Periodic Reporting for period 2 - VALUABLE (VALorisarion of fUngAl Biomass using noveL Enzymatic technology)
Reporting period: 2024-03-01 to 2025-08-31
The concept of biorefineries relies on the constant availability of sustainable biomass feedstocks. In this context, underutilised residual biomass streams from different industries are of special interest as raw materials for future biorefinery platforms. Modern biorefinery concepts aim for a zero-waste approach by also valorising waste streams besides their conventional feedstock.
The VALUABLE project separates residual Aspergillus niger biomass from citric acid production into two fractions: chitin for bio-based chemicals and a nutrient-rich solution to cultivate oleaginous yeast. The resulting yeast oil can replace fossil- and plant-based oils, saving fossil resources, freeing land for food production, and preserving biodiversity.
Thereby, key objectives were formulated to guide the research activities towards implementation of an integrated biorefinery concept. These included (1) assessment and validation of the environmental footprint and commercial viability, (2) demonstration of the viability of the VALUABLE platform process, (3) demonstration of the economic benefit and improved industrial competitiveness and (4) the dissemination of the results and activities of VALUABLE.
The VALUABLE process was developed as a bio-based, circular alternative to fossil-based chemicals, demonstrating commercial viability and a reduced environmental footprint compared to conventional chitosan or palm oil production, enhancing economic and industrial competitiveness. End-user trials showed VALUABLE chitosan has high purity (90% chitin) and can be directly used in plywood production, with promising cosmetic potential requiring further research. VALUABLE yeast oil also showed excellent properties as a drop-in alternative in cosmetics and resins. Project results were widely disseminated to raise public awareness of this innovative approach.
The VALUABLE project separates residual Aspergillus niger biomass from citric acid production into two fractions: chitin for bio-based chemicals and a nutrient-rich solution to cultivate oleaginous yeast. The resulting yeast oil can replace fossil- and plant-based oils, saving fossil resources, freeing land for food production, and preserving biodiversity.
Thereby, key objectives were formulated to guide the research activities towards implementation of an integrated biorefinery concept. These included (1) assessment and validation of the environmental footprint and commercial viability, (2) demonstration of the viability of the VALUABLE platform process, (3) demonstration of the economic benefit and improved industrial competitiveness and (4) the dissemination of the results and activities of VALUABLE.
The VALUABLE process was developed as a bio-based, circular alternative to fossil-based chemicals, demonstrating commercial viability and a reduced environmental footprint compared to conventional chitosan or palm oil production, enhancing economic and industrial competitiveness. End-user trials showed VALUABLE chitosan has high purity (90% chitin) and can be directly used in plywood production, with promising cosmetic potential requiring further research. VALUABLE yeast oil also showed excellent properties as a drop-in alternative in cosmetics and resins. Project results were widely disseminated to raise public awareness of this innovative approach.
VALUABLE demonstrated its platform process by valorising A. niger biomass waste to produce chitin, chitosan, and yeast oil. An enzymatic chitosan production route was successfully developed and scaled up, supported by novel enzyme technologies achieving 73% biomass mobilisation and 90% chitin purity. Fungal hydrolysates were valorised into yeast oil at lab and pilot scale, confirming the holistic approach. Pilot trials showed strong growth performance, with crude yeast oil production reaching 142 kg, by far exceeding the 80 kg milestone. Industrial end-user trials demonstrated encouraging results, including improved bend strength in plywood applications and successful use of yeast oil as a drop-in alternative to vegetable oils in resins and creams.
Experimental work was supported by assessments of environmental footprint, resource efficiency, and commercial viability for yeast oil and chitin/chitosan production. A key outcome was the demonstration of a waste-free process using low-value A. niger biomass, converting industrial by-products into high-value bio-based products. Economic feasibility was evaluated across different configurations, showing that on-site enzyme production reduces operating costs, while fully enzymatic routes require further optimisation. The most competitive setup combines enzyme production, chemical deacetylation, and water recycling, improving resource efficiency and reducing external inputs. Although profitability is sensitive to reference oil prices, the process remains viable at levels acceptable to end users, indicating strong potential for market adoption and scalability.
