California Cultured Pioneers Cocoa Butter Production in Plant Cell Culture

California-based startup California Cultured has recently filed a groundbreaking patent that focuses on the production of cocoa butter from plant cell culture, marking a first in the industry.

The Challenge in Replacing Cocoa Butter

As cocoa prices surge and the market experiences volatility, food companies are increasingly exploring alternative sources for cocoa powder. Options such as plant cell culture and upcycled agricultural products are being evaluated, yet the task of replacing cocoa butter stands out as particularly complex, according to Steve Stearns, the head of strategy and business development at California Cultured.

“For years, companies have been attempting to find substitutes for cocoa butter,” Stearns explained to AgFunderNews. “While alternatives like hydrolyzed palm fats and shea butter have been utilized, they often lack the same melting characteristics and can be greasy.”

Efforts to mimic cocoa butter’s unique melting properties through microbial fermentation have also encountered setbacks. “Various microbes can produce triglycerides, but they fail to achieve the correct ratios. Additionally, many countries have a standard of identity for chocolate that mandates the use of cocoa butter,” he stated.

The Role of Somatic Embryos

Until now, most endeavors within cocoa cell culture have relied on callus cells—mature cells reprogrammed to function like stem cells. However, Stearns pointed out that while callus cells excel in producing cocoa powder, they do not yield fat. “Without fat, it’s impossible to replicate the qualities and melting traits inherent to real chocolate.”

Advancements with Somatic Embryos

California Cultured is currently building a pilot plant in Sacramento that will produce cocoa flavanols and powder using callus cells, but the company has also been developing a cocoa butter production method utilizing somatic embryos for the past two years.

Somatic embryos are generated by reprogramming somatic (non-reproductive) cells from cacao plant tissue into embryo-like structures. “Unlike callus cells, somatic embryos produce high levels of fat, including essential triglycerides such as POP, POS, and SOS—qualities that define cocoa butter,” Stearns elaborated. “These triglycerides provide the solid state at room temperature and the delicious melting experience associated with real chocolate.”

Moreover, he noted, “Somatic embryos possess a more robust aromatic profile compared to callus cells, resulting in a rich cocoa aroma directly from the bioreactor.”

Strategic Patent Filings

Stearns emphasized the comprehensive nature of the patent, detailing that it encompasses all processing methods for chocolate reliant on somatic embryos. This provides a significant competitive edge, safeguarding California Cultured’s innovations in this specialized domain.

The patent specifies cells that yield at least 10% lipids. However, Stearns asserted the necessity of achieving a minimum of 30% cocoa butter to ensure viable production economics. “The cell line will also be explored for other applications, including chocolate liquor,” he shared.

“We are not resorting to genetic engineering to enhance production; instead, we are planning to leverage various alternative methodologies,” he added.

The Future Ahead

When asked if the venture remains solely in the research phase, Stearns stated, “We consider our callus cell approach—focused on flavonols and conventional cocoa powder—to be our 1.0 technology. The somatic embryos represent our 2.0 advancement.”

“We foresee progress with somatic embryos by 2027-2028, as we’re already distributing samples to our customer partners, moving beyond the initial R&D stages.”

Conclusion

As California Cultured embarks on this innovative journey, the potential implications for the chocolate industry are significant. By leveraging advanced techniques in cocoa butter production, the company positions itself at the forefront of sustainable and innovative food technology.

For more insights, watch our recent interview with California Cultured CEO Alan Perlstein at the SynBioBeta conference below: