Stop Shipping Water!

Why Disruptor® Technology is the processing game-changer the food and beverage world needs

In the world of food and beverage/product processing and manufacturing, one glaring issue has been overlooked for too long: the inefficiency and wastefulness of shipping water instead of real value.  

Let’s take the global commercial seaweed industry as an example.  According to Fortune Business Insights, “the seaweed industry is expanding due to its diverse applications in food and beverages, agriculture, animal feed, pharmaceuticals, and cosmetics. Factors such as rising consumer demand for plant-based products, technological advancements in algae cultivation, and the growing use of seaweed as a bio stimulant in agriculture are driving this growth.”

There are currently (Feb 2025) no accurate calculations as to the size of the seaweed market at present, but all agree that it has huge potential to be a multi-billion-dollar industry, with multiple applications.  Aside from its potential to make money, handled sensitively and correctly, the seaweed industry can put the planet on a better trajectory to wellness. 

However, like its counterparts, it is subjected to outdated processing methods that bottleneck progress – and price points.  These methods are also not environmentally friendly. So, whilst great strides have gone into new farming methods and in creating new incredible biomaterials and bio stimulants, the bit in the middle (the how it’s made) negates any true and meaningful advancement. 

Conventional methods can also usually only produce syrups, pastes, or emulsions with a meagre 2-2.5% total solids. That means that when these companies dispatch their goods, they are shipping products that are 97.5–98% water.

Let that sink in.

The problem: shipping water, not seaweed

When you consider that almost the entirety of the global seaweed industry is stuck at this benchmark, the implications are staggering. Whether sourcing from Africa, the EU, China, South America or beyond, the current standard means shipping unnecessary weight and volume in the form of water. This inefficiency has a direct impact on costs, environmental footprint, and overall productivity.

The total solids revolution

Enter Dynamic Cellular Disruption® (DCD®) technology from Green Cell Technologies® (GCT®).  By rethinking the way seaweed is processed, GCT is redefining what’s possible in the industry. Thanks to the DCD process, whilst their very own Disruptors are on order, GCT is currently producing up to 20 tons per month of seaweed purees for certain clients, with up to 15% total solids, far surpassing the industry standard.

Even when diluted to 10% for usability, these emulsions are vastly superior to the competition, delivering higher yields and better efficiency.  For clients requiring ultra-viscous material, the solution is simple: high shear mixing with a small micro cutter ensures seamless handling of even the densest total solid ingredients/purees/emulsions.  (We can also assist with recommendations in this regard). 

Shipping smarter, not more

The efficiency gains don’t stop at production. The real magic lies in how much product can now be shipped compared to standard products using conventional processing.

Using the DCD process through Disruptor® technology, the following can be achieved:

• At 15% total solids – 1 container for every 6 containers shipped by competitors
• At 20% total solids – 1 container for every 8 containers shipped by competitors
• At 25% total solids – 1 container for every 10 containers shipped by competitors
• At 30% total solids – 1 container for every 12 containers shipped by competitors
• At 35% total solids – 1 container for every 14 containers shipped by competitors.

This means fewer shipments, less fuel consumption, and a significantly reduced carbon footprint—all while delivering higher-quality seaweed -based products. Economies of scale are self-explanatory. 

Why it matters

For the industry, this shift represents a seismic change. Higher total solids mean more active ingredients per cubic metre, allowing clients to achieve greater yields with less material. It also eliminates the unnecessary cost and environmental impact of shipping water around the globe.

For the environment, fewer shipments translate into a smaller carbon footprint—a crucial step in an industry that’s closely tied to sustainability. Less packaging, less labour, less power consumption and so on. For example, 1 x 200kg drum of DCD® processed material is now equal to up to 14 drums made by most current processes. 

GCT’s Disruptor technology isn’t just improving seaweed processing; it’s redefining the standards of what’s possible.  By focusing on total solids, we’re addressing the inefficiencies that have plagued this industry for decades, delivering better results for clients and the planet alike.

The message is clear: the days of shipping water are over. Better, more affordable processing methods must be adopted for industry to meet the demands of a modern, sustainable world.

The same principle applies to most food and beverage manufacturing…

Take the orange juice industry as another key example. 

Currently, orange juice is made by peeling, squeezing and discarding a whole bunch of waste (around 60%).  The resultant liquid lacks not only much of the nutrients contained in the so-called ‘waste’ but is also heavy to transport.

Now, imagine if the ‘waste’ (peels, pith and pips), could be processed to their molecular level realising all their available actives and goodness, including fibre, and put back into the juice?  Then, if that is condensed to a high total solid format.  A), it would be more nutritious and beneficial, and B), it would be cheaper to transport.  It would then be reconstituted at its destination – using water from that environment. 

There are so many possibilities…

To speak to us about DCD® and Disruptor® technology and how we can help you increase sales, and save the planet at the same time, please email: info@greencelltechnologies.com or see www.greencelltechnologies.com for more info as to how you can purchase and license this technology.