Periodic Reporting for period 2 - KB-BIOREFINERY (A biorefinery for upcycling coffee waste into sustainable, healthy, high-value ingredients)
Reporting period: 2022-11-01 to 2024-03-31
Kaffe Bueno (KB) is a pioneering bioscience company dedicated to addressing a pressing environmental challenge—coffee waste. With over 10 billion kilograms of coffee consumed globally in 2023, the industry faces a critical sustainability crisis. More than 80% of this coffee turns into waste, predominantly ending up in landfills where it decomposes, producing significant quantities of methane—a potent greenhouse gas. This alarming scenario underscores the urgent need for innovative solutions that promote sustainability and reduce the environmental footprint of the coffee industry.
KB's project revolves around the innovative concept of a Coffee Biorefinery, designed to upcycle coffee by-products into valuable ingredients.. By harnessing green chemistry, biotechnology, and nanotechnology, KB aims to valorise 100% of coffee by-products, transforming them into active, functional, and multifunctional ingredients. This approach not only mitigates the methane emissions from coffee waste but also introduces sustainable alternatives to petrochemicals and synthetic ingredients widely used across various sectors.
This project serves as an example that should enhance the understanding of consumer behaviour towards sustainable products, the societal impact of reducing environmental footprints, and the cultural shifts necessary to embrace biobased alternatives.
The primary objective of the KB-BIOREFINERY project is to establish a fully operational Demo Biorefinery with the capacity to process 250 tons of coffee by-products annually. This facility will focus on producing sustainable ingredients and their derivatives. The launch of this biorefinery is anticipated to significantly influence the industry by replacing unsustainable ingredients with natural alternatives.
In conclusion, the KB project not only aims to solve a significant environmental issue but also sets a precedent for how industries can pivot towards more sustainable operations. The expected impact of the project is substantial, offering a scalable model that could be replicated in other contexts, thus contributing profoundly to a more sustainable and biobased global economy. By demonstrating the feasibility and benefits of upcycling coffee waste into valuable products, KB is paving the way for a greener, more sustainable future. This project exemplifies how targeted innovation and collaboration can drive progress towards achieving the United Nations Sustainable Development Goals.
KB's project revolves around the innovative concept of a Coffee Biorefinery, designed to upcycle coffee by-products into valuable ingredients.. By harnessing green chemistry, biotechnology, and nanotechnology, KB aims to valorise 100% of coffee by-products, transforming them into active, functional, and multifunctional ingredients. This approach not only mitigates the methane emissions from coffee waste but also introduces sustainable alternatives to petrochemicals and synthetic ingredients widely used across various sectors.
This project serves as an example that should enhance the understanding of consumer behaviour towards sustainable products, the societal impact of reducing environmental footprints, and the cultural shifts necessary to embrace biobased alternatives.
The primary objective of the KB-BIOREFINERY project is to establish a fully operational Demo Biorefinery with the capacity to process 250 tons of coffee by-products annually. This facility will focus on producing sustainable ingredients and their derivatives. The launch of this biorefinery is anticipated to significantly influence the industry by replacing unsustainable ingredients with natural alternatives.
In conclusion, the KB project not only aims to solve a significant environmental issue but also sets a precedent for how industries can pivot towards more sustainable operations. The expected impact of the project is substantial, offering a scalable model that could be replicated in other contexts, thus contributing profoundly to a more sustainable and biobased global economy. By demonstrating the feasibility and benefits of upcycling coffee waste into valuable products, KB is paving the way for a greener, more sustainable future. This project exemplifies how targeted innovation and collaboration can drive progress towards achieving the United Nations Sustainable Development Goals.
Key activities:
Delivering the Demo Plant
The successful delivery of the Demo plant involved several critical steps:
1. Equipment Datasheets and Process Flow Diagram & Design
2. Installation and Setup
3. Permits and Approvals
4. Environmental and Regulatory Assessment
Process Optimization
• Increased Efficiency: We evaluated the efficiency of various innovative systems designed to enhance the oil extraction process.
• Solvent Recovery: A method and design for solvent recovery procedures were developed, achieving a 99.8% efficiency rate.
• Impurity Removal: Various mechanisms for removing impurities from the extracted oil were evaluated.
• Efficiency Enhancements: The use of innovative systems to increase the efficiency of the oil refinery process was assessed, resulting in optimized purification procedures and improved product quality.
• Separation Mechanisms: The best mechanisms for separating novel fractions from the SCGs were identified.
