Periodic Reporting for period 1 - WInScale (BRINGING THE PLASTIC WASTE TRANSFORMATION BY THE INSECTS AT SCALE)
Berichtszeitraum: 2023-07-01 bis 2024-06-30
The traditional linear plastic industry business model results in an ever-growing amount of accumulated waste which contributes significantly to the
negative environmental impact of the global plastic industry. One of the biggest issues concerning the recycling of used polymeric materials,
packaging, textile, furniture, is the handling of complex waste streams consisting of mixtures, co-polymers, and other recalcitrant materials, such as
thermosets (non-melting plastics, foams), that can be only burned or disposed of on the landfills. Yet, neither of these solutions is acceptable from the
environmental point of view, therefore the new regulations and EU directives aim to limit these methods.
We have developed a novel approach towards handling of complex plastic waste streams, where there is no available recycling alternative, thanks to
under patent technologies. The approach is based on one specific insect, Galleria mellonella, the greater wax moth, and we have developed a scalable
vertical farming process that enables the insects to digest and transform polymeric materials into proteins, lipids and biofertilizers. The long-term goal
of this developed process is an environmentally-sound and commercially-successful transformation facility.
WINSCALE focuses on the scaling up of the transformation process. Namely, it focuses on the biochemical and technological development of the
solution applied to two specifically difficult waste streams: sludge coming from the waste treating companies and polyurethane foam coming from
matrass recycling facilities.
WINSCALE enables the overall improvement of the investor readiness of the developed solution, contributes to the creation of new, cross-sectoral
value chains of waste transformation to added value products, thus promoting European competitiveness in the knowledge-based modern economy
and women’s leadership in the deep tech industry.
negative environmental impact of the global plastic industry. One of the biggest issues concerning the recycling of used polymeric materials,
packaging, textile, furniture, is the handling of complex waste streams consisting of mixtures, co-polymers, and other recalcitrant materials, such as
thermosets (non-melting plastics, foams), that can be only burned or disposed of on the landfills. Yet, neither of these solutions is acceptable from the
environmental point of view, therefore the new regulations and EU directives aim to limit these methods.
We have developed a novel approach towards handling of complex plastic waste streams, where there is no available recycling alternative, thanks to
under patent technologies. The approach is based on one specific insect, Galleria mellonella, the greater wax moth, and we have developed a scalable
vertical farming process that enables the insects to digest and transform polymeric materials into proteins, lipids and biofertilizers. The long-term goal
of this developed process is an environmentally-sound and commercially-successful transformation facility.
WINSCALE focuses on the scaling up of the transformation process. Namely, it focuses on the biochemical and technological development of the
solution applied to two specifically difficult waste streams: sludge coming from the waste treating companies and polyurethane foam coming from
matrass recycling facilities.
WINSCALE enables the overall improvement of the investor readiness of the developed solution, contributes to the creation of new, cross-sectoral
value chains of waste transformation to added value products, thus promoting European competitiveness in the knowledge-based modern economy
and women’s leadership in the deep tech industry.
The project technical and scientific activities were divided into two work packages (WPs):
WP1: Biochemical Development
This WP focused on the growth, thermo-mechanical treatment, and characterization of larvae to extract proteins and lipids, assessing their suitability for feed applications. Key activities included:
- Optimization of larval surface and volumetric density.
- Refinement of thermo-mechanical treatment to extract biomass components.
- Comprehensive characterization of proteins, lipids, and frass, including amino acids, fatty acids, and safety checks for heavy metals and plasticizers.
- Comparison of larval content with EU standards for pet food and organic fertilizers.
WP2: Rearing Device Development
This WP aimed at developing and evaluating an industrial-scale rearing device to optimize larval growth. Key activities included:
- Modeling and prototyping a 60 kt/y waste transformation factory and assessing its CAPEX and OPEX.
- Engaging with stakeholders to refine the concept, leading to the design of a modular, portable rearing unit with a 7 kt/y capacity.
- Economic evaluation and stakeholder validation of the new design.
Project Achievements
WinScale has surpassed expectations with key achievements, including:
- Optimized larval growth, achieving a 95% survival rate.
