Inline blending is reshaping how hybrid proteins are best produced, says KROHNE’s Ryan Kromhout, with real-time precision process control helping scale with consistency, control, and consumer trust.
In the protein space, ‘blending’ no longer means compromise – it means most efficient control. A quiet revolution is happening in the pipes, not the headlines, and Ryan Kromhout is at the heart of it. As Global Industry Manager for Food at KROHNE, Kromhout isn’t just tweaking gauges and flow rates – he’s laying the groundwork for a hybrid food future built on precision, repeatability, and trust.
“Don’t be intimidated by the complexity,” he says. “With the right partners and the right technology, hybrid products can be made with the least tolerance possible, and both reliable and scalable.” That confidence comes from a simple but profound shift: replacing batch-based guesswork with real-time, in-line measurement. In a sector where even minor inconsistencies can make or break consumer trust, the ability to engineer every gram with surgical accuracy is no longer a luxury – it’s fast becoming the baseline.
From chipotle sausages to seaweed-infused chicken, the next generation of hybrid products is emerging. And behind the scenes, it’s instruments such as KROHNE’s Coriolis mass flow meters that ensure every bite tastes (and behaves) exactly the same, every time.
The physics of repeatability
Kromhout’s job isn’t to design the next viral vegan burger. His job is to make sure that, when it gets scaled to industrial production, it still tastes like the first bite consumers loved. Because in this field, quality isn’t a one-off achievement – it’s a standard that must be replicated endlessly.
At the core of KROHNE’s offering is the Coriolis mass flow meter – a deceptively simple device that reads like a physics textbook but works like a chef’s most exacting tool. Picture a guitar string vibrating. When fluid flows through it – anything from soy isolate to algae slurry – it alters the frequency of the vibration. That disturbance is directly proportional to mass flow and the process density of the measured goods.
“What you get is two critical measurements,” explains Kromhout. “Mass flow, which is pressure- and temperature-independent. And density, which tells you how much mass is in a given volume. Both are essential for consistent product formulation.”
The margin of error? Just ±0.1% on mass flow and ±0.2g/cm³ on density. “If you’re blending at 200 tons per hour, that’s a tolerance of just 200kg. That’s how tight we’re talking,” he says. This kind of precision becomes especially important with viscous, unpredictable inputs – think fermented soy, sourdough, or anything laden with air pockets. “Even in difficult conditions, we can still measure with 0.5% accuracy, and then help customers fine-tune from there,” he adds.
Why hybrid products need inline tech
Kromhout is bullish on hybrids. Not because they’re a shortcut to a plant-based future, but because they’re a realistic, scalable, consumer-friendly solution – and one that respects the diverse motivations of modern eaters. “What Lidl has done in the Netherlands is a brilliant example,” he says. “They introduced a 50:50 meat and plant blend, priced it lower than meat, and matched the taste. Consumers are cutting CO₂ emissions in half – without even noticing the difference.”
But to make that kind of blend work, repeatability is essential. If one batch tastes great and the next is dry or chewy, trust evaporates. Inline blending ensures that both plant and animal inputs are added in perfect proportion – continuously and in real time – before entering a static or dynamic mixer.
“It’s not just about quantity,” Kromhout emphasizes. “It’s about behavior. Plant-based inputs and animal fats behave differently under stress. That’s where understanding shear, rheology, and flow profiles becomes vital.”
KROHNE’s instrumentation captures exactly that – feeding back real-time data on how materials interact inside the pipe. “You can tweak flow velocity, mixing intensity, even adjust for temperature-based fat behavior,” he explains. “It’s like having eyes and ears inside the pipe.”
Inline systems also address some of the most pressing concerns in food tech – namely, label transparency and nutritional compliance. Many producers hedge against variation by overdosing expensive ingredients.
“I’ve seen it everywhere,” says Kromhout. “Facilities aiming for 32g of protein per serving will actually target 34g, just to avoid falling short. That drives up cost – and it’s unnecessary if your process is under control.”
With inline measurement, that safety buffer can be narrowed. Processors hit their targets without overcompensating, hence cleaner label, less ingredient waste, and better nutritional consistency across batches.
Raising the bar on repeatability
KROHNE’s systems are widely validated in the pharmaceutical sector – where standards for accuracy are often stricter than food. “These sensors don’t drift,” says Kromhout. “The reading you get on day one is the same you get on day 1,000. That kind of repeatability is how you build consumer trust.”
And in the competitive world of consumer-packaged goods, that trust can be everything. A single discrepancy – whether in nutritional value or sensory performance – can trigger reformulation, recalls, or reputational damage.
Hybrid formulations aren’t just about merging two ingredients. They’re about merging behaviors. Animal fat solidifies at different rates than coconut oil. Soy isolate thickens differently than whey. And when emulsifiers are removed – either for cost or label clarity – there’s no margin for error.
“Our systems detect phase separation in real-time,” says Kromhout. “If your emulsion is breaking, we see it in the sine wave of the sensor. You can correct it immediately.”
This early warning system doesn’t just catch faults – it prevents them. “Better control upstream means fewer problems downstream,” he adds. “That applies to foaming agents, stabilizers, even suppliers.
If we detect too much air in your spinach blend, maybe it’s a sourcing issue – not just a blending one.”
It’s a reminder that precision doesn’t just save money – it prevents crises. And when time, ingredients, and consumer attention are all finite, that’s a powerful form of risk management.
Scaling without losing soul
In Kromhout’s view, the biggest hurdle for many new players isn’t formulation – it’s scale. “Too often, startups work with engineering firms that offer legacy solutions – tank, scale, whisk. That’s not how modern food production should operate.”
KROHNE is taking a more collaborative approach, offering sensors on a trial basis and working side by side with teams developing new hybrid ideas. “These companies are experts in taste and texture. They don’t need to become experts in process control – that’s our role.”
And the beauty of inline systems is that they don’t require producers to lock themselves into rigid infrastructure. “If you’re switching from soy isolate to ground beef to single-cell protein, no recalibration is needed. You just keep flowing.” Such flexibility is especially crucial for smaller companies operating in pilot environments, where batch size is limited and speed of iteration is key. “The goal,” he continues, “is to give innovators the tools they need to scale without losing what made their product great in the first place.”
Looking ahead
For those still wondering where hybrid applications shine brightest, Kromhout has a clear answer: meat and cheese. “Meat is the obvious one,” he says. “It’s where the biggest impact lies – in sustainability, cost, and taste. Cheese is more complex – but also more exciting. It’s notoriously difficult to replicate with plants alone. Hybrids might be the bridge.”
But more broadly, Kromhout sees a transformation coming – not just in the products we eat, but in how we make them. “Process control isn’t just about machines,” he says. “It’s about making better decisions, earlier. If we want consumers to trust new protein formats, we have to deliver consistency, nutritional integrity, and a great sensory experience every single time.”
That requires data, precision and a willingness to move beyond legacy methods – to embrace real-time insights, advanced instrumentation, and a mindset focused on continuous improvement and future-ready processes. “There’s a future of advanced methodologies out there,” Kromhout concludes. “Let’s not rely too heavily on the past.”
