Periodic Reporting for period 1 - SUSTAINEXT (NEXT GENERATION, ZERO-WASTE, DYNAMIC, MULTIVALORIZATION ROUTE BIOREFINERY FOR SUSTAINABLE BOTANICAL INGREDIENTS:SHOWCASING A REPLICABLE AND VERSATILE MODEL FROM EXTREMADURA TO BIO-BASED INDUSTRY IN EU)
Berichtszeitraum: 2023-06-01 bis 2024-11-30
SUSTAINEXT is the first FLAGSHIP project funded by the Circular Bio-based Europe Joint Undertaking (CBE JU), aiming to revolutionize the botanical extracts industry with a replicable model for the European bio-based sector. It will transform an existing facility into a cutting-edge digitalized circular biorefinery focused on producing plant-based ingredients from local medicinal and aromatic plants (MAPs) and agricultural biomass.
Led by Natac and 20 European partners, SUSTAINEXT will deploy a smart, multi-product biorefinery, validating an innovative business model for the plant-based ingredient sector. It will introduce 46 innovative extracts, 13 entirely new to the market, and 12 newly produced in Europe.
The project’s goal is to turn Natac’s facility in Hervás (Extremadura) into a state-of-the-art, sustainable biorefinery, optimizing biomass use and striving for “zero waste” and “zero pollution.” This will significantly improve environmental performance, enhancing resource and energy efficiency while setting a benchmark for sustainability.
Extremadura, with its strong agro-industrial tradition, faces key challenges that SUSTAINEXT will address by establishing value chains for six raw materials—three agro-industrial biomasses (olive, artichoke, pomegranate) and three MAPs (rosemary, chamomile, lemon verbena)—boosting economic potential and promoting their use in plant-based ingredients. This will create new opportunities for farmers while encouraging sustainable agricultural practices.
SUSTAINEXT will also position MAP cultivation as a viable alternative to the region’s declining tobacco industry, ensuring economic stability through eco-friendly crops. Additionally, it will valorize underutilized agricultural biomass—6.8 million tons annually—by upcycling it into high-value ingredients, fostering a circular production model that minimizes waste.
To optimize land use, the project will integrate MAP cultivation with solar farms through an agrivoltaic model, combining renewable energy production with sustainable agriculture. This approach promotes environmental sustainability while maximizing land efficiency.
Through these innovations, SUSTAINEXT will drive the transition toward a circular economy, generating economic benefits while promoting efficient resource use, reducing emissions, and fostering rural sustainability.
Led by Natac and 20 European partners, SUSTAINEXT will deploy a smart, multi-product biorefinery, validating an innovative business model for the plant-based ingredient sector. It will introduce 46 innovative extracts, 13 entirely new to the market, and 12 newly produced in Europe.
The project’s goal is to turn Natac’s facility in Hervás (Extremadura) into a state-of-the-art, sustainable biorefinery, optimizing biomass use and striving for “zero waste” and “zero pollution.” This will significantly improve environmental performance, enhancing resource and energy efficiency while setting a benchmark for sustainability.
Extremadura, with its strong agro-industrial tradition, faces key challenges that SUSTAINEXT will address by establishing value chains for six raw materials—three agro-industrial biomasses (olive, artichoke, pomegranate) and three MAPs (rosemary, chamomile, lemon verbena)—boosting economic potential and promoting their use in plant-based ingredients. This will create new opportunities for farmers while encouraging sustainable agricultural practices.
SUSTAINEXT will also position MAP cultivation as a viable alternative to the region’s declining tobacco industry, ensuring economic stability through eco-friendly crops. Additionally, it will valorize underutilized agricultural biomass—6.8 million tons annually—by upcycling it into high-value ingredients, fostering a circular production model that minimizes waste.
To optimize land use, the project will integrate MAP cultivation with solar farms through an agrivoltaic model, combining renewable energy production with sustainable agriculture. This approach promotes environmental sustainability while maximizing land efficiency.
Through these innovations, SUSTAINEXT will drive the transition toward a circular economy, generating economic benefits while promoting efficient resource use, reducing emissions, and fostering rural sustainability.
