Periodic Reporting for period 1 - CHEERS (Producing novel non-plant biomass feedstocks and bio-based products through upcycling and the cascading use of brewery side-streams)
Période du rapport: 2022-09-01 au 2024-02-29
The CHEERS project proposes an innovative method to valorize waste streams from the brewing industry. It combines insect and microbial platforms to convert waste materials like spent grain, wastewater, CO2, and methane into 5 valuable industrial products: insect protein, disinfectant, microbial protein, ectoine, and caproic acid.
Project Highlights
High Efficiency: maximizes waste utilization and achieves a 45% carbon footprint reduction.
Sustainable and EU-Aligned: supports the European Circular Economy and Bioeconomy strategies.
Collaborative: fosters knowledge exchange among European stakeholders.
Robust Methodology: covers waste stream identification all the way to pilot-scale product validation.
Comprehensive Analysis: considers environmental impact, economic aspects, and commercialization strategies.
The CHEERS project has the potential to generate transformative results in the biorefinery industry:
New biomass platforms: The production of 13.5 tons/year of insect protein from 40 tons/year of spent grain is expected, demonstrating the viability of this technology. In addition, the conversion of CO2 and CH4 into valuable ingredients is expected.
Producing circular and sustainable products, including protein for beverages, a mixture of volatile fatty acids (VFAs), a chlorine-based disinfectant product, ectoine for cosmetics, and single-cell protein (SCP)-based pet food.
Technological advancements: A technology readiness level (TRL) of 7 is expected to be achieved in 5 key biological conversions: spent grain to insect protein conversion, CO2 bioconversion to caproic acid and bioCH4, CO2 bioconversion to hypochlorite and bioCH4, CH4 bioconversion to ectoine, and CH4 bioconversion to high-quality SCP.
Large-scale implementation: The installation of 100 valorization plants in the EU is expected after 5 years of commercialization, representing a significant impact on the industry.
Knowledge transfer.
The CHEERS project presents enormous potential to transform the biorefinery industry towards a more sustainable and circular future. The integration of insect and microbial platforms, along with the development of high-value-added bioproducts, offers an innovative and efficient alternative for waste management and the production of renewable materials.
Project Highlights
High Efficiency: maximizes waste utilization and achieves a 45% carbon footprint reduction.
Sustainable and EU-Aligned: supports the European Circular Economy and Bioeconomy strategies.
Collaborative: fosters knowledge exchange among European stakeholders.
Robust Methodology: covers waste stream identification all the way to pilot-scale product validation.
Comprehensive Analysis: considers environmental impact, economic aspects, and commercialization strategies.
The CHEERS project has the potential to generate transformative results in the biorefinery industry:
New biomass platforms: The production of 13.5 tons/year of insect protein from 40 tons/year of spent grain is expected, demonstrating the viability of this technology. In addition, the conversion of CO2 and CH4 into valuable ingredients is expected.
Producing circular and sustainable products, including protein for beverages, a mixture of volatile fatty acids (VFAs), a chlorine-based disinfectant product, ectoine for cosmetics, and single-cell protein (SCP)-based pet food.
Technological advancements: A technology readiness level (TRL) of 7 is expected to be achieved in 5 key biological conversions: spent grain to insect protein conversion, CO2 bioconversion to caproic acid and bioCH4, CO2 bioconversion to hypochlorite and bioCH4, CH4 bioconversion to ectoine, and CH4 bioconversion to high-quality SCP.
Large-scale implementation: The installation of 100 valorization plants in the EU is expected after 5 years of commercialization, representing a significant impact on the industry.
Knowledge transfer.
The CHEERS project presents enormous potential to transform the biorefinery industry towards a more sustainable and circular future. The integration of insect and microbial platforms, along with the development of high-value-added bioproducts, offers an innovative and efficient alternative for waste management and the production of renewable materials.
The CHEERS project has completed a series of technical and scientific activities that have significantly advanced the development of a circular and sustainable biorefinery:
1. Side-stream mapping and optimization of side streams generated in the brewing industry, including spent grain, wastewater, CO2, and CH4, was conducted.
2. Development and start-up of insect and microbial platforms: Insect (Tenebrio molitor) and microbial (Pseudomonas putida, Bacillus subtilis) platforms were optimized and scaled up for valorization of the target side streams. Cultivation and feeding protocols were developed to maximize conversion efficiency and bioproduct quality. Control and monitoring systems were established to ensure the efficient and safe operation of the biological platforms.
3. Integration and cascading of biomass processing: taking advantage of the synergies between insect and microbial platforms. Operating conditions were optimized to maximize bioproduct yield and minimize waste generation. Separation and purification strategies were developed to obtain high-quality bioproducts.
4. Bioproduct development and validation: The 5 target bioproducts – insect protein, disinfectant, microbial protein, ectoine, and caproic acid – were developed and validated at the laboratory scale. Stability studies were conducted to determine the shelf life of the bioproducts under different storage conditions.
