Periodic Reporting for period 3 - UNLOCK (Unlocking a feather bioeconomy for keratin-based agricultural products)
Okres sprawozdawczy: 2023-11-01 do 2025-04-30
The poultry sector in Europe represents the second largest meat producing sector, accounting for a 31 % of meat production. As part of the meat production process feather waste is produced with the associated management costs. Currently, just around 25% of the feathers generated are collected separately for feather meal and fertiliser applications (mid-low value application with high processing costs and a low profit margin), while the rest is either disposed in landfills and incinerators or collected together with other poultry by-products for poultry meal production. However, feathers are composed of nearly 90% of keratin, a valuable protein which can be used as a source of raw materials for biodegradable materials, such as bioplastics, to be applied in agriculture.
In this context, the main objective of UNLOCK project has been the design and demonstration of an economically and environmentally sustainable supply-chain for a feather-based bioeconomy to generate innovative bio-based functional materials for agricultural applications.
UNLOCK proposed new keratin-based bioplastics and geotextiles that can provide added functionalities and advantages derived from the use of feather keratin: i) tailor-made biodegradation adjusted to the crops’ duration, ii) input on nitrogen to the soil, iii) zero waste generation at their end of life and iv) cost competitive materials.
The results have demonstrated the feasibility of such value chains for the application of treated feathers into 4 end-products for the agricultural sector, including the construction of a demo plant for feather processing directly at the slaughterhouse.
In this context, the main objective of UNLOCK project has been the design and demonstration of an economically and environmentally sustainable supply-chain for a feather-based bioeconomy to generate innovative bio-based functional materials for agricultural applications.
UNLOCK proposed new keratin-based bioplastics and geotextiles that can provide added functionalities and advantages derived from the use of feather keratin: i) tailor-made biodegradation adjusted to the crops’ duration, ii) input on nitrogen to the soil, iii) zero waste generation at their end of life and iv) cost competitive materials.
The results have demonstrated the feasibility of such value chains for the application of treated feathers into 4 end-products for the agricultural sector, including the construction of a demo plant for feather processing directly at the slaughterhouse.
Within WP2, the poultry sector in five key EU countries—France, Germany, Spain, Italy, and Poland—was analysed, covering breeding, meat processing, and ABP rendering. The study mapped company numbers, sizes, and feather feedstock volumes, and assessed waste management practices. Its aim was to understand the regional availability of feathers and how they are currently handled, providing a basis for developing circular solutions in the poultry industry.
Within WP3, business case arrangements addressed key supply chain hurdles—many of which, such as logistics and feather quality, persist in current and future value chains. UNLOCK’s demo cases were analysed for economic, technical, and sustainable feasibility. A feather-based bioeconomy is technically viable and environmentally promising but faces key challenges: economic viability depends on product value, technical issues involve water and energy, and regulation needs updated legal frameworks.
In WP4 feather-based bioplastic formulations have been developed for the 4 target applications and tested with good results regarding biodegradation behaviour and performance, which were selected for upscaling. Moreover, biodegradability of feathers treated by the main technologies involved in the project, as well as feather-based bioplastics have been investigated. These results are part of 3 publications of UNLOCK and another under revision.
Within WP5 the technologies for feather treatment have been demonstrated at demo scale. End-products prototypes have been prepared and validated in terms of performance in field and biodegradability according to the different schemes of EoL. Main results include associated deliverables to this WP5 as well as the construction of a demo plant for the sanitation and mechanical grinding of feathers with an optimised capacity of 300 Kg/h.
WP6 addressed the Sustainable, Economic and Social assessment of the project. The final LCA confirmed that feather-based biorefineries offer a viable circular alternative, especially when supported by renewable energy and water reuse. LCA reveals that final products like mulch films, geotextiles, and seed trays outperform fossil-based equivalents. Modelling and simulation showed that all three feather processing methods are technically feasible at industrial scale. Microbial fermentation offers the highest value but is complex to control. Steam explosion is energy-efficient, while milling is simpler yet water-intensive. Integration and resource efficiency are key to sustainability. The social LCA found that most social risks are not linked to feather use itself but to upstream factors like energy sourcing and equipment supply. Key concerns include occupational safety, public health, and potential corruption in procurement.
Regarding exploitation of results, specific business plans for UNLOCK demo cases have been prepared in WP7. Dissemination and Communication Strategy of WP8 have included the creation of the Visual identity of the project and communication materials (brochure, leaflet, website, social media, etc.) as well as the creation of specific contents to increase the impact of project results (publications, podcasts).
In summary, main results of UNLOCK include a collection of 60 deliverables, including 15 public deliverables, as well as 3 scientific articles already published and 3 additional under revision or submission, together with 18 publications for dissemination and communication purposes.
Within WP3, business case arrangements addressed key supply chain hurdles—many of which, such as logistics and feather quality, persist in current and future value chains. UNLOCK’s demo cases were analysed for economic, technical, and sustainable feasibility. A feather-based bioeconomy is technically viable and environmentally promising but faces key challenges: economic viability depends on product value, technical issues involve water and energy, and regulation needs updated legal frameworks.
