First-of-its-kind, large-scale, lowest-cost, zero-waste biorefinery for the production of proteins for food and feed application from low cost sustainable feedstocks.

Project Information

PLENITUDE

Grant agreement ID: 838104

DOI

10.3030/838104

Project closed

EC signature date 11 July 2019

Start date 1 October 2019

End date 31 December 2025

Funded under

• INDUSTRIAL LEADERSHIP - Leadership in enabling and industrial technologies – Biotechnology

Total cost

€ 28 943 716,72

EU contribution

€ 16 937 253,61

Coordinated by

3F BIO LIMITED
United Kingdom

Periodic Reporting for period 3 - PLENITUDE (First-of-its-kind, large-scale, lowest-cost, zero-waste biorefinery for the production of proteins for food and feed application from low cost sustainable feedstocks.)

Reporting period: 2022-10-01 to 2024-03-31

Summary of the context and overall objectives of the project

PLENITUDE addresses the protein challenge by integrating two established processes into a flagship, large-scale, first-of-its-kind, biorefinery producing bioethanol and sustainable food protein in an integrated process.

PLENITUDE brings together 10 key players in the bioeconomy spanning 5 EU member states and representing every link in the value chain. This includes expertise in primary processing and industrial operations (Cargill), biotechnology (3F BIO Limited, ENOUGH BV), product development and applications (International Flavors & Fragrances I.F.F. B.V) primary research and protein expertise (Wageningen University) a specialist consultants covering marketing and sustainability (Bridge 2 Food, Life Cycle Engineering Srl), and three end-users covering food categories (Mosa Meat, Vivera, ABP) as well as one end-user covering bio-plastics (Lactips).

The global consumption of “meat” protein currently totals around 500 million tonnes per year, with less than 1% derived from non-animal sources. Experts including the Food and Agriculture Organization of the United Nations (FAO) predict that the demand for non-animal proteins may increase to account for 10-20% of the growing total demand, which would create a need for 100-200 million tonnes of plant protein by 2050.

With initial output capacity of 10k tonnes per annum, this flagship project will increase the availability of sustainable, high-quality food protein. The collaboration between the biorefinery operator, food producers and technology providers will create new cross-sector interconnections, new bio-based value chains, and new bio-based ‘consumer’ products.

The project includes a full assessment of the environmental, economic, health and social impacts of the developed products or processes, using LCA/LCC/S-LCA methodologies based on available standards to validate the sustainability and food safety of the products and value chain. Based on a target to produce 1 million tonnes of protein by 2030, it is estimated that this could equate to a reduction of >5 million tonnes of carbon dioxide emissions.

Within the 3rd reporting period, the majority of activity relates to the completion of the flagship plant construction and initial continuous operation (MS6) This included testing and engineering project handover (MS7) and characterisation and confirmation of regulatory equivalence (MS8). Studies about mycoprotein and its commercialisation were progressed using plant material and will accelerate with product availability.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Over the project duration, the activities in all workstreams are substantially on track. There has been some delays re construction, commissioning and product supply.

A summary of the cumulative achievements:

WP3 Flagship Plant Construction (led by 3F Bio): The flagship plant just took a year to complete construction and after some delays in commissioning has been fully handed over to production teams.

WP4 Production Validation & Testing (led by Enough): Successful recruitment and training of team to support the operational activities. The plant has been acceoted from the project team and engineering handover completed. There has been successful initial manufacture and ongoing optimisation to improve production rates.

WP5 Characterisation of the Inputs and Outputs (led by Wageningen University): This work package has been completed with strong delivery across characterisation, extrusion, ambient storage and digestibility of material. A detailed study has been conducted to find out consumer preferences.

WP6 Exploitation and Commercialisation Outputs (led by 3F Bio): There has been detailed development of a range of high quality, representational products using Abunda. The focus has been on meat alternatives, especially meat free chicken products.There has also been work on hybrid (meat/non-meat) ,cultured meat and bioplastics with consortium partners.

WP7 Dissemination & Communications (led by Bridge 2 Food): A range of dissemination activities were carried out regularly, including videos, social media posts and webinars. The website has been updated and broader engagement with industry and policy audiences.

WP8 Market Mapping – Environmental, Economic and Social (led by Life Cycle Engineering): A preliminary LCA has been undertaken using initial available data for production in Sas van Gent plant. There has been input from other partners across the supply chain.

WP9 Project Management (led by 3F Bio) : There has been efficient project management to ensure deliverables and milestones delivery and mitigation planning. This has included project extension by 9 months and also funding reallocation.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

Progress Beyond the State of the Art

Cross-Sector Connections & Collaboration:

The project has successfully initiated 4 new cross-sector connections. This collaborative model integrates various industries that traditionally operate in silos, fostering synergies to enhance sustainability.


Expected Results Until the End of the Project

Product Launch and Commercialization: The project aims to launch 10 new products spanning the food, pet food, and bioplastics industries. These products will address the increasing demand for alternative protein sources, with mycoprotein offering a cleaner ingredient list and high versatility.
The expected uptake of mycoprotein in food production will lead to new market opportunities, as the cleaner, scalable, and affordable protein becomes a viable option for mass consumers.
Reduction in Environmental Impact:

By the end of the project, a >20% reduction in carbon footprint from protein production is expected, which will be achieved through improved processes and lower resource utilization in comparison to traditional protein production methods.
Further Life Cycle Assessments (LCAs) will quantify these environmental benefits, establishing mycoprotein as a more sustainable option.
Job Creation and Rural Economic Development:

The project has already created 40 direct jobs in a rural area in South Netherlands, with hundreds more involved in the construction and development of the plant. Additional supply chain jobs are anticipated as the plant expands.
Future investment in plant capacity is expected to generate more employment opportunities, helping to revitalize rural economies through the growth of a new, green industry.

Potential Impacts

Socio-Economic Impact: The project’s contribution to job creation in rural areas has been a key socio-economic impact. The direct employment of staff and supply chain involvement is transforming the local economy by providing high-quality jobs and stimulating growth in adjacent industries.
As production scales, the affordability of mycoprotein will increase, providing a wider range of consumers access to sustainable protein sources, which will drive further economic and social benefits.
Wider Societal Implications:

Shift Towards Sustainable Consumption: As the market for microorganism-based proteins grows, the project will play a critical role in shifting consumer behavior towards sustainable food choices. Mycoprotein’s clean, scalable production aligns with increasing consumer demand for environmentally conscious products.
The scalable model for protein production ensures a more sustainable and resilient food system, capable of meeting the growing global demand for protein without the high environmental costs associated with traditional livestock farming.

Abunda Mycoprotein