BIOLOGICAL TRANSFORMATION
AND BIOECONOMY

3

“

I THINK THE BIGGESTINNOVATIONS OF THE
21ST CENTURY WILL
BE AT THE INTERSECTION
OF BIOLOGY AND­TECHNOLOGY. A NEW
ERA IS BEGINNING.”
Steve Jobs

4

Into the future with biologization and digitalization!
German products, processes and equipment are competitive and, as such, in big demandthroughout the world. As the country’s leading application-oriented research organization,
the Fraunhofer-Gesellschaft contributes toward this success in many areas of technology. Here,“the question of sustainability is becoming increasingly important. Furthermore, the powerful
growth of knowledge in the biosciences has spawned all manner of synergies in the fields of

IT IS DIFFICULT TOIMAGINE ANY AREAOF OUR FUTURE LIFE
THAT WILL NOT BE
IMPACTED BY
BIOLOGICAL
TRANSFORMATION.”

medicine, nutrition, energy and, in particular, digitalization, thereby creating a platform for
exciting new innovations.
As the examples in this magazine show, the Fraunhofer-Gesellschaft is at the forefront of­developments in the field of bioeconomy and is therefore paving the way for our country’s
continued economic success. Fraunhofer researchers draw inspiration from biological principles
and from the material cycles in nature. The products developed in this way each respond to amajor c­ hallenge of our times: the need for palatable, healthy food that is not based on­environmentally harmful meat production; stem cell research to replace animal experimentation;the ­development of strong, durable materials from renewable sources; the growing of vegetables
in an urban setting – to name but a few.
It is difficult to imagine any area of our future life that will not be impacted by biological­transformation. I wish everyone at the Fraunhofer-Gesellschaft continuing success in thiscrucial field.
Yours,

Prof. Dr. Wiltrud Treffenfeldt
DOW Europe, Chief Technology Officer Europe, Middle East, Africa & India
Member of the Senate of the Fraunhofer-Gesellschaft

6

In Germany, there is a tradition of drawing inspiration and innovation from nature. Back in the
1990s, the federal government identified biotech as a key technology for the future. In 2007,
under German presidency, the Council of the European Union issued a road map for a moresustainable future: “En route to the knowledge-based bioeconomy”. And with its national
research strategy “Bioeconomy 2030”, the federal government has placed the biosciences atthe very heart of its high-tech agenda.

“

AT FRAUNHOFER,­B IOLOGICAL
TRANSFORMATIONGOES HAND IN HAND
WITH DIGITAL
TRANSFORMATION.”

Meanwhile, the Fraunhofer-Gesellschaft is now looking to amalgamate digital change­(connectivity) with biological change (sustainability). This yields the concept of biological­transformation: a process that describes the increasing technological utilization of principles,
structures and materials derived from living nature with the goal of establishing sustainablesystems of value creation. Biological transformation is a diverse process. It includes, forexample, as one of the essential pillars of a future bioeconomy, the use of renewable raw
and residual materials as a replacement for basic materials derived from fossil fuels.
Part of this process involves applying the findings of molecular biology to the development of
new and individual forms of therapy. Similarly, the principles of nature can help us understandand control complexity – essential for the creation of self-organizing manufacturing systems or
self-contained digital ecosystems.
Yet it would be wrong to claim that biological transformation is sustainable per se. Its role is tocontribute toward achieving the sustainable development goals of the United Nations. And let
us not forget that the examples presented here are but a selection – colorful and diverse, justlike their inspiration – nature. That so many others could have been added to this list – car tires
made from dandelion rubber, for example, or butadiene fermented from renewable raw­materials – merely serves to demonstrate the scope and continuity of our engagement in thisfield. In other words, this overview presented here is merely the beginning. We hereby invite
you to join us on our journey of biological transformation!
Yours,

Dr. Patrick Dieckhoff
Head of Science Policy of the Fraunhofer-Gesellschaft
Coordinator for Biological Transformation

