Periodic Reporting for period 2 - EcoFLEXY (A natural and biodegradable nanocellulose alternative to plastic barrier coatings)
Reporting period: 2022-04-01 to 2023-09-30
Cellugy was founded with the vision of creating a natural ingredient that eliminates plastic pollution through the power of biotechnology.
In alignment with the Green Deal objectives, an innovative platform technology has been developed that harnesses the power of sugar fermentation to create biocellulose through a mild, energy-efficient process without using fossil-derived ingredients or harsh chemicals. The biocellulose ingredient named EcoFLEXY stands out as a unique solution that can disrupt different industries with its high-quality performance and versatility.
One of these industries is the packaging industry, which currently contributes to high amounts of landfill waste, CO2 emissions, and ocean pollution. Much of the packaging used nowadays consists of non-biodegradable and non-biobased plastic coatings on cardboard, plastic which causes pollution and ultimately penetrates the human body and its immune system. Our focus was to combat these threats by creating a biobased and biodegradable coating that can be incorporated with existing application methods and aid recycling practices, empowering manufacturers to create sustainable packaging solutions.
In alignment with the Green Deal objectives, an innovative platform technology has been developed that harnesses the power of sugar fermentation to create biocellulose through a mild, energy-efficient process without using fossil-derived ingredients or harsh chemicals. The biocellulose ingredient named EcoFLEXY stands out as a unique solution that can disrupt different industries with its high-quality performance and versatility.
One of these industries is the packaging industry, which currently contributes to high amounts of landfill waste, CO2 emissions, and ocean pollution. Much of the packaging used nowadays consists of non-biodegradable and non-biobased plastic coatings on cardboard, plastic which causes pollution and ultimately penetrates the human body and its immune system. Our focus was to combat these threats by creating a biobased and biodegradable coating that can be incorporated with existing application methods and aid recycling practices, empowering manufacturers to create sustainable packaging solutions.
The main results of the project can be summarized as follows:
- Scaling technology
We successfully scaled up our technology from 2 L to pilot plant, marking a crucial step in scaling up the production of EcoFLEXY. Several key activities were undertaken to ensure the seamless transition of the fermentation process from the laboratory scale to pre-pilot and eventually pilot scale, while maintaining consistent performance. The careful selection of a pre-pilot plant facility was a critical first step, necessitating infrastructure compatibility and the availability of equipment suited for downstream processing. Scaling up the fermentation process from 2 L to a minimum of 150 L, accompanied by matched downstream equipment, was a focal point of these efforts. During this scale-up, emphasis was placed on studying and adjusting critical parameters such as aeration rate and agitation rate to guarantee the homogeneous distribution of pH and nutrients.
- Installation of pilot plant
We identified three pilot locations in Denmark for pilot plant locations. After analyzing several criteria based on access to resources, supportive infrastructure, regulation compliance and cost, we concluded to go with Alfa Laval Innovation House. Once the location was secured, our activities to build the pilot plant were executed successfully.
- Partnership trails and EcoFLEXY refinement
EcoFLEXY was actively deployed with a broad base of validation partners with the overarching goal of collecting feedback for production improvement. Through the deployment of EcoFLEXY, the project sought to evaluate its real-world applicability, performance, and effectiveness in diverse operational contexts. The feedback garnered from validation partners played a crucial role in iteratively improving the coating, ensuring its alignment with practical requirements and performance expectations. The go-to-market plan was revised based on market research and trial users’ feedback.
- Certifications
Throughout the project implementation, EcoFLEXY successfully attained the necessary regulatory compliance, safety, and quality standards. Through meticulous testing and assessments, EcoFLEXY demonstrated its adherence to a comprehensive regulatory framework outlined in the project work plan.
- Patents
The project has resulted in remarkable achievements in IP protection, surpassing our initial targets. As envisaged in the project application, we have successfully submitted 3 patents, ensuring the protection of our product key characteristics and utilization. Furthermore, our work during this project has resulted in an additional patent, currently in draft form and set to be submitted by year-end.
