Kelp’s journey to your plate
Donning a hair net, white jacket, and shoe covers, Casey Ballin, director of operations and sustainability, enters a spotlessly clean, brightly lit room in the basement of a converted warehouse. A hulking silver metal processor sits in the center, stretching for 75 feet. This is the processing facility for Atlantic Sea Farms, the company that Dobbins started. Now, it sources kelp from 40 farmers, including Nate Johnson.
The massive machine is a veggie processor adapted for kelp. The seaweed is cut—the shredder can chop 10,000 pounds per hour—then cooked at 175 degrees, and left to cool. The process takes just 7 to 8 minutes per batch. The superfood is then made into an array of products—salads, burgers, and even smoothie cubes. (Dobbins says he gave some seaweed to a local smoothie shop, and it caught on.)
The facility is humming with movement, as factory workers place tops on jars of seaweed salad in one room while researchers examine new ways of growing kelp across the hall. Atlantic Sea Farms is vertically integrated, meaning that they are involved with every step of the process, from giving the kelp spores to farmers to packaging the final products. When it arrives in the grocery store, there is full traceability of each product down to the day and location it was harvested.
Getting to this point hasn’t been easy. There was no precedent for processing kelp in the US, so figuring out the best system to do so took some experimentation. They even learned from spaghetti processing because there were similarities.
At Luke’s Lobster, a popular Maine restaurant overlooking the water, five burgers are set down on the table. They look like normal burgers but are actually made with kelp by Atlantic Sea Farms, possibly from Johnson’s farm across the bay.
There is a lot of room for growth—98% of seaweed consumed in the US is imported from six countries in the western Pacific. Atlantic Sea Farms sees this as only the beginning. “We want kelp in every aisle of the grocery store, and not just food,” Ballin says.