Skid system for side streams valorization
This project develops a modular skid system for continuous production of protein nanofibrils from dairy whey, enabling novel biopolymer applications in packaging and microplastic-free materials.
Factsheet
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Schools involved
School of Agricultural, Forest and Food Sciences
School of Engineering and Computer Science - Institute(s) Consumer-focused Food Production
- Research unit(s) Food Process Technology and Sustainable Innovation
- Funding organisation Innosuisse
- Duration (planned) 01.04.2025 - 30.09.2026
- Head of project Dr. Massimo Bagnani
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Project staff
Dr. Massimo Bagnani
Dr. Christoph Denkel
Prof. Lukas Moser
Melchior Borer - Keywords Protein nanofibrils; Bioprocessing; Skid system; Biopolymers; Dairy whey valorization; Sustainable materials
Situation
Protein nanofibrils represent a new class of bio-based polymers with unique structural and functional properties, including film formation, mechanical reinforcement, and compatibility with food-contact applications. Their potential as sustainable materials has been demonstrated at laboratory scale, yet industrial adoption is hindered by the lack of scalable, reliable production systems. Currently, nanofibril preparation relies on batch processes that are energy-intensive, difficult to standardize, and unsuitable for continuous industrial operation. At the same time, the dairy industry produces large amounts of whey, a protein-rich side stream that remains underutilized or is processed at low value. Converting whey proteins into nanofibrils through scalable technology offers both ecological and economic opportunities. The absence of a robust pilot-scale process platform remains a major bottleneck. To bridge this gap, a modular skid system is required to integrate ultrafiltration, controlled fibrillation in a reactor, and real-time process monitoring, providing reproducible and scalable nanofibril production.
Course of action
The project will design, build, and validate a modular skid system combining: (1) Ultrafiltration (UF) – for protein concentration and pre-treatment of whey. (2) Reactor module – enabling controlled fibrillation under defined pH, temperature, and shear conditions. (3) Control and monitoring unit – equipped with sensors and automated feedback loops to ensure reproducibility and process stability. The skid will be engineered for scalability, flexibility, and compliance with food-grade standards. System performance will be benchmarked through protein conversion efficiency, nanofibril yield, and energy/water consumption. Validation will include: (1) Material characterization (fibril morphology, rheology, stability). (2) Application testing in films, coatings, and dispersions. (3) Techno-economic and sustainability assessments. The system will provide a transferable platform for future industrial bioprocessing of protein nanostructures.
Looking ahead
The next phase of the project will focus on full assembly of the skid system and pilot-scale validation. Special emphasis will be placed on process robustness, automation, and compliance with food-grade engineering standards. Scaling trials will be conducted with dairy whey supplied by industrial partners, enabling proof-of-concept under realistic operating conditions. Parallel studies will assess techno-economic feasibility and environmental impact, including energy and water efficiency. Application development will target bio-based films, coatings, and dispersions, validating the material performance of nanofibrils produced via the skid. Long-term, the system is expected to serve as a blueprint for industrial facilities seeking to valorize protein side streams into high-value biomaterials. This will accelerate commercialization pathways for nanofibril-based packaging and microplastic-free formulations.
