1
Novel
protein production
Sharpened environmental requirements have made it necessary for many domestic and foreign
companies to consider alternative ways of disposing of fruit water. Karup Kartoffelmelfabrik has
arrived on the scene as the producer of high-quality protein who emphasizes environmental and
energy considerations.
T
he rising environmental
requirements along with cost
reductions in connection with
building new plants, encourage
the potato starch factories to find
alternative possibilities for disposing
of fruit water.
transforming the fruit water to highvalue protein, and perhaps in the
longer term to a fertilizer concentrate
or biomass for energy production
and clean water that can be used in
production instead of groundwater.
The first step
More proteins in circulation
Karup Kartoffelmelfabrik (Denmark)
has just ended its first campaign that
entailed the use of novel environmental
and energy saving techniques.
Mr. Jens Mikkelsen, the company’s
CEO, tells of the considerations that
went into the establishment of the
protein factory:
-As environmental requirements for
fertilization, storage and disposal of
the fruit water have become increasingly restrictive, the fruit water has
gradually become more and more
difficult to handle and dispose of.
Therefore, we decided to embark on
a long term strategy with the aim of
The first step in this direction was
taken in 2003, where Karup Kartoffelmelfabrik applied for EU funds
under EU’s Life scheme. The funds
were earmarked for protein production
testing using innovative techniques.
-The protein factory’s expected energy
saving and environmentally friendly
production methods, have resulted
in a grant from EU’s LIFE Environment
department of 10.1 million DKK, says
the CEO happily.
The project lasts from December
2003 to December 2006.
-By extracting the protein, we can
remove at least half of the nitrogen from
the fruit water, says Jens Mikkelsen.
Low energy may produce
additional money
In the process of planning the new
factory, focus was put on keeping
energy costs at a minimum.
-We have chosen to
invest in new state of
the art technology,
and expect to
achieve high
energy savings
in return. One
example is that we recycle the heat in
order to arrive at very low costs in this
area, says Jens Mikkelsen.
The use of EU funds commit the
factory to serve as a demonstration
unit/factory. It must be “public” to
the market, and inform the market
players of how energy savings and
environmental improvements have
been achieved and allow others to
benefit from Karup’s experience.
Starting up
Mr. Jens Mikkelsen says that in the
beginning there were problems with the
power supply at the protein factory:
-But after the first 8-10 days of initial
difficulties, everything has gone
smoothly, and every attempt has been
made to live up to the expectation of
the EU.
Establishment costs in connection
with the protein factory have so far
amounted to a total of 46 million DKK.
All production functions under
production tests etc. will be controlled
via computer.
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From fruit water to protein
Fruit water production is expected to
run parallel to starch production. The
fruit water is transported directly from
the starch factory through pipes over
to the protein factory.
Here acid is added to the fruit
water, and then the whole thing is
heated up. The combination of acid
and heat makes the protein precipitate
in the fruit water.
The protein is separated from
the liquid in a decanter, after which
it consists of 45-50% dry-solid. The
remaining liquid is called protein water,
which is basically fruit water from
which half of the nitrogen has been
extracted.
Then the protein is dried down to
a content of only 10% water, and the
finished protein product is ready to be
transported for storage in the silo.
Apart from a reduced amount
of nitrogen, the protein water still
contains residual fertilizers, for
example potassium and phosphor.
The protein water can, just like the
fruit water, be applied to the growers’
fields.
But today’s farmers have to
consider the content of phosphor and
potassium in the fertilizer. If protein
water is being used, the amount
of potassium and phosphor in the
water will limit how much of it can be
applied to the fields. Therefore it is
also necessary to post fertilize using
nitrogen.
Now also for people
The protein is first and foremost sold to
the industrial community, but also to a
limited extent, as animal feed.
-To extend our customer base, we
have adopted a long-term strategy of
EU Grants.
The protein
factory is a very
energy-saving undertaking. EU has
subsidized this by
granting DKK 10.1
million, tells CEO
Jens Mikkelsen.
producing a protein with a low solanine
content which has a pretty, light color,
explains Jens Mikkelsen.
Solanine is a toxin produced in
potatoes that have been exposed
to sun light. This can be seen by the
fact that the potatoes turn green. Due
to the solanine content, the protein
cannot be used for human purposes.
