Whitepaper

Animal Feed
Insect protein -
Environmental
necessity to
fledgling
industry
Innovations for a better world.
Content.

1. Introduction 3

2. Why the need for an alternative protein source? 3

2.1. How to solve the protein gap 4

3. What are alternative proteins? 4

3.1. Algae 4

3.2. Microbial protein 5

3.3. Clean Meat 5

3.4. Processed animal product and food waste 6

4. Insects as an alternative protein source 6

4.1. Insect feed in aquaculture 6

4.2 Live insects as chicken feed 7

5. Turning insects into feed 7

5.1. Rearing 7

5.2. Larvae 7

5.3. Insect processing 7

6. Regulation and insect feed 8

7. The insect feed market 9

8. Current challenges 10

9. Conclusions 10

10. References 11
Bühler Whitepaper
Alternative Protein

1. Introduction 800
additional
protein
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You cannot open the pages of a magazine aimed at the

Primary protein production in million tonnes

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animal feed industry without coming across a mass of 400
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articles on the use of insects in animal feed. It is an exciting
200 s s
new frontier for agriculture, driven by what many see as a
p o
looming global pro- tein gap as incomes rise, diets change
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and populations grow.
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Bühler Whitepaper
Alternative Protein

teins, the new market is decade or so. t r s

in its infancy. While o o
Protei
there is a great deal of There is only a finite amount n w o
opti- mism around the of protein in the world. produh i f
industry, the amount of Sources of protein for ctionu n
has to
animal feed being humans either come from
copem g t
produced from animals or in the form of withaa h
alternative proteins is pulses, nuts, seeds, and growin b e
actually small and cur- grains. Wheat, rice, maize, ng u
world
rently targeted at niche soybeans and rapeseed populb t p
markets. meet over 80 per cent of our ation.
e l
protein needs. In 2015 it h t a
This White Paper will look was calculated that we a h n
at the reasons why there produced globally 525 H v e e
is a need to find new million tons of plant protein o i t
protein sources and how each year in the form of w - a
demographics and corn, rice, wheat or e s a
populati- on growth are soybeans. This is enough to v o p r
driving change in the feed feed the 7.6 billion people e r i e
sector. It will also look at cur- rently living on the r . r
what alternative protein planet1. , a a
sources might be N t l
available and exp- lain n o i s
why insect protein is o t o o
looking the most t n
commercially viable. The h o s i
paper will explore how i n n
the insect protein market n l a
is evol- ving, investigate g y n f
the challenges the d l
producers are facing and i i u
the difficulty of achieving s s a x
the sort of economies of p .
scale nee- ded to make c t p
alternative protein o h e A
sources profitable. n e t s
s i
t g t c
a l e o
2. Why the n o s u
t b n
need for
a o t
an w l f r
alternativ h i
e p l e
e protein
n o a s
source? p r
i u g d
To understand why the
t l e e
creation of alternative
a v
proteins is gene- rating
c t s e
so much interest in the
o i w l
animal feed industry we
m o a o
need to first appreciate
e n t p
the context in which this
s h
new industry has
g e a
emerged over the past
4
 Bühler Whitepaper
Alternative Protein

nd become change their eating

wealthier their habits as they can
populations start to afford more
demand more from processed foods and
life and what animal-based
sustained past protein3.
generations is no
longer acceptable Population growth is
as expectations the other driver
rise. increasing projected
meat consumption.
According to the Not only is the UN
Brookings predicting that global
Institution2 the popula- tion will
world’s middle clas- increase to 9.7 billion
ses are growing by 2050, but most of
faster than ever this increa- se is likely
before as they to happen in the very
increase in ab- regions where meat
solute numbers by consump- tion is
140 million a year. already expanding at
Numbers are its fastest.
expected to
increase even While meat
further to 170 consumption has
million annually been relatively static
over the next five in the de- veloped
years. Most of world, in developing
these new entrants countries per capita
will be from meat consumption
emerging has doubled since
economies such as 1980 and according
Asia, India and to the Food and
China in particular, Agriculture
while in Europe Organization of the
and North America United Nations (FAO)
the demographic economic,
shift is effectively demographic and
stagnant. One of population changes
the fundamental are set to in-
expressions of
increased wealth
and status is what
we choose to eat.

More of us are
also living in cities,
with 54 per cent of
global population
now classed as
urban. Those who
migrate to cities
find they have
more money in
their pockets and
so are able to
5
crease meat consumption by 50 per cent by the time we to grow more crops. The problem here is the finite amount of
reach 20504.

The question now is whether we can produce enough

plant-based protein to satisfy this added demand for meat.
In short, the answer is “no”. There is just not enough
available land to produce the amount of additional plant
protein we are going to need to satisfy anticipated demand.
This explains why there is currently such a push to discover
alternative proteins as a source of animal feed.

In its 2017 analysis of future food trends the FAO highlights

the uneven demographic expansion that is already taking
place as one of the top challenges facing food and
agriculture in the co- ming decades. To understand the
scale off this challenge we need to do a quick protein
calculation.

