16 March 2006,
Article to the Jubilee Book for IPU/The Institute for Product Development – DTU
A unique protein product based on a bacteria
For several years UniBio A/S and IPU have cooperated closely on the development of a fermentation plant to the production of a protein-rich and nutritious product UniProtein (Single Cell Protein)
The company is now starting to build a production and focusing further on a targeted development of UniProtein.
UniBio’s CEO Ebbe Busch Larsen tells that: “It all started in Plöner See, a lake in Germany in the beginning of the 1980s, where German researchers from the Max Planck Institute for Evolutionary Biology, Plön, isolated the now patented methanotrophic (metamorphic) bacteria M102. They found the bacteria in 6-8 metres deep water, where it feeds on methane, which rises from the bottom of the lake as marsh gas.”
“At that time I was in contact with Dr. M. Naguib Keddis and Professor Jürgen Overbeck from the Max Planck Institute and together we continued the examination of the bacteria. Soon after we entered into cooperation with DTU and the University of Southern Denmark in order to evolve the best growth conditions for the organism. The goal of the cooperation was to develop an optimal production process for a protein-rich and nutritious product which could be used as a supplement in animal feed and in foodstuffs. For that purpose it was necessary to develop a new and more effective fermentation plant to the production of the protein. In the 1986-1990 period we developed the technology in cooperation with DTU and with economic support from the Technology Agency. At first it was a 500 litres plant in Odense, which was enlarged several times, ending up with a newly developed 20 m3 U-loop fermentor. Subsequently patents were applied for, most recently in 2001. The development continued in cooperation with DTU. The optimisation of the plant, with considerable support from the Danish Energy Agency, resulted in a 7 metres high U-loop fermentor (please see page 4). It was set up at BioCentrum, Pilot Plant, DTU, in the project period of 2000-2004. In the period of 2004/05 the Danish Energy Agency supported a project on process optimisation, too. The total energy saving with the new technologies and optimisation is about 50% compared to the traditional fermentors.”
As mentioned the plant was set up in the experimental building at BioCentrum-DTU, where it is still used. In 1982, when Ebbe Busch Larsen bought the patent of the bacteria M102 and know-how from the Mac Planck Institute, it was also the start signal of the foundation of Dansk BioProtein A/S in 1985. Ten years and more development projects later the independent company UniBio A/S was founded. The purpose of the company is among other things to develop techniques and methods to fermentation in the most efficient way in order to sell licences and know-how globally. Furthermore it is the aim of the company to continue the development of the production process, to target the product and to develop new applications of UniProtein and to extract from the product amino acids, enzymes, aroma and flavoured additives. It is still given high priority to develop the cooperation with IPU and Ramboll A/S and to establish a real “UniBio industry” in Denmark and abroad with its own production, educational and development activities.
”UniProtein® is a single-cell protein based on fermentation of a single-cell organism of common occurrence. After fermentation the bacteria are killed by heat treatment. The result is biomass with a high content of protein, which can easily be packed and transported, which is easy to store and which has a long shelf life irrespective of climate. The content of protein is above the level of fishmeal and refined soya products and can be used as a nutritional supplement (protein concentrate) to animal feed and human feed together with local crops.”
A product with great possibilities
“The project took its beginning in a lake in Germany many years ago. After many years of cooperation with Professor John Villadsen and later on with Vice Chairman Alan Friis, BioCentrum-DTU, Professor Lars Hein and Administrative Director Torsten Rich, IPU, UniBio A/S, together with its partners DTU and Ramboll A/S, has accumulated know-how and now has a unique product with a wide scope for applications. UniProtein ® can replace or improve a number of products within animal feed and the lacquer and glue industry and can even be used for human food.”
”UniProtein will be essential for people in countries where drought, failure of crops and undernourishment give rise to famine. The fight against hunger is a tremendous problem. About 2 billion people on the earth today live below the subsistence level, and for them our product can be one of the ways to solve the undernourishment problem. UniProtein can e.g. be mixed with corn, rice etc. to ensure that the food contains the protein and nourishment vital for a normalised state of health and a normal development of the body functions. Another great advantage of our product is that it is not genetically engineered. Therefore there are no obstacles in connection with production and sales in countries that ban genetically engineered products. UniProtein is produced of organisms of common occurrence which are found in streams and lakes all over the world. Generally speaking UniProtein can be produced everywhere close to the areas where the demand is and particularly in countries where the gas on which the bacteria feeds has a high content of methane and a low price and is often burnt to the detriment of the environment. Contrary to gas, UniProtein can be transported in containers at a low price over long distances.”
The first factory Is on its way
UniBio A/S has tested the product in terms of production process, effectiveness and quality assurance. The tests turned out so well that the company is now close to its goal of commercially exploiting the technology and starting a large-scale production.
”Now we are in the final negotiations on cooperation overseas, in a country in which the basis of cooperation in principle has come to an end and where the natural conditions are very favourable. The planning of the construction of a very big factory is ongoing. The project entails investment of a considerable amount of dollars and big deliveries from Denmark. This spring we expect to start up the project with a demonstration, education and training plant. In connection with the start-up of the project and the cooperation with the country in question we are in close contact with IPU. IPU becomes a partner in the project and is to coordinate the activities that we need from DTU’s researchers and technicians. Ramboll A/S is to be responsible for projecting and building the plant. The cooperation with IPU is a great help for us as continuity is ensured and we only need one point of contact to find the right people. IPU also takes part in the development work which will now be focused on products targeted to feed for different groups of animals, to industrial production of lacquer and glue and to human use.”
“But there is still research and development ahead before we have targeted the product to animal feed, industrial products and human food. In cooperation with IPU, BioCentrum and KVL we have now begun to optimise the product. The cooperation with BioCentrum has resulted in the development of a unique fermentation plant for the production of UniProtein, the so-called U-loop/nozzle-U-loop fermentor (please see the picture below). The fermentor has been adjusted to the process with methanotrophic bacteria. With advantage the plant can be used to processes where different gasses or other food substances are added to the fermentation in order to allow the processes to run optimally with the highest possible output of biomass. Output is measured as kg output per m3 fermentor per hour at the lowest possible energy consumption. We will keep focus on adjusting the technology and the product,” concludes Ebbe Busch Larsen.
Jubilee book article by: Science reporter Mette Minor Andersen, 16 March 2006
Fermentation plant
1. Degassing unit
2. Continual harvest of biomass
3. CO2 outlet
4. Two-phase nozzle, where fluid from the fermentor is mixed with air and then reinjected into the fermentor to achieve small bubbles
5. Nozzle pump
6. Injections of media
7. Cooling
8. Propeller pump for moving the fluid through the loop
9. Engine for pump
10. Static mixers. Prevent bubbles from merging while moving through the loop
Pilot plant at BioCentrum, DTU (patented to UniBio A/S)