variety of applications, including plant-based meats and confectionery.
The innovation comes at a time when the environmental cost of food production is under increasing scrutiny.
Palm oil, for example, is estimated to account for around 10% of global deforestation, while the World Wildlife Fund has linked food production systems to a 70% decline in terrestrial biodiversity since 1970.
By turning low-value side streams into high-value functional ingredients, Äio aims to reduce the environmental footprint of the food and personal care sectors.
CEO and co-founder Nemailla Bonturi reflected on the journey: “As a scientist, I’ve been developing this fermentation process since 2013. Seeing something that I started in a small lab in Brazil now being produced at this scale in Europe is incredibly rewarding. This first tonne is the first of many to come, and crucially, it proves our process can scale beyond pilot settings and validates the commercial potential we’re working toward.”
The company’s next target is to establish a commercial production facility capable of producing 2,000 tonnes annually.
Pre-engineering concept work has already been completed, and Äio is building partnerships around feedstock supply, distribution and off-take agreements.
Product samples are being shared with manufacturers in both the food and personal care sectors, while a fundraising round is planned for late 2026 to accelerate expansion.
Äio’s CFO, Martin Mets, noted that unit costs have already fallen by 80% thanks to scaling and process optimisation. He expects costs to continue dropping, driving competitiveness against conventional oils.
Bonturi added that with regulatory pressure and supply chain challenges reshaping the market, precision fermentation now offers a commercially viable and sustainable path forward for manufacturers worldwide.
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