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Processing insects for the production of protein
Insects: A new protein source for Europe?
Circular Bioeconomy Days
Aarhus University, Forskningscenter Foulum, DenmarkDIRK SINDERMANN, TJELE, DENMARK, 27TH JUNE 2019
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GEA – “engineering for a better world”
2
GEA is one of the largest suppliers of process technology to the food industry and to a wide range of other industries.
The company is listed on the German MDAX stock index (G1A, WKN 660 200) and included in the STOXX® Europe 600 Index. In addition, the company is listed in selected MSCI Global Sustainability Indexes.
The international technology group focuses on process technology, components and sustainable energy solutions for sophisticated production processes in diverse end-user markets.
4,751 million order intake (EUR)
17,863employees (FTEs)
1.31earnings per share (EUR)
564million operatingEBITDA (EUR)
4,605million revenue (EUR)
12.2% operating
EBITDA margin
27th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
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Our applications – in touch with GEA every day
3
Approx. one quarter of
processed milk comes from
GEA production systems
Every third chicken
nugget is produced
using GEA technology
Approx. every third process line for instant
coffee was installed by
GEA
Approx. every second liter
of beer is brewed with the aid of systems and process
solutions from GEA
Every fourth liter of human
blood for making
plasma-derived products is processed using GEA equipment
More than one third of all polymer
producers are using
GEA drying technology
Each industry we serve
utilizes industrial
refrigeration technology from GEA
Every second container ship
in the world sails with
GEA marine equipment on
board
Dairy Farming and Processing
Food Beverages Pharma Chemical Utilities Marine
27th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
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4
Processing insects for the production of protein
27th June 2019
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Image of Insects in Western Cultures
5Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
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Population development
627th June 2019
2019 2050
We will have to feed
9.7billionpeople
Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
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GEA activities in protein production –today and tomorrow
727th June 2019
Animalproteins
Plant proteins
Alternative proteins
Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
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Impacts of conventional protein production
827th June 2019
On land
Water use and pollution
Greenhouse gases
Land use
Feed price volatility
Antibiotic resistance
Soil degradation
In the ocean
Overfishing
Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Habitat loss
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Sustainability of Insects?
927th June 2019
1 G = 3.8L / 1P = 0.45 kg
Gallons of water needed to produce one pound of meat
Pound of feed needed to produce one pound of digestible meat
Greenhouse gas emissions
Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
?
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Potential for Food, Feed and Bio Materials
1027th June 2019
Feed
Aquacultures
Livestock
Petfood
Bio materials
BiofuelChitin
Fertilizer
FoodFood additives
Protein-fortifieddry products
Edible fats
SnacksFunctionaladditives
Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
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Estimated Protein Production from Insectswithin Europe
11Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
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Insects for Food: Mealworm Larvae
12Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Lesser Mealworm (Little Beetle)Alphitobius diaperinus
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Insects for Food: Burgers from Mealworm Larvae
13Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Co-creation @GEA Insect burgerNew: up to 64%
insects inside
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Fundamental principles of centrifugal separation
14Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Density difference: Separators and decanters can be used for the separation of the following liquid mixtures:
Liquid/ solid Liquid/ liquid Liquid/ liquid/ solid
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Insects for Food: Recovery of Protein and Fat from Mealworm Larvae
15Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
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Insects for Feed: Black Soldier Fly Larvae
16Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Black Soldier Fly (BSF)Hermetia Illucens
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Insects for Feed: EU Perspective
17Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
http://ipiff.org/publications-position-papers/
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Low Temperature ProcessProcess for Food and Feed
18Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Fat
Stickwater
Solids
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Low Temperature ProcessPilot Plants for Product Development
19Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
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Enzymatic Hydrolysis ProcessProcess for Food and Feed
20Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Recovery of chitin as separate phase possible
Pilot plant Haaksbergen, NL
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Insects for Feed: Low Temperature ProcessDevitalisation of Larvae
21Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
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Insects for Feed: Low Temperature ProcessMechanical Separation
22Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Composition BSFDry Substance 28 – 30 %Fat 9 – 11 %
Protein 10 – 12 %
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Composition BSF Meal
Moisture 6 – 10 %Protein (DM) 54 – 64 %Fat (DM) 8 – 12 %
Insects for Feed: Low Temperature ProcessMechanical Separation
23Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Stickwater:- Can be evaporated and added- Reducing fat content and
increasing protein content
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Insects for Feed: BSF Meal
24Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Source: Bühler, Networking days 201627th June 2019
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Insects for Feed: Low Temperature ProcessMechanical Separation
25Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
Fat from Black Soldier Fly:- low in unsaturated fatty acids- nutty taste and smell
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Circular Economy
2627th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Rearing
Fertilizer
Fats and proteins
Larvae processing
Residueprocessing
Insectslife cyclePupae Eggs
Young larvaeLarvae
Adult insects
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Circular Economy
2727th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Rearing
Fertilizer
Food processing
Animalfarm
Fats and proteins
Larvae processing
Residueprocessing
Insectslife cyclePupae Eggs
Young larvaeLarvae
Adult insects
Crop / primary protein production
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Circular Economy
2827th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Retail
Consumer
Rearing
Fertilizer
Food processing
Animalfarm
Fats and proteins
Larvae processing
Residueprocessing
Insectslife cyclePupae Eggs
Young larvaeLarvae
Adult insects
Energy production
LandfillOrganic waste
Crop / primary protein production
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Production 25 – 35 days
7 kg of (wet) feed for 1 kg larvae
Foot Print of 20,000 m² for 50,000 t larvae /a
365 day/a production
27th June 2019
Case Example
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Upscaling: Breeding and RearingCase Example
30Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Breeding &Rearing
50,000 t/a7,700 h/a production6.5 t/h capacity
Larvae(estimated)
Feed Management
350,000 t/a1,030 t/d50 Trucks per day
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Upscaling: ProcessingCase Example
31Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Processing
50,000 t/a7,700 h/a production6.5 t/h capacity
Endproducts(estimated)
Larvae(estimated)
1.1 – 1.5 t/h Meal
0.5 – 0.7 t/h Fat
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Upscaling Protein Meal and Fat ProductionCase Example
32Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
Breeding &Rearing
Feed-Management
Processing Distribution of Final Products
350,000 t/a1,030 t/d
8,500– 11,500 t/a 1.1 – 1.5 t/h Meal
3,800 – 5,400 t/a0.5 – 0.7 t/h Fat
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Circular EconomyFuture Green Solutions
33Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
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• Process know-how available
SummaryApplication
34Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum 27th June 2019
• All process steps can technically be covered
• Not replacing existing protein sources but helping to fill the protein gap sustainably
• Room for further innovations
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SummaryRegion
3527th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
• In many regions fit for food
• In many regions fit for feed
• Product design helps (for food)
• Movement where restrictions are still in place
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SummaryTechnology
3627th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
• We are ready, no new machines
• Opportunities for Farming (alliances and co-operations)
• Collecting furthercompetence for alternative proteins
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OutlookNext steps
3727th June 2019Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
• Further testing with different raw material, substrates, equipment,…
• Committed regarding alternative proteins without loosing focus on traditional applications
• Co-operating with partners to be able to offer complete solutions
• Open minded regarding new trends and developments
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Insects as Alternative Protein Source
3827th June 2019
Application
Region
Technology Next steps
Circular Bioeconomy Days, Aarhus University, Forskningscenter Foulum
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gea.com 39