Out of the 525 million tons of plant-based protein presently

avai- lable to us annually, 60 per cent is used for animal
feed, 25 per cent goes directly into the human food chain
and 15 per cent is lost in waste throughout the whole value
chain. It is the 60 per cent being used for animal feed that
poses the greatest challen- ge. When you feed an animal it
uses most of that protein to sus- tain itself. As a result, on
average, it takes four plant-based pro- teins to produce one
animal-based protein for human consumption. This results in
75 per cent of protein fed to ani- mals being lost. Which is
why the more people who eat meat on the planet, the wider
the gap becomes between the amount of protein we need
and the amount that is available to grow.

Andreas Baumann Head of Technology Bühler Insect

Techno- logy Solutions explains: “If you take the value of
meat producti- on provided to us by the FAO and calculate
back how much protein will be needed by 2050, including all
the feed losses, we find we are going to need an additional
265 million tons
of protein a year. That means we are going to have to
some- how increase protein production by 50 per cent by
2050.” The stark truth is we either need to produce more
protein or stop eating meat.

2.1 How to solve the protein gap?

We know that our current plant-based agricultural model
will not sustain predicted rises in demand for meat as
global de- mographics shift and the world population
increases.

The next question is what can we do about it? One solution

is
land at our disposal. If we want to produce more
crops like soy it will mean making ever-greater
destructive inroads into our fast disappearing forests,
with all the associated environmental consequences.
We are already using 85 per cent of available land to
grow plant-based proteins. It is difficult to see how we
are going to be able to produce 50 per cent more
plant protein with what is left. There is just not
enough land.

Another option is to stop eating meat. If we were all

to become vegans then the current plant- based
protein being produced could sustain a global
population of 18 billion. Certain commu- nities,
typically in the West, are starting to appreciate the
public health risks associated with meat-rich diets
and others are be- coming vegans or vegetarians due
to environmental or animal welfare concerns.
However, the numbers turning their back on meat
does not compensate for the millions who are turning
to meat as their status and aspirations rise.

The third option is to find alternative protein sources

that do not require growing crops on land. At
present this appears to be the most practical
solution to the impending protein gap. There are a
number of different sources of alternative protein
being explored.

3. What are alternative proteins?

While there are a number of different ways of

increasing availa- ble protein, the use of insects in
animal feed is currently the most developed and is
looking the most viable commercially. But there are
other options that should be considered and will be
discussed here.

3.1 Algae

Nutritious and tasty: algae are also consumed as food.