In WP4 feather-based bioplastic formulations have been developed for the 4 target applications and tested with good results regarding biodegradation behaviour and performance, which were selected for upscaling. Moreover, biodegradability of feathers treated by the main technologies involved in the project, as well as feather-based bioplastics have been investigated. These results are part of 3 publications of UNLOCK and another under revision.
Within WP5 the technologies for feather treatment have been demonstrated at demo scale. End-products prototypes have been prepared and validated in terms of performance in field and biodegradability according to the different schemes of EoL. Main results include associated deliverables to this WP5 as well as the construction of a demo plant for the sanitation and mechanical grinding of feathers with an optimised capacity of 300 Kg/h.
WP6 addressed the Sustainable, Economic and Social assessment of the project. The final LCA confirmed that feather-based biorefineries offer a viable circular alternative, especially when supported by renewable energy and water reuse. LCA reveals that final products like mulch films, geotextiles, and seed trays outperform fossil-based equivalents. Modelling and simulation showed that all three feather processing methods are technically feasible at industrial scale. Microbial fermentation offers the highest value but is complex to control. Steam explosion is energy-efficient, while milling is simpler yet water-intensive. Integration and resource efficiency are key to sustainability. The social LCA found that most social risks are not linked to feather use itself but to upstream factors like energy sourcing and equipment supply. Key concerns include occupational safety, public health, and potential corruption in procurement.
Regarding exploitation of results, specific business plans for UNLOCK demo cases have been prepared in WP7. Dissemination and Communication Strategy of WP8 have included the creation of the Visual identity of the project and communication materials (brochure, leaflet, website, social media, etc.) as well as the creation of specific contents to increase the impact of project results (publications, podcasts).
In summary, main results of UNLOCK include a collection of 60 deliverables, including 15 public deliverables, as well as 3 scientific articles already published and 3 additional under revision or submission, together with 18 publications for dissemination and communication purposes.
The consortium has proved the suitability of the technologies addressed in UNLOCK to produce treated feathers for the different applications and the scalability of these technologies. UNLOCK showed that feathers had a different behaviour on biodegradation depending on the treatment and proved a significant improvement on degradation of materials in different environments (industrial and home composting and soil biodegradation conditions). Moreover, prototypes of the targeted end-products were produced (trays, films, foams and geotextiles) and validated in laboratory and in field conditions.
Concerning potential impacts of UNLOCK, these include:
1. Extract ≥50 % more value from residual streams
CEDROB’s pilot facility demonstrates a value increase of feather, far exceeding the 50 % target. Compared to feather meal, the switch to ground feathers nearly triples the economic return, confirming strong added-value potential.
2. Produce at least one B2B or B2C product in validating quantities
The project successfully validated five B2C products (e.g. seed trays, mulching films) and three B2B outputs (e.g. keratin-based compounds, fermentation and steam explosion technologies). Licensing models were explored, confirming both technical viability and market potential for multiple applications.
3. Increase competitiveness and regional impact
The new value chain has the potential of creation of 34 new jobs, enhancing local employment and strengthening bioeconomy clusters. In the case of mechanically ground feathers technology, it offers a stable, diversified income stream that reduces market risk linked to feather meal volatility. Business plans show profit potential for several partners, and several technologies have replication potential across Europe.
4. Societal implications.
The UNLOCK project contributes to a more sustainable and circular economy by transforming poultry feather waste into valuable biobased products. This not only reduces environmental burden but also supports rural development and green job creation. By promoting waste valorisation, UNLOCK fosters greater public awareness and acceptance of bioeconomy innovations.
Concerning potential impacts of UNLOCK, these include:
1. Extract ≥50 % more value from residual streams
CEDROB’s pilot facility demonstrates a value increase of feather, far exceeding the 50 % target. Compared to feather meal, the switch to ground feathers nearly triples the economic return, confirming strong added-value potential.
2. Produce at least one B2B or B2C product in validating quantities
The project successfully validated five B2C products (e.g. seed trays, mulching films) and three B2B outputs (e.g. keratin-based compounds, fermentation and steam explosion technologies). Licensing models were explored, confirming both technical viability and market potential for multiple applications.
3. Increase competitiveness and regional impact
The new value chain has the potential of creation of 34 new jobs, enhancing local employment and strengthening bioeconomy clusters. In the case of mechanically ground feathers technology, it offers a stable, diversified income stream that reduces market risk linked to feather meal volatility. Business plans show profit potential for several partners, and several technologies have replication potential across Europe.
4. Societal implications.
The UNLOCK project contributes to a more sustainable and circular economy by transforming poultry feather waste into valuable biobased products. This not only reduces environmental burden but also supports rural development and green job creation. By promoting waste valorisation, UNLOCK fosters greater public awareness and acceptance of bioeconomy innovations.