Periodic Reporting for period 3 - EXCornsEED (Separation, fractionation and isolation of biologically active natural substances from corn oil and other side streams)
Reporting period: 2020-12-01 to 2023-02-28
EXCornsEED aimed to exploit the convergence between science, chemistry, biology, engineering and biotechnology tools for the creation of new knowledge and innovative applications, with the main goal to develop and validate an integrated process of innovative and highly sustainable extraction/purification/concentration technologies to be applied to bio-refineries side streams (i.e. corn oil from bio-ethanol and rapeseed meal from biodiesel production) for the recovery of proteins and several other bio-active compounds and characterization/preparation of these as ingredients for food, detergents and cosmetics markets. The production of added-value bio-based products from these side streams, following the emerging EU paradigms of integrated biorefinery and circular economy, will maximize full biomass-to-products value along the whole value chain, making the production costs of biofuels competitive without any governmental support. The project objectives are the following:
-To assess industrial side streams and coproducts of two biotech processes (bioethanol and biodiesel production), characterizing the quality and amount of extractable compounds
-To develop, upscale and validate an innovative and environmentally friendly process to extract/purify/concentrate proteins and bioactive compounds from industry side streams
-To test and validate the application of the extracted compounds as ingredients in food, detergents and cosmetics
-To assess the environmental sustainability, technical performances, cost-benefits of technological solutions and final products, as well as preindustrial feasibility
-To evaluate the business potential of the proposed innovative approach and build solid business cases for the exploitation of the project’s results
-To raise awareness, engage stakeholders and build a robust network around the project’s results through a well-designed dissemination & communication strategy and activities.
-To assess industrial side streams and coproducts of two biotech processes (bioethanol and biodiesel production), characterizing the quality and amount of extractable compounds
-To develop, upscale and validate an innovative and environmentally friendly process to extract/purify/concentrate proteins and bioactive compounds from industry side streams
-To test and validate the application of the extracted compounds as ingredients in food, detergents and cosmetics
-To assess the environmental sustainability, technical performances, cost-benefits of technological solutions and final products, as well as preindustrial feasibility
-To evaluate the business potential of the proposed innovative approach and build solid business cases for the exploitation of the project’s results
-To raise awareness, engage stakeholders and build a robust network around the project’s results through a well-designed dissemination & communication strategy and activities.
The project successfully developed efficient and reproducible extraction/valorisation technologies at the laboratory scale 2, namely, i) protein extraction and purification procedure from rapeseed meal ready to be transferred to the pilot scale and ii) a complete downstream processing of corn oil that allowed the purification of classes of high valued compounds. At least 25 utilisable bioactive compounds belonging to group of phytosterols, polyphenols, phenolic compounds, fatty acids, tocols, flavonoids, carotenoids were successfully identified.
The EXCornsEED process was upscaled from lab level (few grams, TRL3) up to the semi-pilot level and the industrial pilot (up to 1t/d capacity). A the full-scale plant design and engineering was prepared for full-pilot scale facility to scale 50kg and 100kg RSM/batch for proteins. The lab process was successfully replicated with similar yield and protein quality that at smaller scale achieving TRL5, demonstrating its reproducibility at full pilot scale.
All the extracted compounds were tested and validated as ingredients for food, cosmetic and detergent products. Final food and cosmetic products were formulated and fortified with ingredients derived from the semi-scale and full-scale processes were assessed and validated. 5% EXCornsEED protein isolate from RSM was applied as an ingredient for texture-modified food for elderly, with three products optimised and validated (chicken breast, carrots and bread), also other food matrices fortified with RSM protein isolate were tested, namely fish, pea or printed chocolate-cake containing protein.
Cosmetic products enriched with RSM polyphenols (sinapic acid) and peptides, an outdoor cream formulation with antioxidant activity and an Indoor cream with anti-aging activity were also formulated and validated.
High amounts of samples were analysed for detergent application. The feasibility of amino-acid based surfactants was shown as well as the design of the laboratory synthesis.
The optimal operating conditions were evaluated and served for techno-economic analyses to assess the sustainability aspects by means of a decision matrix (multicriteria decision analysis). Environmental evaluation of EXCornsEED technologies at laboratory scale was also carried out applying the life cycle assessment methodology.
The EXCornsEED process was upscaled from lab level (few grams, TRL3) up to the semi-pilot level and the industrial pilot (up to 1t/d capacity). A the full-scale plant design and engineering was prepared for full-pilot scale facility to scale 50kg and 100kg RSM/batch for proteins. The lab process was successfully replicated with similar yield and protein quality that at smaller scale achieving TRL5, demonstrating its reproducibility at full pilot scale.
All the extracted compounds were tested and validated as ingredients for food, cosmetic and detergent products. Final food and cosmetic products were formulated and fortified with ingredients derived from the semi-scale and full-scale processes were assessed and validated. 5% EXCornsEED protein isolate from RSM was applied as an ingredient for texture-modified food for elderly, with three products optimised and validated (chicken breast, carrots and bread), also other food matrices fortified with RSM protein isolate were tested, namely fish, pea or printed chocolate-cake containing protein.