8

BIOLOGICAL TRANSFORMATION

Conclusion

A ny one w a lk i n g b a re fo o t n e a r a n a n th i l l i s wel l adv i s ed to c arry on mov i ng. The al l -femal e s ol dier ant s

come more or less unchanged from nature. The next milestone

a re quic k t o a tta ck . At th e s l i g h te s t p ro voc ati on, they wi l l s warm out to defend thei r c i tadel against an

came in the 1970s, when Stanley Cohen and Herbert Boyer

all-powerful enemy. Their prompt reaction shows that the seeming chaos is but apparent. As a collective,

pioneered the replication of DNA in foreign cells. Their discovery

Biological transformation is based on knowledge gleaned fromt he c olony is i n co mp l e te co n tro l . B o th organi z ati onal l y and phy s i c al l y, ants c oul d teac h us humans agave rise to biotechnology: the application of technology to

the life sciences. Germany is a leading player in the fields oft hing or t w o: h o w to wa l k u p s i d e d o wn on s mooth s urfac es , for ex ampl e, or how to av oi d traff ic jam s

living organisms. Today, biological organisms are used toenvironmental technology and resource efficiency. In essence,on c onge st e d ro a d s . De s p i te th e i r h u g e numbers , they l i v e i n harmony wi th nature al l ov er the w or ld.

produce a whole range of substances: bacteria, fungi, and other

the German term Industrie 4.0 was coined to define a digitally

H um a ns c a n l e a r n a l o t fro m n a tu re .

microorganisms are efficient producers of v­ itamins, specialty

supported strategy that promotes greater connectivity andchemicals, biofuels and humanized implants. What’s more,

efficiency – not an agenda for greater sustainability. This isdetergents are now as effective at 30 °C as they once were at

where biological transformation comes in – a process that

90 °C. That saves energy.

describes the increasing technological utilization of materials

Bionics has given us Velcro and zipper fasteners, supersmoothanimals right around the world. These findings have revealed

surfaces with the lotus effect and camera lenses based on theconnections between habitats that were once considered as

The application of biological principles has led to radical

compound eye of an insect. Nature is a constant source ofentirely distinct. Some of the findings have proved less palatable:changes in a whole range of business sectors, including

Thanks to extensive ongoing funding, Germany occupies a­inspiration. More than half of all pharmaceutical ingredients

global studies on the consequences of climate change­pharmaceuticals, the consumer goods industry, food production

strong position in the life sciences. Biological transformation

have their origin in natural substances. Advances in­(deforestation, glacier retreat, desertification etc.) have revealed

and agriculture. This process is expected to intensify in therefers to a process based on a whole range of scientificand principles from nature to establish a sustainable economy.

biotechnology mean that bacteria, fungi and plants now play

its true dimensions and impact on ecosystems. At the other end

future, as biology and IT increasingly converge. Today, advances­disciplines, which is now promoting the establishment ofa key role in the chemical industry. Drones are piloted accordingof the scale, computer-controlled microscopes have shone ain a­ rtificial intelligence and machine learning are alreadysustainable economic systems such as a bioeconomy. In otherto ­principles derived from the workings of a bee’s brain. Indeed,light on minuscule structures at the molecular level, thereby

giving rise to what are known as social machines along withwords, biological transformation is an innovation process that

wherever we turn, the use of the principles and materials of

leading to the ­development of nanoscopic substances andinnovative logistics, robust manufacturing systems anddescribes the application of scientific results and, potentially,nature is on the increase. Out of the multitude of individualmaterials. ­Computer-based (“in silico”) simulations help reduce

self-optimizing machines.

systemic change. As such, it forms a bridge between scienceexamples, a recognizable trend is emerging: a growing

our use of animal testing. Meanwhile, we are now able to­convergence of nature and technology, with the aim ofcreate digital ecosystems. And one day, we may well conceive

Digital transformation and biological transformation are

as a bioeconomy, on the other. It therefore constitutes an­establishing a sustainable economy. Here, experts talk ofof DNA as a highly efficient data memory or neuronal interface.

complementary strategies: the former aims primarily atinterdisciplinary task for science, politics and society.