5. Environmental and economic impact assessment considering aspects such as life cycle, cost-benefit analysis, and carbon footprint. The main opportunities and challenges for large-scale implementation of the project were identified. Implemented Commercialization strategies for the developed bioproducts.
Key Technical and Scientific Achievements
- Built a pilot biorefinery using insects and microbes to convert 40 tons/year of brewery waste into valuable products (innovative and sustainable model).
- Produced five valuable bioproducts per year:
- 13.5 tons of insect protein (animal feed) from spent grain
- 100 kg of disinfectant from wastewater
- 17 kg of microbial protein (cosmetics) from CO2
- 20 g of ectoine and 15 kg of caproic acid (bioplastics) from CH4
- Achieved TRL 7, a major step towards commercial viability.
- Reduced the carbon footprint through sustainable waste management and bioproduction.
This project demonstrates a circular bioeconomy model for the brewing industry and other sectors to reduce waste and create valuable products.
1. Side-stream mapping and optimization of side streams generated in the brewing industry, including spent grain, wastewater, CO2, and CH4, was conducted.
2. Development and start-up of insect and microbial platforms: Insect (Tenebrio molitor) and microbial (Pseudomonas putida, Bacillus subtilis) platforms were optimized and scaled up for valorization of the target side streams. Cultivation and feeding protocols were developed to maximize conversion efficiency and bioproduct quality. Control and monitoring systems were established to ensure the efficient and safe operation of the biological platforms.
3. Integration and cascading of biomass processing: taking advantage of the synergies between insect and microbial platforms. Operating conditions were optimized to maximize bioproduct yield and minimize waste generation. Separation and purification strategies were developed to obtain high-quality bioproducts.
4. Bioproduct development and validation: The 5 target bioproducts – insect protein, disinfectant, microbial protein, ectoine, and caproic acid – were developed and validated at the laboratory scale. Stability studies were conducted to determine the shelf life of the bioproducts under different storage conditions.
5. Environmental and economic impact assessment considering aspects such as life cycle, cost-benefit analysis, and carbon footprint. The main opportunities and challenges for large-scale implementation of the project were identified. Implemented Commercialization strategies for the developed bioproducts.
Key Technical and Scientific Achievements
- Built a pilot biorefinery using insects and microbes to convert 40 tons/year of brewery waste into valuable products (innovative and sustainable model).
- Produced five valuable bioproducts per year:
- 13.5 tons of insect protein (animal feed) from spent grain
- 100 kg of disinfectant from wastewater
- 17 kg of microbial protein (cosmetics) from CO2
- 20 g of ectoine and 15 kg of caproic acid (bioplastics) from CH4
- Achieved TRL 7, a major step towards commercial viability.
- Reduced the carbon footprint through sustainable waste management and bioproduction.
This project demonstrates a circular bioeconomy model for the brewing industry and other sectors to reduce waste and create valuable products.
By the end of the first year of project execution a revision of the Key Exploitable Results coming from the project was performed. The conclusion from this revision was that the eight preliminary exploitable results foreseen in the Grant Agreement were transformed into 11 KERs, mainly due to a split of some of them into differentiated results. The ownership of the results was reassigned in agreement with all partners, and the background provided by every owner was described.
Preliminary list of Exploitable results included in the Grant Agreement.
R1: Insect farming using bagasse in the diet, transformation of the insects in protein.
R2: BES technology and optimal operating parameters (Cl2 disinfectant).
R3: CO2 elongation and optimal operating parameters for caproic acid production.
R4: Biofermentor design for improved gas-liquid transfer (for SCP from CH4) and optimal process parameters.
R5: Taylor flow biofermentor design for CH4 fermentation to produce ectoine.
R6: Process parameters for ectoine production.
R7: DSP technology and process parameters.
R8: Brewery side-streams best management and pre-treatment for biorefinery model.
Since the project implementation is still at M18 of of 48 months, all results are currently under development or at the stage of prototyping. The construction and installation of the insect and microbial plants has been delayed for different reasons, the demonstration all the different upstream and downstream processes comprising the biorefinery is still pending. A first definition of potential target market and IP protection tools have been done. However, no move towards commercialisation or IPR registration has been initiated yet.
Preliminary list of Exploitable results included in the Grant Agreement.
R1: Insect farming using bagasse in the diet, transformation of the insects in protein.
R2: BES technology and optimal operating parameters (Cl2 disinfectant).
R3: CO2 elongation and optimal operating parameters for caproic acid production.
R4: Biofermentor design for improved gas-liquid transfer (for SCP from CH4) and optimal process parameters.
R5: Taylor flow biofermentor design for CH4 fermentation to produce ectoine.
R6: Process parameters for ectoine production.
R7: DSP technology and process parameters.
R8: Brewery side-streams best management and pre-treatment for biorefinery model.
Since the project implementation is still at M18 of of 48 months, all results are currently under development or at the stage of prototyping. The construction and installation of the insect and microbial plants has been delayed for different reasons, the demonstration all the different upstream and downstream processes comprising the biorefinery is still pending. A first definition of potential target market and IP protection tools have been done. However, no move towards commercialisation or IPR registration has been initiated yet.