Fraunhofer Lighthouse Project "FutureProteins"

Closed-loop agriculture to secure an environmentally friendly protein supply

Recent decades have seen an increase in intensive agricultural practices involving the use of large quantities of fertilizers and pesticides. This has had a substantial impact on the environment. In combination with the effects of climate change, this is set to affect the supply of protein. In the industrialized western world, foods of animal origin, produced with a high energy input and large amounts of feed, remain the number one source of protein. Yet if proteins are to be produced in a sustainable manner that conserves resources, alternative sources must be found. In the FutureProteins project, scientists are developing closed-loop forms of agriculture that produce alternative sources of protein while also making use of the various by-products. The challenge is to create economically efficient processes and systems that can then be scaled up for industrial use.

New Proteins from plants, insects, fungi and algae

FutureProteins is focusing on the use of plants (e.g., potatoes, wheatgrass and alfalfa), insects, filamentous fungi and microalgae as alternative sources of protein. Alternative protein sources should have a good balance of high-quality amino acids and be easy to process. In addition, the sensory properties of alternative proteins are crucial for their use in foods and should therefore be improved . In order to meet the project’s sustainability criteria, Fraunhofer researchers are seeking to develop four closed-loop systems of cultivation which will enable year-round, climate-independent production and that are therefore efficient, resilient and sustainable:

• Vertical farming
• Insect farming
• Fungiculture with culture media
• Algae cultivation with photobioreactors

The sustainable production of insect proteins as feed for livestock and food for humans represents a globally booming alternative to conventional protein sources such as meat and dairy products. Since January 2018 the EU’s Novel Food Regulation has allowed foods made from insects to be marketed in Europe. The first food insect farm in Germany has been in operation since 2019.

Insects as protein source: Need for pathogen detection

However, the production of insects on an industrial scale also promotes the spread of diseases, which can lead to the collapse of insect breeding, production losses and thus serious financial losses. In addition, the insect-based food must be free of human and animal pathogens. A specific and efficient detection system for pathogens in insect farms that is automated, digitized and capable of high-throughput, and that can deliver results promptly and on site, is still missing.

Currently, classic, culture-dependent methods or metagenomic approaches are applied to identify microorganisms in the gut and in the breeding tanks of insects. Both approaches are expensive, time-consuming and tedious, and thus not suitable for daily routine inspections in insect farms.

DNA-based detection of insect pathogens

As part of the FutureProteins lighthouse project, the IGB is developing an automated monitoring system for insect farming together with the Fraunhofer institutes IME and IVV: For this purpose, a molecular detection system covering the eleven most important insect-associated pathogens is being developed at the IGB.

Using insect sample material, DNA signatures of the pathogens are amplified and fluorescently labeled using an isothermal amplification technique. Specific binding to an immobilized probe results in a fluorescent signal that is identified optically and evaluated using a simple matrix. This technique allows for much easier handling than the commonly used PCR applications. In the future, the detection system developed for routine inspection at production sites will be integrated into a partially or fully automated inline system and can ultimately help to minimize the use of antibiotics and promote the resource-saving production of proteins.

Optimized protein extraction and purification

In order to optimize the extraction of proteins, researchers at Fraunhofer IGB digest fungi and microalgae using pressure change technology. Thus, by utilizing various methods, they separate solid and liquid fractions into their individual components, which can either be processed into protein products or be returned to cultivation processes.

Closed-loop agriculture enables cost-effective recycling of by-products

The FutureProteins project is implementing a closed-loop of material and energy flows in all cultivation systems. At the IGB, process water is treated for reuse, and nutrients are recovered for new cultivation cycles. This means that any by-products of the cultivation process will be put to valuable use, e.g. as a substrate for cultivating insects, fungi or algae.

Product manufacturing: high-quality foods from alternative protein sources

Each of these alternative protein sources display different sensory and functional properties. Researchers are seeking for specific extraction and modification processes in order to optimize protein properties. Another important research task is to develop recipes for appetizing foods that will have high consumer acceptance.

Sustainability assessment and maximization of closed-loop recycling

In addition, the closed-loop agricultural systems and protein extraction methods developed for this project will be assessed to determine whether they make better use of resources and are more sustainable than conventional methods. A further aspect of this cross-institute project will be to ensure maximal closed-loop recycling of the materials and energy used in such systems.