­biological transformation. By this, they mean that the utilization

In other words, digital transformation first enabled biological­interconnectivity and efficiency, the latter at sustainable

and combination of knowledge from the life sciences across alltransformation. They go hand in hand and can even reinforce­development. Each is necessary, but neither is in itself sufficient.

Dr. Bernhard Aßmus, Dr. Isabella Wedl, Dr. Patrick Dieckhoff

areas of technology is now promoting the establishment of

one another.

They must therefore be thought out and pursued in combination.

Fraunhofer-Gesellschaft, www.fraunhofer.desustainable economic systems such as a bioeconomy.

and research, on the one hand, and an economic system, such

Unlike digitalization, which is now largely accepted as a
From today’s perspective, we can identify three different phases­necessity, the process of biological transformation is still in need

As a field of inquiry and activity, biological transformation isof biological transformation. Each emerged at a different time;of political support. In fact, biological transformation can help

driven by our growing understanding of biological principles

each makes use of different principles, structures and materials;

achieve the sustainable development goals set out by theand processes. This knowledge, in turn, has been made possible

and each continues to this day. In the beginning, there was

United Nations (SDGs), which serve as a reliable benchmark

by ever more powerful information technology. It was thebionics, which analyzed structures and processes from nature inagainst which to measure sustainability.

­availability of immense computing capacity that first enabledorder to apply them to technical problems. The first everscientists to sequence the human genome – and, since then,German bionics patent – a “dispersion mechanism” based on

many other genomes. Out of a jumble of letters, scientists havethe seed capsule of the opium poppy – was registered in 1920.

been able to develop new diagnostic procedures andYet that was only the start. During the first half of the 20th­individualized therapies. Analysis of huge datasets has helped

century, health care benefited from numerous developments indisclose unknown global patterns. With the help of GPS

pharmaceutical drugs and diagnostics – from antibiotics to­navigation, we have been able to follow the migration ofblood glucose test strips – based on active ingredients thatTHE CONTRIBUTION OF BIOLOGICAL­TRANSFORMATION TO THE SUSTAINABLE­DEVELOPMENT GOALS* OF THE ­UNITED NATIONS

SDG 2

SDG 3

SDG 6

SDG 7 und SDG 13

Zero hunger

Good health and well-being

Clean water and sanitation

Affordable, clean energy and climate action

A synergy of technology-based approaches (smart

Examples of biologically inspired therapies andBiological processes play a well-established role in

The sustainable use, as a source of energy, of biomass­agriculture, the latest plant-breeding methods) with­diagnostics include biopharmaceutical products,­wastewater treatment. For example, microorganisms

or – in line with a cascading use – its derivative products­biology-based approaches (microbiome research and­regenerative medicine, biofunctionalized materials forhelp break down dissolved pollutants and other waste

can help replace fossil fuels. Bioenergy can contributeagricultural biodiversity, for example) will help increase

medical purposes, tissue engineering and microbiome-basedmaterials in wastewater or even convert them into

to a varying degree – depending on the region –agriculture’s efficiency, resiliency and environmental

research. In addition, biological transformation will

usable raw materials. Biosensors and molecular

toward providing a sustainable source of fuel, heatcompatibility (reduced use of fertilizer). Research into

enable the development of cell-based testing­biotechnology are used in environmental analysis toand e­ lectricity. Meanwhile, modeled on plants andalternative protein sources to replace meat, for example,­procedures, thereby reducing animal experimentation.

accurately determine pollution levels in water. Similarly,­microorganisms, catalytic processes are now being

will also enable the progressive replacement of

At the same time, machine learning and advanced

bio-­electrochemical and biomimetic membrane systems

developed to produce basic chemicals from carbon­greenhouse gas-intensive animal products.

computer simulation can enhance our understanding of

enable energy-efficient water treatment. In agriculture,

dioxide with a view to establishing a “closed

complex biochemical processes in cells and organisms,

precisely controlled irrigation systems inspired bycarbon cycle economy”.

thereby accelerating the development of new active­biological principles help ensure water is used

ingredients for pharmaceutical drugs.

more efficiently.