- Enhanced thermo-mechanical processes, with potential patent applications underway.
- Characterization of larval and frass content, confirming compliance with EU standards for pet food and organic farming.
- Validation that larvae fed waste streams, including flexible packaging and polyurethane, do not contain harmful elements but include beneficial trace elements.
- Development of a compact, modular rearing system ready for industrial-scale implementation.
WP1: Biochemical Development
This WP focused on the growth, thermo-mechanical treatment, and characterization of larvae to extract proteins and lipids, assessing their suitability for feed applications. Key activities included:
- Optimization of larval surface and volumetric density.
- Refinement of thermo-mechanical treatment to extract biomass components.
- Comprehensive characterization of proteins, lipids, and frass, including amino acids, fatty acids, and safety checks for heavy metals and plasticizers.
- Comparison of larval content with EU standards for pet food and organic fertilizers.
WP2: Rearing Device Development
This WP aimed at developing and evaluating an industrial-scale rearing device to optimize larval growth. Key activities included:
- Modeling and prototyping a 60 kt/y waste transformation factory and assessing its CAPEX and OPEX.
- Engaging with stakeholders to refine the concept, leading to the design of a modular, portable rearing unit with a 7 kt/y capacity.
- Economic evaluation and stakeholder validation of the new design.
Project Achievements
WinScale has surpassed expectations with key achievements, including:
- Optimized larval growth, achieving a 95% survival rate.
- Enhanced thermo-mechanical processes, with potential patent applications underway.
- Characterization of larval and frass content, confirming compliance with EU standards for pet food and organic farming.
- Validation that larvae fed waste streams, including flexible packaging and polyurethane, do not contain harmful elements but include beneficial trace elements.
- Development of a compact, modular rearing system ready for industrial-scale implementation.
The project has delivered two major breakthroughs: optimizing the transformation of plastic waste by G. mellonella larvae and developing an innovative rearing device.
Both results feature multiple achievements that push beyond the current state of the art:
1. Optimization of Plastic Waste Transformation: We addressed both upstream and downstream aspects with groundbreaking advancements:
- Upstream: We optimized larval density, demonstrating that surface density significantly improves larval growth and survival, reducing overall mortality.
- Downstream: We pioneered a novel approach that simplifies and accelerates processing while uncovering new high-value products, such as foam formed by the emulsion of larval lipids with small water-soluble proteins.
Furthermore, our in-depth analysis of larval and frass content provided the first clear evidence of the safety and suitability of these products for the European pet food and organic farming sectors. This is a critical step towards transforming policy and practice regarding the safe use of waste streams to produce high-quality insect-derived products.
2. Development of a Rearing Device: We created a compact, continuous system that not only optimizes G. mellonella rearing but also sets a new standard for the broader insect-rearing industry. This modular, economically viable system offers robust feeding and sorting mechanisms that enhance resilience and adaptability across different insect species, potentially revolutionizing the sector.
Overall, this project has revealed untapped potential in advanced processes and systems, marking a significant leap beyond the existing state of the art.
Both results feature multiple achievements that push beyond the current state of the art:
1. Optimization of Plastic Waste Transformation: We addressed both upstream and downstream aspects with groundbreaking advancements:
- Upstream: We optimized larval density, demonstrating that surface density significantly improves larval growth and survival, reducing overall mortality.
- Downstream: We pioneered a novel approach that simplifies and accelerates processing while uncovering new high-value products, such as foam formed by the emulsion of larval lipids with small water-soluble proteins.
Furthermore, our in-depth analysis of larval and frass content provided the first clear evidence of the safety and suitability of these products for the European pet food and organic farming sectors. This is a critical step towards transforming policy and practice regarding the safe use of waste streams to produce high-quality insect-derived products.
2. Development of a Rearing Device: We created a compact, continuous system that not only optimizes G. mellonella rearing but also sets a new standard for the broader insect-rearing industry. This modular, economically viable system offers robust feeding and sorting mechanisms that enhance resilience and adaptability across different insect species, potentially revolutionizing the sector.
Overall, this project has revealed untapped potential in advanced processes and systems, marking a significant leap beyond the existing state of the art.