Press release From lab to fab: innovations in microbial protein are scaling up in Ghent, Belgium
Making soft cheeses with milk protein without animal cells, producing a protein alternative to fish meal on ethanol starting from industrial emissions (CO2), harvesting new raw materials for food and feed from residual streams from the food industry. These are existing examples of a promising, innovative technology: microbial protein. ILVO and Bio Base Europe Pilot Plant (BBEPP) are taking another important step in the development and scaling-up of this technology with new pilot infrastructure. Together, the pilots of ILVO and Flanders'FOOD in Melle and of BBEPP in Desteldonk now have the necessary equipment and expertise to support lab and pilot-scale testing of all the necessary steps in the production, purification and processing of the new proteins. Like the existing technology park, the new infrastructure is open and accessible to knowledge institutions and companies. During a well-attended event on Nov. 19 in Melle and Desteldonk, potential users got an inside look at them both.
Driven by the global search for more sustainable and circular production systems, the technology behind microbial protein is developing rapidly. High-quality proteins, enzymes, additives and fine chemicals are produced there under controlled conditions by fermentation of bacteria, microalgae, yeasts or fungi on renewable raw materials or low-grade and abundant residual streams or industrial emissions.
“Flanders continually reinvents itself. We are a European leader in innovation across various fields”, says Flanders Minister-President Matthias Diependaele. “We recognize and support the sustainability potential of fermentation technology. It is a vital tool for our economy and has the potential to be a game-changer in key industrial sectors that drive Flanders prosperity.”
Microbial milk protein for soft cheeses
A well-known example of microbial protein that immediately shows its potential impact for the Flemish protein strategy is the production of the milk protein casein by fermentation. Casein is a rather complex protein that behaves in a special way that makes it suitable for making cheese. But this fermentation does not involve any cow or other mammal. The Ghent-based organization Those Vegan Cowboys is in the process of perfecting the production of microbial casein and scaling it up together with BBEPP (MiProCas project). It finds a partner in food companies looking for good cheese alternatives, or concerned about milk shortages in the future.
Fermentation residue stream becomes animal feed
A fermentation that is already common today in the food industry is that of Pichia pastoris. The yeast is programmed to produce enzymes for the clarification of fruit juices, among other things. After secreting the enzymes, however, protein-rich yeast cells remain that have potential as raw material in animal feeds. As a demonstration for the potential of the new infrastructure, BBEPP concentrated the residual stream, Food Pilot dried the mass using a new drum dryer, and ILVO compared the stabilized feedstock with the properties of soy. The results of these analyses indicate that the protein content and amino acid composition offer opportunities toward valorization in animal feeds, and based on further sector inquiry initially in poultry and pig feeds.
Annatachja De Grande (ILVO): “This is a promising result for the feed industry and the livestock industry that are looking for more sustainable raw materials. In that context, ILVO is investing in a new Feed Pilot in Merelbeke, which will allow us to produce very precise feeds for the most common farm animals with various new raw materials.”
Feed value and digestibility can also be evaluated in feed tests with cattle, pigs, poultry and aquatic species in ILVO's research facilities.
Protein for fish feed from industrial emissions (CO2)
Fermentation technology can also convert industrial emissions into protein. With the new Steelanol site, Arcelor Mittal converts emissions from the steel plant in Ghent into sustainable ethanol, which can then be valorized by fermentation technology from UGent into high-quality protein (CEMPA project). Taking advantage of the new investments, that technology was scaled up at BBEPP, already producing 50 kg of protein. Kemin, a producer of additives and specialty proteins for the feed industry, conducted a first successful trial with this in feeds for salmon and shrimp.
Nele Ameloot (UGent): “We are ready for the next step and that is scaling up from kilograms to tons. The industry is looking for ways to valorize their emissions. The feed industry is looking for sustainable alternatives to fishmeal. And society is enjoying the climate and biodiversity gains. That makes this case a win for everyone.”
