Animal-Free Milk Proteins BioTechFactory - Precision Fermentation Process Development and Scale-Up for Industrial Production of Dairy Ingredients

• Grant number: 24/00541-6
• Support Opportunities: Research Grants - Innovative Research in Small Business - PIPE
• Start date: February 01, 2025
• End date: January 31, 2027
• Field of knowledge: Biological Sciences - Microbiology - Applied Microbiology
• Principal Investigator: Manoela Martins
• Grantee: Manoela Martins
• Company: FUTURE COW TECHNOLOGIES LTDA
• CNAE: Pesquisa e desenvolvimento experimental em ciências físicas e naturais
• Principal investigators: Deborah Kimie Yonamine
• Associated research grant(s): 25/08424-1 - VivaTech, AR.EXT
• Associated scholarship(s): 25/05332-9 - Study of heterologous expression and scaling of milk proteins (b-lactoglobulin, a-casein, b-casein and k-casein) by precision fermentation, BP.TT; 25/01898-8 - Animal-Free Milk Proteins BioTechFactory: precision fermentation process development and scale-up for industrial production of dairy ingredients, BP.PIPE

Abstract

The establishment of biofactories for protein ingredient production, like any technology based on living microorganisms, involves challenges in various areas, including biotechnological research and development, bioprocesses; scalability (scale-up) and process reproducibility; cost and product competitiveness; market acceptability; ethical and regulatory aspects; sustainability and environmental impact; logistics and distribution; competition and innovation; and strategic partnerships. Simultaneously, in addition to the mentioned challenges, precision fermentation involves distinct and highly specialized technical-scientific competencies to address the intrinsic needs of technological adoption at scale, such as process control and production parameter definition; genetic modification and stability; data integration and modeling; real-time monitoring and control; sustainability and production efficiency; and economic cost. Therefore, these challenges/opportunities have the potential to elevate Brazilian science to the levels of disruptive technologies worldwide. In response to these challenges, the global demand for food is increasing, necessitating the application of new ways to address societal advancements. Population projections indicate continuous and accelerated growth in the coming decades, propelling industries, including dairy and dairy ingredient production, to generate bio and technological alternatives to meet this market demand. Milk proteins play a crucial role in the dairy ingredient industry, and the growing demand for food is driving the need for greater production efficiency. International reports reveal that the global per capita consumption of cow's milk is expected to increase by an average of 19% by 2050, resulting in a 51% increase in global demand for dairy products/inputs/ingredients. In this context, the Brazilian startup Future Cow Technologies is leading a revolutionary and sustainable approach to produce milk proteins of interest to the dairy ingredient industry. Future Cow Technologies employs precision fermentation, a consolidated process with the company's expertise. The company is already producing milk proteins (caseins) on a laboratory scale, using fermentation tanks of up to 15 liters, and plans to expand production to meet industry demand through a standardized, reproducible, scalable, and modular process. In addition to the biotechnological process, the company aims to promote the replacement of the carbon source used in the laboratory (glucose/sugar) with agro-industrial waste, a factor that aims to achieve a drastic reduction in production costs, estimated at over 200%, compared to competing products/processes. With highly competitive prices and productive scale, Future Cow Technologies offers a product molecularly identical to proteins found in cow's milk, including the highly desirable taste characteristic. However, it is without the undesirable presence of lactose, hormones, pesticides, and antibiotics, making it a healthier, sustainable, and scalable option, meeting demand through production modules. As a result of the current project, in Phase 2, pre-industrial parameters for scaling up the production of caseins (beta-casein, kappa-casein) and two whey proteins (²-lactoglobulin and ±-lactalbumin) will be developed. At the end of the project, the inputs produced from precision fermentation-derived proteins will be provided for evaluation and field validation with partners active in the dairy ingredient market, along with a proof of concept involving milk restoration. (AU)