Breeding alt-protein success: Bühler propels industrial insect farming with new tech partner

30 Aug 2023 --- Bühler is partnering with insect technology company Entocycle to drive the adoption of large-scale black soldier fly farms. The companies aim to provide solutions and expertise to serve customers in this emerging segment, from concept and basic engineering to the execution of facilities worldwide. 

The non-exclusive partnership is designed to create a highly complementary offering, with Bühler bringing proven industrial-scale technologies in feedstock processing, larvae rearing and product processing and Entocycle delivering proprietary breeding technology.

Although Bühler still sees the biggest potential for insect protein in animal feed applications, it also anticipates an expanding market for insect-based human food items.

“Rather than replacing other conventional protein sources in food completely, insect-based products will provide consumers that want to cut down on their meat consumption with a wider selection of more eco-friendly and healthy alternatives, such as burger patties made from mealworm ingredients,” Nicolas Braun, business development at Bühler, tells Food Ingredients First.

“Limitations that we currently see for such applications are local regulation to allow insect-based products to be sold on the market and consumer acceptance that will need some time to grow in geographies where eating insects has not been practiced.”

We recently explored how insect protein can help feed a growing world population and contribute to environmental sustainability goals despite obstacles related to the rise of plant-based diets and complications around halal and kosher certifications.Insect protein holds much potential, but industrial-scale operations are still emerging.

Industrial challenges
According to Bühler, a world-leading processing technology group, one of the challenges of the burgeoning insect industry has been how to ensure a steady supply of young larvae at an industrial scale.

“While the pioneers in this industry had to develop their own technology out of necessity to ensure a robust black soldier fly breeding, companies now venturing into this industry will be able to rely on a proven and scalable solution,” says Andreas Baumann, head of market segment Insect Technology at Bühler.

Within the animal feed market, Baumann highlights three main challenges for insect farmers, which Bühler’s solutions can help overcome.

“Firstly, insect-based products need to be available in the agreed volumes in time. Therefore, a fast ramp-up of insect plants is needed to ensure the availability of the products on the market. Our data-driven technology approach helps to ensure a fast ramp-up and achieve a fast learning curve to gain an efficient production,” he tells us.

“Secondly, insect-based products need to be reliably available in a consistent quality. We have sophisticated climate control on individual crate level, which ensures a uniform growth of the insects.”

“Thirdly, the animal feed market is conservative and cost-sensitive. Therefore, any reduction in production cost helps to facilitate the acceptance of insect-based products. Our plants ensure efficient and economical use of raw materials, land, water and energy.”

Although there are specialized breeding service companies in certain regions, in large parts of the world, there is no alternative to having an in-house breeding operation. With this partnership, Bühler and Entocycle address this challenge by offering scalable end-to-end solutions that significantly reduce the time to market for companies building an insect facility.Bühler brings experience in feedstock processing, larvae rearing and product processing.

Long-term focus
During the last ten years, Bühler has been developing its capabilities in the insect protein industry and already completed several relevant projects in the field.

In 2019, Bühler supported Protix in the realization of the “world’s first” commercial black soldier fly plant in the Netherlands. This year, the company delivered Agronutris’ first industrial black soldier fly plant in France.

Keiran Whitaker, founder and CEO of Entocycle, comments: “Our team is really excited to work with Andreas Baumann and his team to deliver large-scale black soldier fly facilities around the world and make the impact that we know black soldier fly farming can make in creating a more sustainable and efficient global food system.”

Baumann adds: “The industrial use of black soldier fly is rapidly gaining traction among businesses seeking alternative feed protein sources and more sustainable practices. To accelerate scaling this industry, we must contribute to lowering the hurdles for companies to enter this business.”

At the upcoming INSECTA conference (September 13-14 in Magdeburg, Germany), Bühler plans to share more insights on how it can help accelerate insect farming projects.

In related developments, US researchers are currently perfecting a technique to build bioplastic from black soldier flies.

By Joshua Poole