Cosmetic products enriched with RSM polyphenols (sinapic acid) and peptides, an outdoor cream formulation with antioxidant activity and an Indoor cream with anti-aging activity were also formulated and validated.
High amounts of samples were analysed for detergent application. The feasibility of amino-acid based surfactants was shown as well as the design of the laboratory synthesis.
The optimal operating conditions were evaluated and served for techno-economic analyses to assess the sustainability aspects by means of a decision matrix (multicriteria decision analysis). Environmental evaluation of EXCornsEED technologies at laboratory scale was also carried out applying the life cycle assessment methodology.
The different applications tested and validated during the EXCornSeed project are innovative and scientifically relevant, as they are designed to meet consumers’ requests for healthy, safe and sustainable products and at the same time add new perspectives to a currently under-utilised biomass like rapeseed meal. The application of RSM fractions to high-value market products is in line with current major societal challenges like responsible management of natural resources, valorization of by-products and human health and wellbeing.
EXCornsEED reflects the BIC’s ambitions to contribute to the society’s long-term sustainability. EXCornsEED will accomplish the following KPIs from the BBI programme:
-To create at least 1 new cross-sector interconnection in bio-based economy clusters
-To set the basis for at least 1 new bio-based value chain, 2 different ingredients or additives with purity levels that enable their use in different application fields, further development of new or optimized value chains based on residual streams from the food or feed industry, agricultural activities or biorefineries
-To obtain an overall reduction of at least 10 % in the carbon footprint of the considered bio-based operation compared with the state-of-the-art.
Other impacts will be:
-Innovation capacity: The innovative process for side streams valorisation is the result of the combination of breakthrough innovations in raw material preparation, compounds extraction and ingredients purification, through the concerted collaboration among top players of the EU scientific community and industry with a sound multidisciplinary and inter-sectorial approach. Important advancements will be achieved in important knowledge areas related to extraction/purification/concentration technologies and their integration/upscale, identification and characterization of bioactive compounds, side streams and by-products analysis, combined reaction processes, techno-economic analysis of industrial process with particular focus on combined effects at different levels (process intensification and optimisation), market-monitoring and integrated-processanalysis.
-New market opportunities: The innovative side streams valorisation process implemented through this project, as well as the set of compounds and ingredients targeted will strengthen the competitiveness and growth of EU companies in the new “Green Revolution”. The project will impact biofuels and agro-food industries as well as the cosmetics, food, and specialty chemicals industries involving them in a totally innovative value chain (i.e. side streams providers, technology providers, plant owners, downstream product transformers). EXCornsEED will offer a solution for reducing the use of feedstock for biofuels and agro-food industries at the same time valorising the feedstock side streams and enabling the transformation of European traditional biotech productions into integrated near-zero waste biorefineries.
-Bring benefits for society: EXCornsEED will contribute to a better implementation of the main EU strategic policies and Directives for environmental protection and transition to a green, low-carbon, energy and resource-efficient economy.
EXCornsEED reflects the BIC’s ambitions to contribute to the society’s long-term sustainability. EXCornsEED will accomplish the following KPIs from the BBI programme:
-To create at least 1 new cross-sector interconnection in bio-based economy clusters
-To set the basis for at least 1 new bio-based value chain, 2 different ingredients or additives with purity levels that enable their use in different application fields, further development of new or optimized value chains based on residual streams from the food or feed industry, agricultural activities or biorefineries
-To obtain an overall reduction of at least 10 % in the carbon footprint of the considered bio-based operation compared with the state-of-the-art.
Other impacts will be:
-Innovation capacity: The innovative process for side streams valorisation is the result of the combination of breakthrough innovations in raw material preparation, compounds extraction and ingredients purification, through the concerted collaboration among top players of the EU scientific community and industry with a sound multidisciplinary and inter-sectorial approach. Important advancements will be achieved in important knowledge areas related to extraction/purification/concentration technologies and their integration/upscale, identification and characterization of bioactive compounds, side streams and by-products analysis, combined reaction processes, techno-economic analysis of industrial process with particular focus on combined effects at different levels (process intensification and optimisation), market-monitoring and integrated-processanalysis.
-New market opportunities: The innovative side streams valorisation process implemented through this project, as well as the set of compounds and ingredients targeted will strengthen the competitiveness and growth of EU companies in the new “Green Revolution”. The project will impact biofuels and agro-food industries as well as the cosmetics, food, and specialty chemicals industries involving them in a totally innovative value chain (i.e. side streams providers, technology providers, plant owners, downstream product transformers). EXCornsEED will offer a solution for reducing the use of feedstock for biofuels and agro-food industries at the same time valorising the feedstock side streams and enabling the transformation of European traditional biotech productions into integrated near-zero waste biorefineries.
-Bring benefits for society: EXCornsEED will contribute to a better implementation of the main EU strategic policies and Directives for environmental protection and transition to a green, low-carbon, energy and resource-efficient economy.