- Dissemination & recognitions
Our dissemination efforts successfully reached a large general audience, educating them about the impact of the project. Notably, our significant achievements in building awareness included receiving prestigious awards and recognitions featured in both newspapers and online media. For example, we have been selected winners of the Special Category “Sustainable Living” in the Social Innovation Tournament (European Investment Bank Institute), Top 10 solutions at the Ray of Hope Prize (Biomimicry institute), 101 top biotechnology startups and companies in Denmark (Best Startups EU), and 8 Cleantech startups catching our eye for the year ahead (EU Startups).
- Scaling technology
We successfully scaled up our technology from 2 L to pilot plant, marking a crucial step in scaling up the production of EcoFLEXY. Several key activities were undertaken to ensure the seamless transition of the fermentation process from the laboratory scale to pre-pilot and eventually pilot scale, while maintaining consistent performance. The careful selection of a pre-pilot plant facility was a critical first step, necessitating infrastructure compatibility and the availability of equipment suited for downstream processing. Scaling up the fermentation process from 2 L to a minimum of 150 L, accompanied by matched downstream equipment, was a focal point of these efforts. During this scale-up, emphasis was placed on studying and adjusting critical parameters such as aeration rate and agitation rate to guarantee the homogeneous distribution of pH and nutrients.
- Installation of pilot plant
We identified three pilot locations in Denmark for pilot plant locations. After analyzing several criteria based on access to resources, supportive infrastructure, regulation compliance and cost, we concluded to go with Alfa Laval Innovation House. Once the location was secured, our activities to build the pilot plant were executed successfully.
- Partnership trails and EcoFLEXY refinement
EcoFLEXY was actively deployed with a broad base of validation partners with the overarching goal of collecting feedback for production improvement. Through the deployment of EcoFLEXY, the project sought to evaluate its real-world applicability, performance, and effectiveness in diverse operational contexts. The feedback garnered from validation partners played a crucial role in iteratively improving the coating, ensuring its alignment with practical requirements and performance expectations. The go-to-market plan was revised based on market research and trial users’ feedback.
- Certifications
Throughout the project implementation, EcoFLEXY successfully attained the necessary regulatory compliance, safety, and quality standards. Through meticulous testing and assessments, EcoFLEXY demonstrated its adherence to a comprehensive regulatory framework outlined in the project work plan.
- Patents
The project has resulted in remarkable achievements in IP protection, surpassing our initial targets. As envisaged in the project application, we have successfully submitted 3 patents, ensuring the protection of our product key characteristics and utilization. Furthermore, our work during this project has resulted in an additional patent, currently in draft form and set to be submitted by year-end.
- Dissemination & recognitions
Our dissemination efforts successfully reached a large general audience, educating them about the impact of the project. Notably, our significant achievements in building awareness included receiving prestigious awards and recognitions featured in both newspapers and online media. For example, we have been selected winners of the Special Category “Sustainable Living” in the Social Innovation Tournament (European Investment Bank Institute), Top 10 solutions at the Ray of Hope Prize (Biomimicry institute), 101 top biotechnology startups and companies in Denmark (Best Startups EU), and 8 Cleantech startups catching our eye for the year ahead (EU Startups).
Cellugy envisions a future where cellulose emerges as a dominant solution, unlocking its full market potential and transforming global industries.
This project is advancing beyond the state of the art by introducing a sustainable, efficient, and scalable platform technology for cellulose production. This innovation eliminates the need for energy, water, and chemical-intensive processes through a fermentation approach with a highly efficient non-GMO organism.
The impact of this project extends to socio-economic and broader societal dimensions. Envisioning a future where cellulose plays a central role in global industries, Cellugy's sustainable approach aligns with environmental goals. The ability to tailor cellulose properties without chemical modification holds promise for diverse applications across industries. From a socio-economic perspective, the technology's scalability and potential for local implementation offer opportunities for job creation, economic growth, and sustainable practices in communities.
This project is advancing beyond the state of the art by introducing a sustainable, efficient, and scalable platform technology for cellulose production. This innovation eliminates the need for energy, water, and chemical-intensive processes through a fermentation approach with a highly efficient non-GMO organism.
The impact of this project extends to socio-economic and broader societal dimensions. Envisioning a future where cellulose plays a central role in global industries, Cellugy's sustainable approach aligns with environmental goals. The ability to tailor cellulose properties without chemical modification holds promise for diverse applications across industries. From a socio-economic perspective, the technology's scalability and potential for local implementation offer opportunities for job creation, economic growth, and sustainable practices in communities.