SDG 9

SDG 12

Industry, innovation and infrastructure

Responsible consumption and production

The adaptation of biological principles can play a key

The replacement of fossil fuels by renewable biologicalrole in making technological systems and infrastructurematerials and chemicals, and the establishment of

more resilient. This applies not only to construction andclosed-loop material cycles, will make a significant

other materials (such as self-healing materials) but also

contribution towards reducing business and industry’s

to entire infrastructure (for example, in the area ofcarbon footprint. Using biological processes andmobility or energy supply), which could then be­biomimetics can help make manufacturing processes

designed on the basis of resilient ecosystems. In

more efficient and thereby reduce their consumption of­addition, the use of natural resources is a prerequisite

raw materials. Similarly, the application of biologicalfor freeing industry around the world from its

principles (such as swarm intelligence as a digital­dependence on materials based on fossil fuels.

process) can reduce logistical requirements and abuildup of industry at particularly impacted locations.

* (SDGs)

BIOLOGICAL
TRANSFORMATION –ITS APPLICATION IN
THE ECONOMY

externally. Crucial, too, is the acquisition of knowledgeand ­experience in handling organisms and biologicalproducts. It will be equally important for companies
to forge new and unusual alliances and to cooperatewith experts specializing in a whole variety of disciplines
and processes. Similarly, the need to manage thecomplexity resulting from an increasing digitalization of

It is a reasonable assumption that biological transformation

manufacturing processes (Industrie 4.0) will yield newwill have a global impact on trade, supply chains,approaches.

­individual sectors of the economy, industrial locations
and employment. In some cases, it will give rise to

Exploiting the potential of biological transformation

completely new ways of doing business. In enabling

involves substantial challenges. For a start, there is the

new tools, new materials and new raw materials (theneed to maintain cost competitiveness (relative to, forutilization of CO2 with biotech methods, plus waste

example, products based on fossil fuels) and to connect

and residual materials, for instance) as well as new

different sectors. Similarly, there is the challenge of­manufacturing methods, machinery, robotic systems

overcoming of path dependencies and of reachingand digital ecosystems, the process of biologicala social consensus on the central goals of biological­transformation will stimulate a host of business sectors.

­transformation and the political and economic action
this will require. To take advantage of the opportunities

In the German economy, for example, the machineryin this new market, it will take substantial innovationand plant engineering sector will play a key role inalong with a raft of accompanying measures. These

driving biological transformation, determining its

include a needs analysis, market analysis, identification

scope and speed. As a key supplier to industry, theof business models, impact assessments, networking

engineering sector will define the structures andactivities and social dialogue.

standards that ­determine the application of biologicalprinciples within the field of technology. These principles

Dr. Sven Wydra, Dr. Thomas Reiss

include redundancy, resilience and material cycles, theFraunhofer ISI, www.isi.fraunhofer.detransfer of which to the manufacturing environment
has major, as yet unexploited, potential. Given their­ iotechnological production processes anduse of b
biological therapies, the chemical and pharmaceuticalindustries are already well advanced along the path of
biological transformation. It is evident that the mostsuccessful companies in this field are those that areable to tap specialized know-how, whether internally or

15

Industrialization, Innovation, Infrastructure –production processes inspired by nature
18 Complexity and balance – digital ecosystems
20 Ultra-efficient manufacturing in the factory of the future
22 Optimizing instead of maximizing – saying goodbye to linear thinking
24 Enhancing the value of crops for the farmer – active substances from the field
26 Fungi as producers – detergents from the fermenter
28 Combining nature and technology – biological-technical interfaces
30 Algae versatility is the key to sustainable chemical production

Renewable resources to ensure health and nutrition
34 High-tech silk – out of the lab and into medical applications
36 All flavor, no remorse – sustainable yet scrumptious vegetable protein
38 A medical (r)evolution – biological therapies and implants
40 Local, smart, urban – the future of food production
42 Cells and steel – automated cell production
44 Aquaculture – another piece in the sustainable food production puzzle
46 Healing nature’s way with bio-inspired wound dressings