One of the advantages of using algae as a potential protein
source is that they do not compete with existing farmland
and in the case of marine algae do not require fresh water.
Algae are made up of macroalgae, also called seaweed,
and microal- gae, unicellular and microscopic organisms of
which there are around 200,000 species. Because of the
harsh environment in which they live, algae have also
developed natural protective systems by producing
pigments like carotenoids, chlorophylls and
phycobiliproteins, which have been put forward as having
health benefits for humans and animals5.
Seaweed has long been a source of nutrition for humans.
Ac- cording to the Food Balance sheets published by the
FAO Chi- na, the Republic of Korea and Japan are the
greatest consu- mer of seaweed. Some seaweed species
can contain as high as 50 per cent proteins (calculated on
dry matter), however, though present in some species, most
essential amino acids are deficient except for the sulphur
containing ones6. While se- aweed has been used
historically as animal feed it can have highly variable
composition depending on the species and the seasons,
has a large water content and can accumulate high amounts
of metals, iodine and other minerals that could poten- tially
lead to a negative impact on animal health. This capacity to
accumulate minerals has at the same time put forward sea-
weeds as a valuable additive for animal feed thanks to their
mi- nerals and bioactive compound concentration.
Microalgae are already being exploited for their high protein
content and can deliver up to six times more protein per
hectare than soya and do not require arable land.
Therefore, microalgae have been underlined as one of the
single cell protein sources with high potential to decrease
pressure of our environmental resources7. Research
suggests that inclu- ding microalgae in animal feed could
improve growth and meat quality in ruminants, pigs, poultry
and rabbits. In particu- lar the microalgae Chlorella, in very
low percentages in poultry feed, seems to enhance growth
parameters. Chlorella and Spirulina are currently being sold
as functional foods for human consumption because of their
high vitamin and mineral content.
One of the challenges around microalgae commercialization
as an alternative protein source to plant-based proteins lies
with the production and processing costs. Phototrophic
microalgae (requiring sunlight for photosynthesis) are classical-
ly cultivated in open ponds or photo bioreactors (glass or
pla- stic tubes or pouches). Such production systems are
typically associated with high production costs of biomass
per
kilogram, large installations, and limited production capacity,
which in turn has led this industry to focus on high added
value ingredients with high margins such as pigments (e.g.
ca- rotenoids or phycobiliproteins). Some microalgae can
also grow in the absence of light, using organic carbon
sources in- stead of the CO2. These heterotrophic
organisms can now be cost effectively cultivated
commercially in large fermenter tanks for the production of
omega-3 fatty acids EPA- and DHA- rich oils with a high
potential for aquaculture. First cases of protein rich flour for
human consumption have also recently come to the market.
This mode of culture also induces lower costs of production
and higher capacity, which may allow pro- tein production for
animal feed in the future. The first industri- al-size
installations for microalgae production and processing on a
large scale are reaching the market for DHA oil producti- on.
It may be that future technological developments in micro-
algae cultivation along with process optimization that will en-
able costs to come down sufficiently to allow use of the
protein fraction in the feed industry.
3.2 Microbial protein
Next to microalgae as one kind of single cell proteins,
microbial proteins gained from bacteria, yeast and fungi
have a big po- tential as future protein source for livestock.
This kind of single cell protein requires nearly no land as the
microbes grow extre- mely fast in aerobic fermentation tanks
reaching high producti- on capacities. Pikaar et al. (2018)
predict that microbial pro- teins have the potential to replace
10-19 per cent of conventional crop-based animal feed
protein by 2050. Next to low land use and high growth rates
microbes are able to utilize various nutrients sources which
do not compete with human ones like lignocellulosic
residues7. Furthermore, there are bac- teria which can be
solely fed on methane or other gases.
Microbial proteins are already listed in the “catalogue of
feed materials” of the EU and are therefore allowed to be
used in animal feed8. With the improvement of cultivation
techniques and decrease of prices it can be expected that
microbial pro- tein will become a price competitive protein
source for animal feed.
3.3 Clean meat
This is one of the more unknown areas of development
which offers the opportunity to produce meat through the
cultivation of animal cells more sustainably than
contemporary meat pro- duction. It was Winston Churchill
who first predicted the pro- duction of clean meat in 1931
“We shall escape the absurdity of growing a whole chicken
in order to eat the breast or wing,
by growing these parts separately under a suitable
medium”. Eighty-two years later it became a reality when
in 2013
Mark Prost, Professor of Physiology at Maastricht
University, made scientific and culinary history by
developing the first la- boratory grown burger and having
this eaten by independent journalists.
The process involves taking a small biopsy from a living
cow and harvesting it to the point where in theory it should
be pos- sible to produce 100 metric tonnes of meat from the
single sample. Since 2013, start-ups across the world, such
as Mosa Meat, Memphis Meats and SuperMeat, are racing
to bring different versions of what is becoming known as
“clean meat” to market. All three start-ups claim to
commercialize their first products by 2021.
While engineering meat in a laboratory is one thing, what is
not clear about this new industry is how the consumer will
re- act and whether the technology will be cost competitive
with traditional meat products.
3.4 Processed animal product and food waste
Another potential source of protein is processed animal pro-
ducts such as blood meal or fat meal. The challenge here is
that the reputation of this process has been poor since the
outbreak of Bovine Spongiform Encephalopathy (BSE) or
mad cow disease in the 1990s. Concerns are mostly
focused on Europe where controls have been introduced
around the fee- ding of animals with animal protein.
The UN estimates that each year 1.3 billion tons of food
pro- duced for human consumption is wasted. In 2012
Europe launched the project NOSHAN to identify functional
feeding ingredients derived from food waste. During the
four years that the project ran it investigated turning fruit,
vegetable, ce- real and dairy waste into pork and poultry
feed. NOSHAN’s business partners are currently looking to
turn their research into a product and to commercialize it
within the next two to three years9.
4. Insects as an alternative
protein source
One of the most promising alternative protein for animal
feed is currently seen as insects. By 2050 it is anticipated
that
insects could provide 15 per cent of the additional protein
that will be needed by then.
The reason there is so much optimism around insects is that
they are such extraordinary protein converters. Overall
insects are able to extract up to 70 per cent of the nutritive
value of their feed. Because they are cold blooded, they
don't require feed to maintain body temperature. That is why
they are able to convert feed into protein at a much higher
rate than lives- tock animals, which partly invest feed to
keep a constant body temperature. Insects are also able to
efficiently absorb protein because they ingest feed several
times. A cricket only requires 1.7Kg of feed to produce 1Kg
of live animal weight. In a typi- cal American production
system to get the same animal weight you would require
2.5Kg of feed for chicken, 5Kg of feed for pork and 10Kg of
feed for beef10. Last but not least, insect rearing does not
require much land, while there is the added advantage that
they can be fed on organic waste.
Land use (m2)
51 4
Water use (m3)
5
34
CO2-eq (kg)
33 6 black soldier fly
chicken Energy use (kJ) larvae
12080
Impact on the environment per kilogramm of protein
Insects can be produced with little environmental impact.
4.1 Insect feed in aquaculture
Insects are a natural food source for many fish, which is
why fly fishing is such a popular pastime and maggots are
used as fish bait. Aquaculture is also the only agricultural
sector in Eu- rope where you are legally allowed to use
insect protein in feed at the moment. Pet food is the other
sector where insect proteins are currently being used. It is,
for example, applied in hypoallergenic dog food.
Out of the 20 million tons of wild seafood caught each year it
is estimated that a quarter goes into fishmeal. Research
publis- hed last year suggest that 90 per cent of this produce
being diverted from the food chain could in fact be fit for
human consumption11. Fishmeal is seen as one of the
drivers contribu- ting to the depletion of our fishing stocks, so
replacing fishmeal content with insect protein is being
considered a more sustain- able solution. Tests have shown
that salmon can be
successfully fed on a diet of up to 50 per cent insect meal
wi- thout any adverse impact on the fish. Research
indicates that the use of insect protein can even help to
maintain a better gut morphology, leading to improved feed
conversion and lower mortality rates during production.
Insect protein is also more likely to become a competitive al-
ternative thanks to the cost of conventional fishmeal.
Aquacul- ture is the fastest-growing agricultural segment in
the world. This has led to rising demand for fishmeal, which
has forced prices up. This price rise has made the relatively
high cost of producing insect-based protein meal less of an
inhibitor when breaking into the aquaculture market.
4.2 Live insects as chicken feed
Feeding live insects to chickens is also possible from a
legal perspective in Europe. The live larvae are added to
the traditi- onal diet of egg laying hens. It is said that using
a live feed encourages the chickens to return to their
natural behavior. Customer feedback on the taste of the
eggs is very good.
However, it needs to be evaluated, how this concept can
be realized on a larger scale since transportation and
storage is complicated.
5. Turning insects into feed
Insect processing for feed on an industrial scale is
currently being seen in terms of the circular economy.
Insects are far- med on organic waste and in turn become
a protein source for animal feed. The backdrop for the
development of the in- dustry is the growing demand for
animal protein set against the growing problem of food
waste.
5.1 Rearing
The first stage of the process is the rearing of the insects.
Species that can be considered for industrial-scale
production require certain characteristics. They need to
have a high re- production rate, a short development cycle,
high survival rates of immatures, the ability to live in high
densities, low vulnerabi- lity to disease and a high potential
of biomass increase, for ex- ample weight gain per day. Two
insect types that meet these criteria and so are considered
most suitable for animal feed are the black soldier fly
(Hermetia illucens) and mealworms (Tenebrio molitor,
Alphitobius diaperinus).
pupae adult fly
larvae eggs
young larvae
Life cycle of balck soldier flies.
5.2 Larvae
Within the life cycle of an insect, the larva is the most
suitable stage for being used as animal feed. They have a
dry matter of 30 per cent of their total wet larval mass, of
which 40-55 per cent is crude protein. Fly larvae can be
raised on a wide range of organic waste products. Since
they have a high lipid content, partial fat separation is
necessary.
Larvae are grown in containers, in which they ingest a
chosen mix of organic residue material and shed skin while
growing. At the end of the growing phase, larvae are
separated from rearing residue, which is composed of
skins, insect excrements and residual food, known as
Frass. Frass can
be dried and turned into pellets ready to be used as
fertilizer or soil conditioner.
Once the larvae are separated from the rearing residue, a
washing step removes any remaining non-larvae material.
Then they are heat treated to inactivate enzymes and
patho- genic microorganisms. Components like lipids or
chitin can be separated in order to achieve insect fractions
with a high pro- tein content. Drying of the protein-rich
fractions, results in a shelf-stable end product.
5.3 Insect processing
At present most companies are focusing on protein meal
and lipid production. Since extraction needs economy of
scale, the insect processing has to be done on a relatively
large scale in order to be cost competitive.
 Protein meal
Amino acid profile similar to fishmeal.