-Therefore we’re investing in a
demonstration unit which enables
us to extract a large percentage of
the solanine and color agent out of
the product, says Jens Mikkelsen and
elaborates:
-It happens by a sort of refining. This
allows us to reduce the solanine
content so considerably that the
protein quite possibly can be used in
food products and all kinds of animal
feed, says Jens Mikkelsen.
potato water contains 2% protein, of
which 1% can be utilized. This figure
is slightly lower this year.
-In Holland, however, the fruit water
contains 3-4% protein. Whether this
is due to the particular potato strain,
I do not know, but we will find out. If
a high protein content is caused by
a high starch content, those strains
will of course be even more appealing,
says Jens Mikkelsen.
Summary of expected results
Summary of the expected results from
the petition to the EU which the factory
expects to live up to in the coming
project periods:
Dutch proteins
The overall objective of the project is
to reduce the environmental impact
of the potato starch industry, through
minimization of waste streams and
energy consumption.
The prices of protein have been low
this year, as there has been a surplus
of protein on the market.
Furthermore, this year the protein
content in potatoes has been very
low, reports Jens Mikkelsen. Normally,
The project objective is to demonstrate
the feasibility of a novel, innovative,
environmentally friendly and energy
saving method for production of potato
protein.
>>
3
The new protein factory.
In the next campaign, a demo-unit
will be build with the aim of reducing
the toxic solanine in protein. “Solanine-free” protein can – contrary to
denatured protein – also be applied
in food products.
Today, potato protein is extracted by
use of heat (direct steam injection)
and acid for reduction of the pH value of the potato fruit juice. Traditionally, the quantity of steam utilized is
equivalent to 10% of the volume of
potato fruit juice. In the case of the
said project Karup Kartoffelmelsfabrik this is equivalent to 10-13 tons of
steam/hour. By implementing the
novel innovative heating technology,
with improved heat recovery, the energy consumption for heating can be
reduced by 40% or more. In the case
of AKK the energy saving is equivalent to at least 5 tons of steam/hour,
or 400 m3 of natural gas (liter of oil)
per hour or approx. 1 million m3/litres
Task Task titel
per campaign. Moreover, a reduction
in nitrogen discharge of 50-60% and
a reduction of water consumption with
up to 60-70%.
The novel process is not least based
on a potential high-value protein
production involving approx. 2.4 m kg
per campaign.
>>
Start date
End date
Actions
15.10.2004
Concept development, designing
and cost benefit
1
Design and concept development
01.12.2003
2
Detailed design
and construction planning
01.04.2004 01.08.2004
Detailed design, planning,
and tendering
3
Demonstration system construction
01.04.2004 01.01.2005
Plant construction, staff training,
commissioning
4
Testing and optimisation of
the demonstration system
01.09.2004 15.03.2006
Testing, modification, optimisation
and verification
5
Construction, test and evaluation of
alternative sub-systems
15.09.2004 01.08.2006
Design, planning and construction
of alternative sub-systems
6
Process viability and
system feasibility
01.07.2005
01.11.2006
Data processing, risk analysis,
feasibility analysis
7
Project management
01.12.2003
01.12.2006
Project tracking, administration,
meetings
8
Dissemination of project objectives
and results
01.12.2003
01.12.2006
Web-site, news letter, seminars,
papers, patents
Tabel 1: Task summary.
4
Status year one
It is assumed by the factory that even
though the project approval from the
EU was received at the factory very
late in the course of the project, which
gave way to some uncertainty as to
the project economy, all participating
persons in the project have, during
the process, been very committed in
promoting the achievement of fine
project results. These persons have,
in the period after the receipt of the
support, proved to be extraordinarily
committed in ensuring that the project
observes all the stated deadlines
and documentations etc. which are
required of the project by the EU.
Furthermore, the factory estimates
that the prepared design for the
demonstation plant, and the technical
and financial and resource-related
estimations concerning environment
and energy, seem very promising
as to the achievement of the overall
objective of the project. Thus, it is
presently assumed that the design
set-up will entail a reduction in
energy consumption compared to
traditional plants of minimum 60%
and a reduction in nitrogen discharge
of approx. 50-60%. At the same time
there will be basis for production of a
protein product which could be used
for foodstuff production contrary to
traditional protein which primarily is
used as basis for animal products.
Finally, it can be informed that
the factory presently finds that the
contact with the EU is very positive
and very promising in terms of future
cooperation.
Objectives and strategic aspects and task summary
The planned objectives for the first year
of the project which will comprise the
project period from the initial starting
of the project on 1 December 2003 to 1
December 2004 were to complete the
work in the different tasks.
The project is divided into 8 tasks
see the table on page 3.
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