Circular economy – sustainable consumption and climate protection
50 Organic waste – versatile coatings from fruit fiber
52 More for less – better management of soil nutrients
54 More than milk – chemicals from whey
56 Too valuable to burn – waste wood as a raw material
60 From climate killer to raw material – CO2 in chemical production
62 Protein from insects – potentially a major new source of animal feed
64 Coatings and paints from vegetable oil – putting a shine on sustainable consumption
66 Editorial notes

16

17

INDUSTRIALIZATION,INNOVATION, INFRASTRUCTURE –PRODUCTION PROCESSESINSPIRED BY NATURE
With raw materials becoming ever scarcer, green spaces disappearing under built structures, andthe need to protect natural resources such as air, water and ecosystems growing increasingly
urgent, it is time to rethink industrial production. Sooner rather than later, we will have toaccustom ourselves to harvesting food and pharmaceutical ingredients from the walls of houses,
abandoning animal testing altogether and manufacturing products in ultra-efficient ways.

18

19

COMPLEXITY AND BALANCE –DIGITAL ECOSYSTEMSDIGITAL ECOSYSTEMSNATURAL ECOSYSTEM

T he squir re l l i v i n g i n th e wo o d s h a s n o al ter nati v e: i t has to i nterac t wi th the other fores t c rea t ures –a ll t he birds a n d h a re s a n d d e e r, to n a m e j us t a few. A fter al l , i t l i v es i n a natural ec os y s tem. Likew ise,
­i nt e r a c t ion a n d co n n e cte d l i vi n g a re b e c omi ng i nc reas i ngl y i mportant i n i ndus try and s oc i ety, whet her

Subjects

in t he sof t w a re s e c to r o r i n o u r ci ti e s . B ut how c an we opti mi z e thes e di gi tal ec os y s tems ? A nd w hat

Objects– Living organisms

Software ecosystem

Smart ecosystem1– Organizations– Organizations– IT-systems– IT systems– Technical systems­r e quire m e nt s m u s t th e y fu l fi l l ? To a n s wer thes e and s i mi l ar ques ti ons about di gi tal ec os y s tems, w et r a nsf e r a ppro a c h e s fro m n a tu ra l e c o s y s tems to arti fi c i al ones .

Natural ecosystem is a term most people are familiar with.

graphic on the right). To this end, they must interact with

It refers to a community of organisms of different species

other players in the digital ecosystem while also observing

and their inanimate environment. Whether the ecosystem isfixed boundary conditions they can scarcely influence.

Value– Potential for viable offspring– Potential to earn money directly
and indirectly and to survive as
an organization– Potential to earn money directly
and indirectly and to survive as
an organization

Resources– Organisms– Manpower– Capital– Data– Source code (software)– Manpower– Capital– Source code (software)– Machines and other physical entities– Data (including digital twin ofphysical entities)

Environment– Physical (nature)– Digital– Physical (nature and technology)– Digital

marshland, desert, or ocean, the organisms living within it
interact with one another. They come into contact with eachother, mutually help each other (like bees and plants do), act

Example: Smart gridas parasites on each other (like mistletoe) and eat each other.

1 “Smart ecosystems” are software ecosystems that bring together formerly isolated solutions into an integrated overall solution.

When it comes to the boundary conditions that prevail in

An example makes this definition easier to grasp: smart grids.

an ecosystem, the inhabitants can influence them only

These systems help households feed excess energy – such as

many areas of the economy and of life. Interdisciplinarity in­Engineering IESE. At the institute, researchers are combining

to a limited degree: in a desert the ecosystem stays dry;that produced by solar panels – into the grid or take theparticular is tough to master. Classic software development

numerous IT systems. The idea is that once combined, thein a marsh it stays wet. If the wind blows the seeds of aenergy they need from the grid. In general, the idea is to sellmethods and mechanical engineering design techniques are

systems will deliver more benefits than the sum of the­dryness-loving desert plant into a marsh, they will findenergy profitably and purchase it at low rates. Energy

no longer sufficient; what is needed now are development­individual components, leading to an optimization of business­unsuitable growing conditions there and will not germinate.