2015
35 % food

Crop farming
525 mio tonnes protein food
65 % feed

Losses & Waste Lipids

Fatty acid profile similar to palm kernel oil.
1.3 billion metric tons per year (cost-efficient raw materials)

Va
lu
e-
Insect Technology ad
de
Fertilizer d
Insect feed Biomass Composition similar to compost. en
A circulatory d
system: from pr
insects to feed Feedstock Insect Biomass od
and food. preparation rearing processing uc

There are a number of different methods for processing in- are then air-dried, the lipids removed mechanically and then
sects into microbiologically safe food or feed products. the resulting press cake is ground into a defatted insect
They usually involve several processing steps depending meal12.
on the properties of the desired end product. The high fat
content in some insects such as Hermetia illucens (the The aim of these processes is to deliver a raw material that
black soldier fly) often requires lipid removal. Here we is both safe and of high quality. The end product must be
describe three proces- sing methods: of consistent quality, capable of being safely stored,
marketable with different fractions tailored for specific
The first is aqueous insect processing. Insects are first needs.
boiled in excess water after which the insect-water mixture
is mecha- nically pressed into a cake which is then dried into
an insect meal. The remaining liquid is then processed
through centrifu- gation or decanted to remove the lipids.
The soluble proteins are then recovered through
concentration and drying.