Food by-products become new raw material
One challenge delaying some innovations with microbial protein is Europe's Novel Food legislation. An application dossier is now underway for a number of microorganisms as a food raw material, such as for Cupriavidus necator. BBEPP had this bacteria fermented on pure glucose and on sugars derived from potato peelings. BBEPP then processed the entire biomasses using the new investments, ILVO dried the crops with the spray and drum dryer in Food Pilot and screened both powders for functionality and texture for food applications.
Geert Van Royen (ILVO): “This case shows promising results for food applications and makes clear that the chosen food raw material has a lot of impact on the protein composition and its functional properties. Especially the emulsifying capacity of the proteins stands out. However, further development of both the fermentation process and subsequent processing is needed to optimize the properties of the proteins for food applications.”
Instrument in the protein transition and bioeconomy
Microbial protein potentially has a lower environmental impact than animal protein due to more efficient use of resources, space and water. It may also eventually help reduce soy imports for animal feed, which in turn helps make the livestock and feed industries more sustainable. Microbial protein production can thus contribute to a more independent, circular and bio-based economy.
Patricia De Clercq, Agriculture and Sea Fisheries Agency: “Within the Flemish protein strategy, we want to increase and diversify the supply of proteins in food and feed. Microbial proteins can contribute to this. Moreover, they can also make an important contribution to a more bio-based and circular economy, by using low-value by-products from our agricultural and food sector for this purpose.”
Johan Hanssens, Department of Economy, Science and Innovation: “The new European Commission wants to strengthen the competitiveness of the European economy and the new Flemish government is working on an industrial policy agenda to ensure growth in our strategic industrial sectors. Flanders is home to the second largest chemical cluster in the world, we have a strong agri-food industry and we are leaders in the pharmaceutical industry. Biotechnology plays a central role in each of these sectors.”
Support from Flanders, Europe and the province
Thanks to the investments in Food Pilot, Feed Pilot and BBEPP, the number of possible test setups for knowledge centers and companies is now infinite. The investments were funded with the support of the Flemish Department of Economy, Science and Innovation, ERDF VLAIO, Victam and the Province of East Flanders, for the Microbial Protein Transition, INNOLAB, FERM EIWIT, Bio Base Release and Bio Base Advance projects.
Wim Soetaert (BBEPP): “Due to the strong complementarity between ILVO, Food Pilot and BBEPP, and the integration of the new facilities with the existing pilot lines, lab and research infrastructure, the number of possible test setups is now endless. From questions about suitable microorganisms and nutrient soils to protein quality, taste and digestibility. We are making ourselves available to companies and research centers that want to help build on this circular, promising technology.”
The ProteInn Club
ILVO and BBEPP, together with Ghent University and CAPTURE are the founding fathers of The ProteInn Club. This is a unique ecosystem of research centers and companies in the Ghent region working on microbial proteins. As part of its operation, The ProteInn Club mapped the technical, systemic and regulatory obstacles that companies and knowledge centers face if they want to get started with microbial protein. In a recently published policy brief, they elaborated on the obstacles and possible solutions.
About ILVO
ILVO (Flanders Research Institute for Agriculture, Fisheries and Food) is an independent knowledge center in Belgium. Commissioned by the Flemish government, more than 700 employees work on knowledge development around societal challenges related to food and bio-based processes. ILVO is strong in co-creation with companies and other external partners. The pilot food processing plant ‘Food Pilot’ is a good example of this. www.ilvo.vlaanderen.be
About Bio Base Europe Pilot Plant (BBEPP)
Bio Base Europe Pilot Plant (BBEPP) is an independent multi-purpose pilot facility dedicated to the process development, scale-up and pilot production of bio-based products and processes. BBEPP was founded in 2008 and is located in Ghent, Belgium. It is a service provider that has developed into the global reference for the scale-up of biobased innovations and currently employs more than 170 people. www.bbeu.org