producers can actively intervene by means such as pricing. On

methods for overall systems. On top of this, the issues involved

processes. This is similar to an anthill, where the combined

windless days, wind generators do not supply any energy. The

are more complex. For example, security assessments forcapability of the colony far exceeds what the individual ants

price of energy surges and encourages households to feed

digital ecosystems need to evaluate how security, safety andcould achieve cumulatively. Another project is investigating

electricity into the grid or at least to consume less of it. For

privacy mutually influence each other. In addition, many

the use of crowdsourcing: What requirements does a digital

Digital ecosystem? A definition ...

reasons of grid stability, however, there are also limits to this­questions can no longer be answered during development,

ecosystem need to fulfill? In this case, the intelligence of

So far, so good. But what is behind the expression “digital

influence. For example, there is a fixed upper limit to thebut only once systems are running, because they change

everyone involved comes together to give the ecosystem theecosystem”? Digital ecosystems can be defined as

amount of electricity that can be carried through high-voltage

autonomously.

optimal shape and structure. However, such instances of­heterogeneous systems made up of interacting players andpower lines.

“swarm intelligence” can be as damaging as they are

their ­environment. There are many examples. In pure software­beneficial, and therefore their effects on the digital world haveecosystems, for instance, IT systems interact with people.
Many different organizations and companies are thronging theDigital ecosystems in the economy

Taking inspiration from nature: From anthills to swarm

to be researched and adapted. Digital ecosystems throw up

intelligence

many questions that are difficult to answer. Nevertheless,market for software development and web services – and they

­understanding them better is still very much worthwhile, as

are all in contact with each other via networks. Often aDigital ecosystems are playing an increasingly important role in

So as to better understand digital ecosystems and be able to­platform such as the Apple App Store forms the basis for suchour economy, as systems that used to be separate are now

optimize them, the principles of natural ecosystems are

networks; other times it is a common market. If technicalbeing connected. In this way, we can see digital ecosystems

adapted to the technical ones, which has the effect ofProf. Peter Liggesmeyer, Dr. Jörg Dörr

systems are also players, then we speak of “smart ecosystems”.

emerging in many sectors, such as manufacturing (Industrie­biologically transforming them. What that means in practical

Fraunhofer IESE, www.iese.fraunhofer.deJust like the individual beings in a natural ecosystem, the4.0), medicine and the transport industry. Mastering theterms is illustrated by two research projects being undertaken

players in a digital one seek to achieve certain goals (see­challenges that arise from digital ecosystems is thus crucial forat the Fraunhofer Institute for Experimental Software20

the results have all kinds of benefits and uses.

21

ULTRA-EFFICIENT MANUFACTURING
IN THE FACTORY OF THE FUTURE

In m a ny re gio n s o f th e wo rl d , th e c o mp eti ti on for l and on whi c h to l i v e, work and produc e foo d is

Ultra-Efficient Factory – The future of production

int e nsif y ing. At th e s a me ti me , m a n y ra w materi al s – bi oti c and abi oti c – are bec omi ng s c arc er. Bot ht re nds c a ll f o r a re th i n k i n h o w we g o a b out i ndus tri al manufac turi ng. A gai ns t thi s bac kground, t heMaterial waste

Emissions

Waste of resources

U lt r a - E ff ic ie n t Fa cto ry – a n e w a p p ro a c h from the F raunhofer I ns ti tute for M anufac turi ng Engi neer ing
a nd A ut om a t i o n I PA – s e rv e s a s a m o d e l for future manufac turi ng. The goal i s to hav e hi ghl y eff icient
loc a l produc t i o n th a t co n s u me s a mi n i mum of materi al s and energy i n an env i ronment peopl e f indple a sa nt t o li v e i n . A ci rc u l a r fl o w o f m a teri al s and energy del i v ers them bac k to the s tart again f or aMaterial planning factors / ITne w round of p ro d u c ti o n .
Energyrecycling