The second method involves a patent initially owned by

Büh- ler’s partner company Protix that is currently being
transferred to Bühler. In this method the insects are first
squashed into a pulp through squashing or enzymatic Insects are known as food in about 80 % of the world's nations.
hydrolysis. The pulp is then heated to 70 – 100 °C followed
by physical separation either by centrifugation and/or
decanting. The final stage in- volves either spray or air-
drying. 6. Regulation and insect feed
The third method is the dry insect processing pathway. It is The processing and storage of insects clearly need to be
recommended to start with a precautionary decontamination cont- rolled by similar types of health and sanitation
process either by microwaving or steam blanching. The standards that govern more traditional feed items. The
insects biological nature of
insects pose additional food safety concerns, in
particular around microbial safety and toxicity.
Europe is considered to have the tightest legislative controls
on the use of insect protein. Lipids (fats) are not subject to
the same regulatory controls as insect protein. Under
existing laws aquaculture is the only agricultural sector able
to use insect protein at the moment, thanks to the European
Commission permitting the use of insect protein as fish feed
in July 2017.
The unlocking of EU Regulation 2017/893 follows a vote by
EU Member States in December 201613. Earlier this year the
in- dustry received another boost when EU Health and Food
Safe- ty Commissioner Vytenis Andriukaitis told the world’s
first in- sect feed and food conference that the Commission
was looking to authorize the use of insect feed for poultry
and pos- sibly pigs by 2020.
The current authorization is limited to seven species with
cont- rols in place on what they can be fed. The species are:
Black Soldier Fly, Common Housefly, Yellow Mealworm,
Lesser Me- alworm, House Cricket, Branded Cricket and
Field Cricket. Un- der the regulation these insects need to
have been fed on “feed grade” substrates such as vegetal
origin materials or with a limited number of animal origin
materials including: fishmeal, blood products from non-
ruminants, egg and egg products, milk and milk-based
products, honey and rendered fats.
China has an established regulatory framework that is seen
as more favorable towards insect processors than Europe,
as well as having a large enough internal market to make it
easier to achieve the economies of scale needed to make
insect protein production viable.
Never the less, a clear and comprehensive legal framework
at both national and international levels is going to be
needed if the sector is to attract serious investment leading
to the full de- velopment of an international trade in insect
based animal feed products on an industrial scale.
7. The insect feed market
Startups have so far dominated what is a young industry.
Ho- wever, as the industry starts to mature there are signs
that companies are specializing. Businesses involved in all
aspects of production are now focusing on specific sectors
such as
insect breeding, processing, technological solutions or
sales. Larger companies are also recognizing insects to be
an emer- ging commercial opportunity.
Companies who handle large quantities of organic waste
and feed producers are exploring the new commercial
opportuni- ties opening up thanks to technological
advances. The ability to recover 70 per cent of protein from
organic by-products has caught the interest of food
processors, waste companies and government agencies
responsible for processing waste. In the past, waste to
energy and composting have been the two most common
destinations for organic waste streams. Insects are now
providing new opportunities to recycle organic waste into
the food value chain.
Feed producers are also showing an interest in the insect
sec- tor. Historically vulnerable to price fluctuations,
especially if they have to import their raw materials, feed
producers are also watching demand for plant protein
increase as meat consump- tion rises. In their search for
alternative protein sources insects are being seen as an
increasingly viable alternative.
Insect feed products are currently expensive due to a lack of
economies of scale along with relatively high production
costs. Unable to compete directly with more traditional
animal feed producers, companies are carving out niche
markets for them- selves. These include live insects as feed
for egg producing poultry or protein meal for hypoallergenic
dog food. Lipids from insects are also being used in the pig
industry to reduce diarr- hea in young pigs. Another potential
market for insect pro- ducers is as a biological fertilizer to
meet rising demand for al- ternatives to chemical usage.
The high price of fishmeal has resulted in aquaculture being
one of the earlier adopters of insect protein. “At the moment
companies are relying on their niche markets and it is only
when production levels increase that they will be able to
better compete and the market will open up. The area this
is likely to happen first is in aquaculture and once we see
growth here then the industry will start to expand faster
than it can at the moment,” explains Baumann.
Companies currently rely on licenses and patents to
protect their market position. The question is how these
businesses will evolve into the high-volume low-cost
producers that they need to become if they are to
compete with more traditional feed producers.
This will depend on whether insect protein producers will be
able to convince the wider market, by operating on lower
mar- gins, that insect protein is commercially viable. It is
already pro- ven that the basic nutritional composition of
insect feed pro- duct is comparable to more traditional
alternatives. However, insect producers will have to
demonstrate that insect protein can provide improved
performance, whether through higher survival rates or better
animal health. The insect industry also has an interesting
story to tell when it comes to the environ- ment and
sustainability. The question is whether it can leverage this
enough with consumers to give itself a competitive advan-
tage over more traditional feed raw materials.
8. Current challenges
One of the biggest challenges facing insect feed producers
is the scale of the existing animal feed industry and the
typical quantities of feed ingredients required by clients. A
feed stock manufacturer will regularly process millions of
tons of feed in a highly industrial process. With that comes
the sort of econo- mies of scale that a fledgling industry
cannot hope to compete with. An insect feed producer who
can produce a ton of high quality insect meal will have little
impact on the market.
Production constraints are also a problem for the producer.
“At present there are only a few insect protein producers
who can produce reasonable amounts of product and the
costs are still relatively high,” explains Baumann. “But in
order to ser- ve larger feed producers, at least 1000 tons of
insect protein need to be available per year, otherwise there
is no chance to penetrate the feed market.”
Economies of scale are not just about volumes. The insect
producers also need to scale up in order to prove their
reliabili- ty so that consumers can be confident about product
quality, consistency and safety.
Since insects are grown on industrial byproducts and so-
metimes even waste, it needs clear standards in order to
miti- gate feed safety risk. As the industry grows, systems
such as Hazard Analysis Critical Control Point (HACCP) will
need to be developed as well as higher standards put in
place around existing certifications such as GMP+ and
SecureFeed.
The insect feed industry is developing fast. It is attracting in-
creased investment as demand for meat protein rises and
awareness grows about the environmental benefits of insect
protein. However, this speed of growth is creating its own
challenges. New industries normally have the advantage of
being able to evolve steadily as academics, technology
provi- ders, consultants and researchers develop the
required in- depth knowledge. In the case of insect feed it is
the insect producers who are at the vanguard of research,
which is both challenging and time consuming. A lack of
published research on the benefits of insect protein is
making potential buyers re- luctant to take the plunge while
producers struggle to position their products effectively in
the market.
Regulatory bodies are also struggling to keep pace with the
industry. There is currently a lack of consistency as different
regions respond differently to potential risks. Australia, for
ex- ample, is very concerned about bio-security and so has
very strict rules on importing live insects with companies
needing approval to bring in insect-derived feed products.
Therefore, it will need more regulatory cohesion to make it
easier for com- panies to expand geographically and to
facilitate international trade of insect-based products.
9. Conclusion
Alternative protein is an exciting new industry, born of con-
cerns around an anticipated global protein shortfall as the
world population rises and the aspirations of developing
coun- tries mature. Out of the various sources of new
protein availa- ble, insects look the most viable due to their
high protein cont- ent and low environmental impact.
Aquaculture is at the vanguard of change due to the already
high price of fishmeal and strong environmental pressure to
improve the sustainabili- ty of already threatened fish stocks.
However, the insect industry has yet to develop specific
appli- cations for their products by elaborating key benefits
in the animal feed market. The penetration of the very well
establis- hed feed industry with tight margins is only possible
by estab- lishing strong economies of scale. Young
companies are brea- king into the market with niche
products but it is yet to be seen how the sector is able to
mature to the point where it po- ses a real threat to
traditional feed ingredients.
10. References