Trials with industrial partners showed that VALUABLE-derived chitosan and yeast oil can replace conventional raw materials, delivering comparable performance in several applications and strengthening the competitiveness of European bio-based industries. Social impact assessments showed strong stakeholder support, highlighting socioeconomic, environmental, and technological benefits. The process is expected to create medium-term employment, while long-term impacts will require careful management as conventional processes are replaced.
From an environmental perspective, enzyme-based chitosan production showed clear advantages over conventional sources, with lower impacts across most categories. Yeast oil performance was more mixed compared to palm oil, but enzyme-based configurations proved the most sustainable and final applications showed comparable performance, indicating strong potential with further optimisation. VALUABLE products target industries seeking bio-based alternatives to palm oil, cocoa butter, and conventional chitosan and chitin sources.
Greenhouse gas (GHG) assessments showed that optimized VALUABLE processes can reduce emissions compared to conventional routes, particularly for enzyme-based chitosan, while yeast oil showed improvement potential, with enzyme-based configurations performing best.
VALUABLE-derived chitosan and yeast oil were successfully applied in commercial products, demonstrating integration into existing value chains and strong potential for market adoption as sustainable alternatives to vegetable oils and conventional chitosan sources.
Experimental work was supported by assessments of environmental footprint, resource efficiency, and commercial viability for yeast oil and chitin/chitosan production. A key outcome was the demonstration of a waste-free process using low-value A. niger biomass, converting industrial by-products into high-value bio-based products. Economic feasibility was evaluated across different configurations, showing that on-site enzyme production reduces operating costs, while fully enzymatic routes require further optimisation. The most competitive setup combines enzyme production, chemical deacetylation, and water recycling, improving resource efficiency and reducing external inputs. Although profitability is sensitive to reference oil prices, the process remains viable at levels acceptable to end users, indicating strong potential for market adoption and scalability.
Trials with industrial partners showed that VALUABLE-derived chitosan and yeast oil can replace conventional raw materials, delivering comparable performance in several applications and strengthening the competitiveness of European bio-based industries. Social impact assessments showed strong stakeholder support, highlighting socioeconomic, environmental, and technological benefits. The process is expected to create medium-term employment, while long-term impacts will require careful management as conventional processes are replaced.
From an environmental perspective, enzyme-based chitosan production showed clear advantages over conventional sources, with lower impacts across most categories. Yeast oil performance was more mixed compared to palm oil, but enzyme-based configurations proved the most sustainable and final applications showed comparable performance, indicating strong potential with further optimisation. VALUABLE products target industries seeking bio-based alternatives to palm oil, cocoa butter, and conventional chitosan and chitin sources.
Greenhouse gas (GHG) assessments showed that optimized VALUABLE processes can reduce emissions compared to conventional routes, particularly for enzyme-based chitosan, while yeast oil showed improvement potential, with enzyme-based configurations performing best.
VALUABLE-derived chitosan and yeast oil were successfully applied in commercial products, demonstrating integration into existing value chains and strong potential for market adoption as sustainable alternatives to vegetable oils and conventional chitosan sources.
Specifically in the field of enzymatic conversion of chitin to different, high-value chitin derivatives (colloidal chitin, chitosan or chitooligosaccharides) significant scientific advantages were made with the potential to change the praxis of chitin processing in the field progressing from TRL 4 to TRL 7 for chitin production, TRL 6 for chitosan production and TRL 5 for chitooligosaccharide production, respectively. Further, significant advancements were made in the field of enzymatic chitooligosaccharide production reaching TRL 4. This involved i.a. the development of novel enzyme systems for the efficient production of chitooligosaccharides. Additionally, also significant advancements were achieved in the field of single-cell oil production and purification at scale (progressing from TRL 4 to TRL 7 within the project runtime). Notably, specifically the application of chitin and its derivatives showed superior performance in end-user tests.