The adaptable, zero-emissions factory of the future safeguards

or photosynthesis at the low performance end of the scale,

an intact ecological and social environment and is cleverly

for powering distributed sensors for instance. Furthermore,­integrated into its urban setting. In addition to increasing

people’s needs are an important consideration in thedigitalization, biological transformation is also an important­Ultra-Efficient Factory. Technical and organizational measuresrequirement for ultra-efficient production. Increasing thebased primarily on bionic principles take into account the

proportion of biobased materials available locally is anotherbiological needs of people in an optimal manner. Considering

important goal. This is to be achieved through the application

the physiology, health and well-being of employees is veryof bionic principles in product design – specifically throughmuch part of this. Innovative approaches use algorithms

bionic structures, functions and surfaces coupled withinspired by natural processes – such as swarm intelligence,­innovative manufacturing technologies, such as additive

evolution algorithms and neuronal networks – to optimize themethods or selective coating technologies with biogenicorganization of production systems. In addition to process-­­material components. As a result, transport costs fall while

integrated biobased approaches, end-of-pipe solutions arematerial efficiency and r­ esilience to turbulence in the globally

also pursued in order to reduce emissions and waste anddistributed value chain increase.

­minimize environmental harm. This includes biological filter

DIGITAL
TRANSFORMATION

Product
BIOLOGICAL
TRANSFORMATIONVALUE CREATION
Material

Digitalization

Material
recycling

FACTORY

EnergyHuman resources

Capital

NEW RECYCLING TECHNIQUES

mechanisms in the form of bacteria and plants, for example,
Using instead of consuming

and the active use of waste and emissions in intelligent rooftop

dangerous substances, such as utilizing organic waste orThis means that commuting and travel times and thegreenhouses. Production “waste” is reused in biorefineries.

using CO2 as a raw material.

­environmental impact are all reduced, and that the factory
is integrated aesthetically into the urban environment.

In addition, there is huge potential in the fusing of nano- andThe concept of the Ultra-Efficient Factory developed by­Fraunhofer IPA is part of an energy system that is based

Better environmental impact and new

biotechnology in the production environment. This would

Prof. Alexander Sauer, Robert Miehe

primarily on renewable, fluctuating energy sources.

communication systems

involve biological or biobased material communicating with

Fraunhofer IPA, www.ipa.fraunhofer.de/entechnical components. On this basis, we could develop a smart­Consequently, the focus is on maximizing energy flexibility as
well as energy efficiency. In addition to drawing energy from

Some of these technologies are already substantially improving

communication system that would, for example, facilitate­traditional distribution grids, the goal is to adapt local energy

environmental impacts in sectors such as food production andinteraction between Industrie-4.0-enabled manufacturing

generation, distribution and storage to the local geographicalthe process industry. Before they are ready for blanket

technologies and recyclates – that is, recyclable plastics. Thisand material circumstances. In achieving this, there will be a­integration into manufacturing industry, however, the existing

would be particularly useful when dealing with recyclates withrole for the use of regional biological waste products as energy

technologies need to be further tested and adapted.

unknown chemical compositions and which are therefore– i.e. biogas or biobased capacitor/fuel cell combinations – andBiobased management of material cycles also makes it­difficult to recycle. In the concept of the Ultra-Efficient Factory,

also for a decentralized biobased energy supply from bacteria

possible to develop solutions for bonding potentiallymanufacturing is in a symbiotic relationship to its environment.

22

23

OPTIMIZING INSTEAD OF MAXIMIZING –SAYING GOODBYE TO LINEAR THINKING

periods it takes before changes take effect are radically­maximizing the yield from individual processes. They reinforce­shortened. In some cases, they can only be measured throughall three pillars of sustainability: They are ecological in how

the use of digital technology, in particular the analysis ofthey balance different parameters to achieve an optimized

large volumes of data – what we call “big data”.

system; economical in how they use the natural principle ofresource efficiency and material cycles; and social in how theysafeguard basic human needs such as food, health andBiologic a l t r a n s fo rma ti o n a n d d i g i ta l i z a t i on determi ne eac h other. They c an be unders tood as conver ging

Nature is an integrally connected wholea nd m ut ua lly re i n fo rc i n g p ro c e s s e s wh i ch are trans formi ng human ac ti v i ty i n i ts c ore together w it h all

mobility. As such, the goals of biological transformation map
well onto Maslow’s hierarchy of needs.