1
World population clock worldometers.
http://www.worldometers.info/world-population/

2
Global Economy and Development at Brookings, The Unprecedented Expansion of the Global Middle Class An Update.
2017. https://www.brookings.edu/wp-content/uploads/2017/02/global_20170228_global-middle-class.pdf

3
Food and Agriculture Organisation of the United Nations, The Future of Food and Agriculture Trends and Challenges. 2017.
http://www.fao.org/3/a-i6583e.pdf

4
Food and Agriculture Organisation of the United Nations. Press Release. Meat and Meat Products. 2016
http://www.fao.org/ag/againfo/themes/en/meat/home.html

5
Stahl, W., & Sies, H. (2005). Bioactivity and protective effects of natural carotenoids. Biochimica et Biophysica Acta
(BBA)-Mo- lecular Basis of Disease, 1740(2), 101-107.

6
Makkar, H. P., Tran, G., Heuzé, V., Giger-Reverdin, S., Lessire, M., Lebas, F., & Ankers, P. (2016). Seaweeds for livestock
diets: a review. Animal Feed Science and Technology, 212, 1-17.

7
Pikaar, I., Matassa, S., Bodirsky, B. L., Weindl, I., Humpenöder, F., Rabaey, K., ... & Herrero, M. (2018). Decoupling
Livestock from Land Use through Industrial Feed Production Pathways. Environmental Science & Technology.

8
Commission Regulation (EU) 2017/1017 of 15 June 2017 amending Regulation (EU) No 68/2013 on the Catalogue of
feed materials

9
Horizon, the EU Research Innovation Magazine. Turning food waste into animal feed could take a chunk out of livestock
emis- sions. 05 April 2018.
https://horizon-magazine.eu/article/turning-food-waste-animal-feed-could-take-chunk-out-livestock-emissions_en.html

10
FAO Forestry Paper 171 - Edible insects future prospects for food and feed security - page 60. 2013.
http://www.fao.org/docrep/018/i3253e/i3253e00.htm

11
Tim Cashion. Most fish destined for fishmeal production are food-grade fish. 2017.
https://www.npr.org/sections/thesalt/2017/02/13/515057834/90-percent-of-fish-we-use-for-fishmeal-could-be-used-to-feed-
humans-instead

12
Arnold van Huis and Jeffrey K. Tomberlin. Insects as food and feed from production to consumption. 2017..

13
IPIFF Press release. EU legislation on aquaculture utopian insect producers welcome the new EU legislation authorising
the use of insects’ protein in aquaculture. 2017.
http://www.ipiff.org/news-and-events

* Infographics by Daniel Röttele: p.3, p.6, p.7, p.8

Bühler Southeast Asia and Oceania
GQ_DF_Success_Semerang_EN_14287_01

Regional office:
Bühler Asia Pte. Ltd. 73 Bukit Timah Rd,
#04-01 Rex House, Singapore 229832

Telephone
Australia: +61 3 9872 7900
Bangladesh: +880 2 8878066
Cambodia: +855 23 985 282
Indonesia: +62 21 2977 9392
Malaysia: +60 3 5870 2038
Myanmar: +95 9 954 947555
Philippines: +63 2 844 7500
Singapore: +65 6826 6900
Taiwan: +886 3 550 7373
Thailand: +66 2 712 2600-1
Vietnam: +84 272 3769 045

Email buhlergroup.com
 Insects
to feed the world.

Bühler Insect Technology Solutions

Innovations for a better world.

Insects to feed the world.
Bühler Insect Technology Solutions.

An industry of the future

is born.

Nine billion people are expected to live on our planet by

2050. To feed them all, we will need more than 250 million
metric tons of additional protein a year – that is an increase
of 50% compared to today. Providing this growing global
pop- ulation with protein requires new and innovative
approaches as existing sources are overused and
expanding them is prob- lematic for the environment.

