How do we unlock the innovation potential in biomass-based value chains?

On the 6th and 7th of December the BioBIGG project held a two day cross-border workshop in Roskilde, Denmark addressing this question. During the workshop SMEs, universities and local authorities gave presentations on their approach to the implementation of a sustainable and circular bioeconomy with examples of promising utilisation of residues and development of biomass-based value chains.

The Danish SME, DACOFI, was one of the stakeholders that gave a presentation at the workshop. They presented their innovative technology for the filtration of biomass. One of the residues the company has been focusing on is brewers spent grain for the extraction of protein, fibers and vitamins, but the innovative technology has also been successfully applied to potato pulp as well as other types of biomass. Also, Guldborgsund municipality gave a presentation on their approach to developing a sustainable and circular bioeconomy at the local scale.

The second day of the workshop continued with a study tour to the local enterprise Solrød Biogas. Here the participants were first given an introduction to the implementation process – starting from the initial idea to the phase where the biogas plant was taken into operation and innovation efforts since then. Afterwards, participants were given a guided tour of the biogas plant that converts residual products into green energy, and fertiliser that is utilised by nearby farms with benefits for the climate and the environment.

Utilisation of straw for mushroom production in North Eastern Poland

Pieczarki Mazurskie is a family company established in 1988. It is located in northeastern Poland, in the Masuria region. Lakes and forests, which account for about 30% of the area, form a beautiful landscape in the region. Additionally, due to the high afforestation rate and low urbanisation and industrialisation indicators the air quality in Masuria is one of the best in the country.

Currently, the company consists of several mushroom farms. The total mushroom growing surface is 19 000 m. All buildings are equipped with modern air-conditioning devices, which enable controlled growing parameters, such as temperature, humidity, air movement and carbon dioxide. Due to this, appropriate conditions for mushroom growing can be provided, so that they are of the highest quality.

The plant produces mushrooms utilizing a Dutch technology. A group of skilled technologists is constantly watching the production process by keeping an eye on the behaviour of the mushroom spawn during the growing cycle. Through careful observation the crops with the optimum use of the nutrients attainable in the compost are selected. The harvest area is used very intensively so as to provide the maximum number of cycles in a year. All mushrooms are harvested by hand, so a wide range of mushrooms with the highest quality and different sizes is provided. After harvesting, mushrooms go directly into a vacuum cooling chamber, where they are quickly cooled to the temperature of 2°C. Then they are transported to the cold storage room, where they are prepared for sale. Low temperatures keep the products fresh for a long time. After the cultivation and harvesting of the mushrooms, all the buildings are thermally disinfected and compost is changed.

Due to the excellent cooperation with suppliers, many years of experience, the use of its own laboratory and professional management, the highest quality compost for the mushrooms is produced.

The company produces compost in its own compost production facility. The process is continuous as sufficient technical and engineering potential in the company is present. The company has its own straw storage (area above 10 000 m2) for the production of compost. The maximum amount of stored straw is about 100 000 tons, which is enough for two years of company production.

The production of mushrooms is about 3000 tonnes per year. Before distributing, mushrooms are packed according to individual customers requirements or in the standard way:

  • 3 kg boxes of loose mushrooms
  • box with trays, 4 × 500 g
  • box with trays, 4 × 400 g
  • box with trays, 6 × 250 g

Mushrooms can also be sorted to different size:

  • 2 – 4 cm
  • 4 – 5 cm
  • 5 – 6 cm
  • more than 6 cm “Riesen”

Waste from the processing (spent mushroom substrate) are stored at the company field and sold to local farmers as a fertiliser. The company has over 300 tons of spent mushroom substrate weekly.

Heaps of spent mushroom substrate

Pieczarki Mazurskie Fedor is a successful company that produces high-quality mushrooms. The clients of the company are all over the world. The largest recipient is England, but a lot of products are exported to Germany, The Netherlands and France.

A big issue for the company is the relatively high price of straw (40 euro per tonne) and the low price of spent mushroom substrate (3 euro per tonne) which is used as a fertiliser. The company should start working with universities, research centres or biological and chemical laboratories to find a new solutions in the field of bio-plastic, food supplements or pharmaceutics for the high value waste that contains huge amount of macronutrients (P2O5, K2O, CaO, MgO, Na2O, P,K Ca).

Plant Protein Factory at SLU was funded

Sweden´s Innovation Agency, Vinnova, funded the project Plant Protein Factory with about 1 million to build, develop and implement a pilot plant for the extraction of different proteins and protein fractions from plant material. The pilot will be built at the Swedish University of Agricultural Sciences (SLU) in Alnarp outside Malmö and will enable research leading towards increased resource-efficiency of how crops and crop residues can be used to produce intermediate products for the food, cosmetic and healthcare industry as well as the fodder industry. Through the cascading of plant material, also extraction of other high value plant components such as fibres and antioxidants will be investigated. Based on ideas from Eva Johansson and Bill Newson – co-workers in the BioBIGG consortium – Carl Jonson at SLU Holding has developed the project and was able to attract a larger number of industrial partners to the project. The project will run from 2018 to 2020 and be the basis for establishing a full-size plant.