During the first reporting period, significant progress has been made at each stage of the project. In feedstock production, medicinal and aromatic plants (MAPs) were successfully introduced into target zones, adapting well to regional conditions. Initial results have been promising, with crops monitored for optimal growth. Pretreatment techniques for agro-industrial biomass were explored to preserve bioactive compounds.
The development of the new production plant has progressed, with key infrastructure nearing completion. Efforts focused on integrating production units, including a new extraction unit and desolventization system for solvent recovery and reuse, reducing environmental impact and costs.
In product development, key achievements include the characterization and selection of bioactive plant extracts for health applications, optimizing formulation stability, and producing the first prototypes. Botanical extracts were evaluated for potential as antioxidants in food, with prototypes under development to improve efficacy, reduce costs, and maintain sensory profiles. These extracts are also being tested for animal health (pet and farm markets) and cosmetics. The project has tested exhausted biomasses as soil improvers, with promising field trial results.
Progress was made on environmental and regulatory compliance. Life cycle assessment (LCA) methodologies were established to evaluate environmental, economic, and social impacts, while regulatory requirements were thoroughly reviewed for compliance.
In dissemination and communication, a visual identity was created, including a project logo, website, and social media profiles. Informative materials like flyers, roll-ups, and posters were developed, and partners participated in events to showcase SUSTAINEXT’s objectives and achievements. Market studies offered insights into the potential of the project’s outputs, paving the way for future business models and exploitation strategies.
The development of the new production plant has progressed, with key infrastructure nearing completion. Efforts focused on integrating production units, including a new extraction unit and desolventization system for solvent recovery and reuse, reducing environmental impact and costs.
In product development, key achievements include the characterization and selection of bioactive plant extracts for health applications, optimizing formulation stability, and producing the first prototypes. Botanical extracts were evaluated for potential as antioxidants in food, with prototypes under development to improve efficacy, reduce costs, and maintain sensory profiles. These extracts are also being tested for animal health (pet and farm markets) and cosmetics. The project has tested exhausted biomasses as soil improvers, with promising field trial results.
Progress was made on environmental and regulatory compliance. Life cycle assessment (LCA) methodologies were established to evaluate environmental, economic, and social impacts, while regulatory requirements were thoroughly reviewed for compliance.
In dissemination and communication, a visual identity was created, including a project logo, website, and social media profiles. Informative materials like flyers, roll-ups, and posters were developed, and partners participated in events to showcase SUSTAINEXT’s objectives and achievements. Market studies offered insights into the potential of the project’s outputs, paving the way for future business models and exploitation strategies.
SUSTAINEXT is implementing a new model to improve and scale the farming conditions for medicinal and aromatic plants. Innovative agricultural practices like agrivoltaics and crop monitoring sensors enhance sustainability and resource efficiency, optimizing land and energy use while improving agricultural outcomes.
New pre-treatment techniques are being used to modify feedstock phytochemical composition, enhancing efficiency and quality for subsequent valorization processes. The new production plant is designed with dynamic, multi-product capabilities, enabling the processing of various feedstocks to produce a range of products, integrated with the valorization processes developed in WP3. This helps establish the plant as a sustainable, innovative biorefinery.
New technologies have been designed and integrated to improve extraction and purification processes, enabling full utilization of feedstocks and contributing to the goal of zero waste. The first prototypes for new bioproducts have been produced, demonstrating the potential of converting agricultural biomass into valuable, sustainable products.
SUSTAINEXT is also fostering the creation of new bio-based industry jobs, particularly in rural areas, supporting the local economy and promoting more sustainable agricultural practices.
New pre-treatment techniques are being used to modify feedstock phytochemical composition, enhancing efficiency and quality for subsequent valorization processes. The new production plant is designed with dynamic, multi-product capabilities, enabling the processing of various feedstocks to produce a range of products, integrated with the valorization processes developed in WP3. This helps establish the plant as a sustainable, innovative biorefinery.
New technologies have been designed and integrated to improve extraction and purification processes, enabling full utilization of feedstocks and contributing to the goal of zero waste. The first prototypes for new bioproducts have been produced, demonstrating the potential of converting agricultural biomass into valuable, sustainable products.
SUSTAINEXT is also fostering the creation of new bio-based industry jobs, particularly in rural areas, supporting the local economy and promoting more sustainable agricultural practices.