Added to the population challenge is the fact that we don’t

use the food we produce very efficiently. Roughly one-third
of the food intended for human consumption is lost or
wasted every year. This accounts for approximately 1.3
billion metric tons of food that never reaches our tables. This
is not only a loss of valuable nutritional resources, but also a
challenge in terms of disposal. In many regions, landfill or
incineration are the preva- lent solutions for dealing with
food waste, and they come with their own problems. There
is an ongoing quest for new and efficient technologies to
better deal with organic waste.

Insects offer a unique opportunity to address both

challenges: protein supply and organic waste disposal.
Insects close the loop on organic waste as they recycle
nutrients that are other- wise lost and they bring them back
into the food value chain. Today, this sustainable solution is
not only feasible – it can be realized on a large scale and in
an economical way.

Bühler Insect Technology Solutions provides modular

systems for the industrial-scale transformation of organic
residues into quality products such as protein and lipids for
animal feed applications as well as fertilizer suitable for
agricultural and horticultural use. This automated process
solution meets the safety and quality standards required by
the feed industry and will help to sustainably feed the planet.

Watch our video

to learn more.
3
Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.

Insects
contribute
to a
circular
economy.

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l Organization of the United Nations

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Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.

Bühler
Insect
Technology
Solutions.
Our role in
the insect
industry.
We
are
you
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tec
hn
olo
gy
par
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Bl A

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s
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e The protein meal and lipids canThe
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p
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Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.

Feedstock preparation. Feed for the best results.

Our solutions are fully Consistent nutrition is key to quality.
customized.

Even though black soldier fly larvae are very flexible in

terms of what they can eat, the feed mix they are given must
fulfill the necessary energy and protein requirements of the
larvae. Energy is mainly provided by starch, sugars and
lipids, while for proteins, it is not only the amount that is of
importance, but also its digestibility. In addition to these key
nutritional factors, black soldier fly larvae consume their feed
in slurry form. This offers the possibility to not only use dry
sources that have been moistened, but also feedstock with
a moisture content of up to 85-95%. This means that many
wet industrial byproducts do not need to be dried before they
can be used in our facilities. Whether wet or dry, for the
industrial production of larvae it is essential that the feed
provided is consistent over the whole year. With this in mind,
The organic residues are stored in silos before they are mixed into a proper a reliable supply of the feedstock sources is highly
feedstock.
recommended. It is beneficial if the transport of the
feedstock is minimized and the insect processing factory is
built close to the location where organic residues accumu-
Proper feedstock preparation is the first
late. Local regulations should also be taken into account as
order of business for any successful they can limit feedstock options.
insect plant. The objective is to
transform the dif- ferent organic residues
in a timely manner into safe, palatable,
and nourishing feed for insects. Examples of potential feedstock:

Bühler Insect Technology Solutions (BITS) offers process Industrial byproducts Agricultural residues
tech- nologies that can be easily customized in order to deal
with the wide range of potential feedstock suitable for Distiller’s grains – Fruit and vegetable leftovers
rearing insects. The technical solution includes the reception Brewer’s spent grains and yeast
and safe storage of wet and dry raw materials as well as Fruit, vegetable, and potato cutoffs
their mixing into a homogeneous feed with a suitable Fruit juice pulp
composition and moisture content. If required, additional
Sugar beet pulp
Vinasse and molasses
treatments such as grinding and/ or fermentation can be
Dairy residues
applied in order to facilitate the ideal access to nutrients
Corn slurry Retail discards
within the organic materials. Wine remains
Rice and wheat bran
BITS also offers consulting regarding feedstock selection Old bread
Reject grains
and recipe design to optimize larvae growth performance. Supermarket discards
Tofu industry residues
Taking into account the nutritional composition of different Hotel and restaurant leftovers
Oil cakes / pomace
organic residues, the feed can be tailored to the
requirements of the black soldier fly larvae. Additionally, the
structure of the feed is adapted to best suit the needs of the
9 10
Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.
larvae.

9 10
Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.

Insect rearing. Reliable seed larvae supply.

Our solutions enable modular design. Specialists provide sustainable solutions.

As with several other livestock industries, the young animals

needed for rearing – in our case seed larvae – are supplied
by specialized companies with a great deal of experience
and biological know-how. Within this breeding and
reproduction process, it is crucial to understand the full
lifecycle of the insects and create sufficient redundancy in
order to reliably provide seed larvae.

The most suitable seed larvae supply chain needs to be

Crate handling is fully automated to ensure low operational
costs.
evalu- ated case by case and is dependent on the size of
facility, loca- tion, and operational know-how. Seed larvae
can be either produced on-site for direct use, or off-site with
regular ship- ment to the insect production plant. If required,
our partner Protix can be the supplier of the young larvae.
The company has developed proprietary technology and
know-how to en- sure reliable output.

Rearing facilities make up the largest

part of an insect plant. The objective is
to effi- ciently grow young larvae to their
ideal harvesting weight and to separate
them from the rearing residue. Typically
larvae are grown in crates. seed larvae

Bühler Insect Technology Solutions works with

standardized rearing units with a fixed number of crates that
are managed through an automated system. This allows a
modular design of the insect growth area, so that the
capacity of the plant can be easily adapted to feedstock larvae
availability. Larvae are regularly fed with an accurate
feeding station in order to optimize the availability and
delivery of nutrients. For storage, crates are stacked, which
minimizes land use. A ventilation system en- sures uniform eggs pupae
climate conditions in each crate thus facilitating fast and
consistent growth of the larvae. Overall, our solution
enables the customer to set and control the rearing
conditions in a way that ensures a high productivity with
optimized feedstock conversion and minimized
development time.