• Process Efficiency: An assessment of process efficiency was conducted, aiming to find the best balance between performance and sustainability.
• Solubility and Emulsification: The solubility and emulsification properties of the extracted fractions were determined, ensuring their suitability for various applications.
• Fraction Evaluation: Different sizes of extracted fractions were evaluated to identify their unique properties and potential applications.
Delivering the Demo Plant
The successful delivery of the Demo plant involved several critical steps:
1. Equipment Datasheets and Process Flow Diagram & Design
2. Installation and Setup
3. Permits and Approvals
4. Environmental and Regulatory Assessment
Process Optimization
• Increased Efficiency: We evaluated the efficiency of various innovative systems designed to enhance the oil extraction process.
• Solvent Recovery: A method and design for solvent recovery procedures were developed, achieving a 99.8% efficiency rate.
• Impurity Removal: Various mechanisms for removing impurities from the extracted oil were evaluated.
• Efficiency Enhancements: The use of innovative systems to increase the efficiency of the oil refinery process was assessed, resulting in optimized purification procedures and improved product quality.
• Separation Mechanisms: The best mechanisms for separating novel fractions from the SCGs were identified.
• Process Efficiency: An assessment of process efficiency was conducted, aiming to find the best balance between performance and sustainability.
• Solubility and Emulsification: The solubility and emulsification properties of the extracted fractions were determined, ensuring their suitability for various applications.
• Fraction Evaluation: Different sizes of extracted fractions were evaluated to identify their unique properties and potential applications.
Studies, Technical Analyses, and Application Development to Test Ingredient Efficacy in Target Markets
Current SoA: The current market segments with high growth potential include healthy aging and sun protection.
Beyond SoA: During this RP1, we have successfully demonstrated through in vitro studies that our ingredients exhibit highly competitive performance against direct substitutes in anti-aging and sun protection applications. Additionally, we have discovered very promising results in hair care, opening a new market segment opportunity. These findings not only validate our ingredients' efficacy but also highlight their potential to capture significant market share in multiple high-growth segments.
Process for Extracting and Using Melanoidins and Phenols from Defatted SCG at Scale
Current SoA: Existing technologies and extraction techniques are available for the selective separation of molecules from various feedstocks. However, the application of these technologies to defatted SCGs for the extraction of melanoidins and phenols is still emerging.
Beyond SoA: During WP1, we have optimized process parameters through outsourced tests and identified key molecular sizes to achieve the highest performance for target applications. These optimized parameters will be validated in our own pilot biorefinery.
Overview of Results
• Ingredient Efficacy: Demonstrated superior performance of our ingredients in anti-aging, sun protection, and hair care applications through in vitro studies.
• Process Optimization: Developed and validated innovative extraction processes for melanoidins and phenols, ensuring high quality and performance.
• Market Potential: Identified new market opportunities and developed formulations for various applications, positioning our products for success in competitive segments.
• Intellectual Property: Secured patents for our innovative processes and applications, strengthening our market position and protecting our innovations.
Current SoA: The current market segments with high growth potential include healthy aging and sun protection.
Beyond SoA: During this RP1, we have successfully demonstrated through in vitro studies that our ingredients exhibit highly competitive performance against direct substitutes in anti-aging and sun protection applications. Additionally, we have discovered very promising results in hair care, opening a new market segment opportunity. These findings not only validate our ingredients' efficacy but also highlight their potential to capture significant market share in multiple high-growth segments.
Process for Extracting and Using Melanoidins and Phenols from Defatted SCG at Scale
Current SoA: Existing technologies and extraction techniques are available for the selective separation of molecules from various feedstocks. However, the application of these technologies to defatted SCGs for the extraction of melanoidins and phenols is still emerging.
Beyond SoA: During WP1, we have optimized process parameters through outsourced tests and identified key molecular sizes to achieve the highest performance for target applications. These optimized parameters will be validated in our own pilot biorefinery.
Overview of Results
• Ingredient Efficacy: Demonstrated superior performance of our ingredients in anti-aging, sun protection, and hair care applications through in vitro studies.
• Process Optimization: Developed and validated innovative extraction processes for melanoidins and phenols, ensuring high quality and performance.
• Market Potential: Identified new market opportunities and developed formulations for various applications, positioning our products for success in competitive segments.
• Intellectual Property: Secured patents for our innovative processes and applications, strengthening our market position and protecting our innovations.