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Grantee Research Project Results

Final Report: Direct Conversion of Organic Municipal Solid Waste to Lipids Using an Extremophilic Fungus

EPA Contract Number: EPD16007
Title: Direct Conversion of Organic Municipal Solid Waste to Lipids Using an Extremophilic Fungus
Investigators: Kozubal, Mark
Small Business: Sustainable Bioproducts, LLC
EPA Contact: Richards, April
Phase: II
Project Period: February 1, 2016 through January 31, 2018 (Extended to January 31, 2019)
Project Amount: $300,000
RFA: Small Business Innovation Research (SBIR) - Phase II (2015) Recipients Lists
Research Category: SBIR - Biofuels , Pollution Prevention/Sustainable Development , Small Business Innovation Research (SBIR)

Description:

Sustainable Bioproducts (SBP) has developed a breakthrough technology to produce sustainable proteins from a variety of feedstocks for utilization as human food, pet food, animal feed, and other high-value products. The technology is focused on an efficient cost-effective fermentation process using a proprietary microorganism (MK7). The strain is capable of directly converting a wide range of feedstocks to nutritional biomass with high protein content with all essential amino acids, desirable fat profile, high level of vitamins B and D, and excellent fiber content. Furthermore, the cultivated strain has texture, color, taste and smell characteristics that are similar to meat products. The goal of the completed EPA Phase II SBIR was to evaluate our proven process with a variety of organic waste feedstocks. SBP chose a variety of organic waste feedstocks including waste food scraps, crude glycerol, and municipal waste for determining conversion effectiveness to higher value products using our proprietary strain and fermentation process.

Summary/Accomplishments (Outputs/Outcomes):

SBP evaluated multiple published cellulosic feedstock pretreatment methods with previously optimized strain MK7 fermentation conditions on a variety of high-volume organic waste feedstocks. The initial goal was to produce biomass with yield conversions higher than 25% (dry weight biomass/ dry weight feedstock) and MK7 cellular lipid content greater than 40% (dry weight lipid/dry weight MK7 biomass). However, early during the Phase II work the company chose to focus on high protein biomass because of higher value as a component in food products and other commodities.
 
Results from Phase II work showed conversion efficiencies of 28 and 41 g dry biomass/g dry feedstock for pretreated municipal waste and beet pulp in seven-day cultivations, respectively, and between 25-52 g dry biomass/g dry food waste in six days depending on the composition of waste material. The biomass was easily separated from the solid waste material and converted into a variety of food products, bioplastic and leather. The biomass was similar in nutritional composition to the company's standard products, which are currently approaching final stages of development for commercial launch. The initial bioplastic and leather prototypes performed well compared to traditional leather and plastic and have potential to be developed into commercial products with further development and market/economics evaluations

Conclusions:

SBP has successfully converted lower-value carbon waste streams to a variety of high-value products including meat-like food products, dairy alternatives, myco-leather, and bioplastics. The techno-economic feasibility of our process will be further evaluated with high-volume organic waste streams.

Commercialization:

SBP has successfully secured $33 million in series A venture capital funding. The lead investor is 1955 Capital with additional investors: Breakthrough Energy, Gary Lauder, Danone Inc., and Archer Daniels Midland. The funds will be used for further process R&D, food product development, pilot plant construction, general administrative, product marketing and obtaining regulatory approval to sell the product to consumers (GRAS - FDA generally regarded as safe). Furthermore, SBP will use the pilot plant to produce product, verify techno-economics, implement and test process/equipment changes, validate standard operating procedures, determine process flow and mass balance for use in production plants


SBIR Phase I:

Direct Conversion of Municipal and Agricultural Wastes to Biodiesel and Ethanol Utilizing a Unique Extremophilic Fungus  | Final Report

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The perspectives, information and conclusions conveyed in research project abstracts, progress reports, final reports, journal abstracts and journal publications convey the viewpoints of the principal investigator and may not represent the views and policies of ORD and EPA. Conclusions drawn by the principal investigators have not been reviewed by the Agency.

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