At the end of the rearing cycle, a harvesting process

efficiently separates the larvae from the rearing residue.
Our technology achieves an exact selectivity resulting in adult fly
11 12
Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.
clean larvae with minimal losses in the rearing residue.

11 12
Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.

Larvae and rearing residue processing. High quality end products.

Our solutions are flexible. Protein, lipids, and fertilizer.

Protein meal.

Benefits Sample applications

– Balanced amino acid profile. – In pet food products, given its

– Very good digestibility > 85%.
– Highly palatable.
– Adequate techno-functional
properties.
nutritional
profile and hypoallergenic properties.
– In fish feed for high growth
performance, a good feed conversion
rate, and a better gut health.
– In shrimp feed as an attractant for
better feed intake.
– In broiler and pig feed for better
nutrient digestion and satisfactory
productive performances.

Experts at Bühler Insect Technology Solutions ensure the highest quality at all stages of
production. Lipids.

Benefits
Processing is the final stage of the Sample applications
insect plant. The objective is to – High in lauric acid that has
antibacterial and antiviral properties. – In piglet feed for improved
transform the larvae and the rearing feed intake and better gut
– Easily digestible source of energy.
residue into high value end products – Naturally palatable. health.
that are safe and have a consistent – Simple integration into products. – In broiler feed with satisfactory
quality. pro- ductive performances and
overall meat quality.
– In cosmetics and detergents as an
alternative to animal or vegetable
Bühler Insect Technology Solutions offers central processing
fats.
units that have a wide-range of capacity. We work with three
processing lines, which can be operated in two or three
shifts. This gives the customer maximum flexibility and also
allows for future expansion plans. Our patented process Fertilizer.
fulfills good manufacturing practices (GMP) and safety
standards. Besides washing of the larvae to remove any
Benefits
remaining rearing residue, a heat treatment step ensures
inactivation of enzymes and pathogenic microorganisms that – High organic matter (>85%)
might be present. A further valorization is achieved through with nitrogen and minerals. Sample applications
an efficient three-phase sepa- ration. Purification of the lipid – Contains chitin that improves
fraction, as well as drying of the protein-rich fractions, result the defense mechanisms of – In soil amendments for farms,
in products with good shelf life. The defatted protein meal plants. gardens, horticulture, and
can be packaged in bags with varying filling volume. – Slow and constant greenhouse.
nutrient release over time. – In low fertile soil (acid and sandy
The rearing residue is typically dewatered and pelletized in soil) with satisfactory results.
– Safe and ready to be applied on field.
order to achieve shelf-stable product. As an alternative, it – In crop production for higher yields.
can also be prepared for direct offtake.

13 14
Insects to feed the world. Insects to feed the world.
Bühler Insect Technology Solutions. Bühler Insect Technology Solutions.

A plant
overview.
Our
integrated
solution.

S
O
u

Seed larvae R

S
O
u

15
 Insects to feed the world.
Bühler Insect Technology Solutions.

Phased approach.
Step-by-step to a successful plant.

We offer a phased integral solution that goes from the complete plant
feasibility analysis to the successful fulfilment of the project. Moreover, we
provide after- sales service that ensures efficient plant operation for many
years to come.

1. Feasibility
2. Detailed engineering 3. Manufacturing & supply 4. Installation & commissioning 5. After-sales service

The design specifications for an All of the machines and auxiliary Over 90 Bühler Service Stations
economic plant are elaborated parts are ordered, manufactured, around the globe ensure that
with the customer using three and shipped. you are never very far from a
steps: qualified technician.

– Feedstock analysis
– Detailed business case
– Concept engineering

Details are defined so that the

fully specified system can be The planned system is installed
passed on to the plant and the and tested, ensuring operations
service provi- ders responsible for are up to specifications.
manufacturing and installation.
Once fully functional, the plant is
handed over to the customer.

Project management Engineering

We deliver projects in a high quality and timely manner. This is achieved with efficient We engineer customer success. Our technologists and engineers have the in-depth process
project management in close collaboration with the customer. We have dedicated project know-how to design reliable plants that will enable easy and cost-effective
managers with detailed knowledge of the local circumstances to deliver our plants all operation. We also offer advice and services on how to fully utilize the insect plant
over the world. over its lifetime.
Bühler manufacturing factory in Changzhou, China. 18
Bühler Southeast Asia and
Oceania
Regional office:
Bühler Asia Pte. Ltd.
73 Bukit Timah Rd,
#04-01 Rex House, Singapore 229832

Telephone
Australia: +61 3 9872 7900
Bangladesh: +880 2 8878066
Cambodia: +855 23 985 282
Indonesia: +62 21 2977 9392
Malaysia: +60 3 5870 2038
Myanmar: +95 9 954 947555
Philippines: +63 2 844 7500
Singapore: +65 6826 6900
Taiwan: +886 3 550 7373
Thailand: +66 2 712 2600-1
Vietnam: +84 272 3769 045

Email
southeast.asia@buhlergroup.com
buhlergroup.com