PROLIFIC analysed the availability, geographical origin, seasonality, quality, safety and sustainability of the selected legume, fungi and coffee feedstocks. The biggest potential can be tapped in the legumes sector with cultivation in many EU countries.
Partners developed and optimised feedstock specific cascades of extraction processes recovering proteins and other non-protein compounds. Different protein extraction protocols using environmentally friendly aqueous extraction (EFAE), enzymatic-assisted (EAE) or ultrasound-assisted extraction (UAE) were tested for each type of residue. Protein fractions were characterised for their nutritional value and functional properties. Additional (cascading) extraction steps could isolate polyphenols, carotenoids, b-glucans, chitosan and caffeine from protein extraction residues as well as from initial feedstocks. The most efficient processes in terms of mass yield and purity were scaled-up in a small pilot or pre-industrial environment:
• proteins from legumes (both EFAE and EAE),
• coffee polyphenols (with sub-critical water extraction or UAE),
• chitosan from fungi (alkaline method)
Throughout the project, initial feedstocks, extracts and prototypes were fully characterised for their chemical, safety, bioactivity, technical and functional characteristics. They largely complied with sectoral legislation as concerns safety. No major barriers for their further use were identified. The functional properties were confirmed in comprehensive trials. New product formulations were demonstrated in semi-industrial scale for the following prototypes:
FOOD:
• Protein-enriched bread, pasta, flakes and vegan burger patties containing > 20% protein extracts from legume residues
• hamburgers and cured sausages containing coffee polyphenols as antioxidant replacing nitrite or ascorbic acid
COSMETIC:
• anti-microbial toothpaste with fungi chitosan;
• anti-age/whitening creams including coffee polyphenols.
PACKAGING:
• Utilisation of fibrous legume residues after protein extraction in composites formulations for rigid jars for cosmetic products
• Coffee capsule bodies from biodegradable, compostable polymers including coffee silver skin or complemented with coffee polyphenols for antioxidant properties
• antimicrobial flexible coating for meat products including fungi chitosan.
FEED: pig feed formulations amended with coffee polyphenols or coffee solid extraction residues of antioxidant or pre-biotic properties
PROLIFIC generated 15 key exploitable results: five extraction protocols and related fractions used as ingredients in ten different types of prototypes. An exploitation plan was compiled outlining an exploitation roadmap to bring the results to market. The owner of the optimised extraction protocols intend to exploit them by patent application (under investigation), trade secret or contract manufacturing services. The project findings opened new business perspective for the producer of biomass streams, though feedstock stabilisation and supply remain a challenge to be solved.
PROLIFIC has developed a consistent project identity (logo, flyer, website) as frame for all dissemination activities. Project results and product prototypes were presented on various events, such as the BBI Stakeholder Forum Projects Day, Science is Wonderful Event, Researchers' Night, > 20 international conferences or workshops (e.g. RRB 2022 with a dedicated PROLIFIC session) various sectoral fairs and even the Italian TV. Results were published in nine peer-reviewed scientific papers with additional five under preparation.
Addressing industry, policy and the research community PROLIFIC organized a dedicated workshop on “Residual Biomasses for Eco-compatible and Sustainable Food Packaging” and a final event highlighting the project outcome on the "Valorisation routes for agro-industrial side-streams".
