An integrated scalable process for adherent cultivated meat production: From proliferative cell selection to safety-verified product development

Abstract Cultivated meat can contribute to the global food supply; therefore, establishing efficient production processes is an urgent task to meet the growing demand for sustainable protein. Although cell culture technology has historically focused on suspension cells in the pharmaceutical and, subsequently, cultivated meat industries, the development of efficient processes for most adhesion-dependent cells has lagged, with limited examples reported to date. Therefore, this study used primary duck liver-derived adherent cells to develop and evaluate an integrated three-step meat production process involving pre-culture to select highly proliferative cells, packed-bed bioreactor expansion for mass production, and final processing, including packaging and heating. The established process allowed the efficient growth of selected cell populations while maintaining their proliferative characteristics. Moreover, the developed product met the microbiological and heavy metal safety criteria. Comprehensive compositional analysis (nutritional, amino acid, and fatty acid profiles) revealed that the product exhibited a protein profile distinct from that of conventional duck liver paste, along with a unique lower-fat signature. As productivity is dependent on cell doubling time, culture duration and monthly production were estimated for cells from various animal species. Overall, this study established a practical integrated production process for cultivated meat using adherent cells, providing a technological foundation for cellular agriculture applicable to diverse cell types and useful for future food supply diversification. GraphicalAbstract