a spe c t s of su s ta i n a b i l i ty. B i o l o g i c a l tra n sformati on i s us heri ng i n a new way of thi nki ng: c onne ct ivit y

In contrast to linear humans, nature organizes itself as an

inst e a d of lin e a ri ty ; o p ti m i z a ti o n i n s te a d of max i mi z ati on. I n s hort, i f bi ol ogi c al trans formati on and­integrated and connected system. It evens things out,

Advances in the life sciences and information technology­d igit a liz a t ion g o h a n d i n h a n d , th i s c re a tes a W hol e i n A ri s totl e’s s ens e of the term, whi c h i s more t hancorrecting imbalances through negative feedback, fault

over the past few years have enabled us to understand andt he sum of its p a rts .

­tolerances and hierarchically structured connectivity in­simulate complex processes in nature right down to the­intricate, overlapping control loops. One of the principles ofmolecular level and adapt them for human technology. Thisnature is multifunctional optimization, which means thathas given people brand-new tools to help them understandLinear thinking and the blinkered striving to maximize theof ­production and of consumption, which damages theorganisms or organs are always adapted, or optimized, totheir own actions, recognize the complexity of their activity inresults of human activity are endangering the ecosystems ofclimate, pollutes the air with harmful emissions such as carbon

multiple boundary conditions simultaneously. Accordingly,

its many different strands, and modify their behavior in ways

our planet. If we observe the global effects of human activity

dioxide, particulates, nitrous gases, etc., and leads to theeach of these physiological capacities remains below the

apt to optimize the overall system.

and how they impact on nature and the environment, it

pollution, overfishing and acidification of the world’s oceans.

maximum level in favor of a global optimum that ensures the

becomes clear that many fundamental problems – on scales

Palm oil plantations, biofuels, etc. lead to overexploitation ofsurvival capability of the whole organism and that of its

Dr. Oliver Schwarz

ranging from the supra-regional to the global – arethe world’s forests. Excessive livestock farming and meat

descendants.

Fraunhofer IPA, www.ipa.fraunhofer.de/en.html

man-made. By linear thinking and single-minded output

consumption also threaten our climate. Meanwhile, urban­optimization, humans have triggered massive climate changes

development and megacities go one step further, as they

Here we can see a major difference to technical solutions,that are threatening our very existence. Moreover, the rise of

consume non-renewable resources such as sand and metals,

which are maximized to attain a narrow, often time-limited

lifestyle diseases, the outbreak of epidemics, and global

pave over land surface and destroy ecosystems such as moors

main purpose – such as output – and which tend to ignore

species extinction are the result of linear instead ofand marshland.

all but a handful of dependencies. Partly, this is because

connected thinking.

­technical solutions are often developed on a monodisciplinary
If we look back over broad swaths of human history, we seebasis. Negative consequences tend to irrupt unexpectedly atthat linear thinking was mostly sufficient – the complexity wasdifferent times and places because parameters andmanageable. Supra-regional consequences were either rare or­dependencies were not taken into account. Repair attempts

not recognized as such – the impact of people on theiron the fly are also generally based on monocausal thinking,­environment was too small. That said, historians arewhich is not adequate for the requirements of joined-up­optimization, such as when farmers use monoculture to­continually finding examples to contradict this picture of the

problem management.

­maximize their yield and end up overexploiting and destroying

past. For example, when our ancestors killed off the hugefertile land. Biodiversity is shrinking dramatically, and drinking

herds of aurochs that once roamed our continent, forests

water is becoming scarcer because it is being taken fromgrew on what had been open pasture-land. Another example

non-renewable sources or else being contaminated withis when the Romans deforested the Mediterranean area,

nitrates. E­ xcessive livestock farming causes the emission of

causing supra-regional climate change. However, the impact

Like nature, biologically transformed systems are also

greenhouse gases, and virgin land is being broken forof human interventions today is greater by several orders of­characterized by connected material cycles instead of linearity­agricultural ­cultivation. Another example is the maximization

magnitude. Thanks to high-performance technology, the time

– and by optimization of the overall system instead ofSingle-minded optimization causes many problems
There are many examples of this blinkered focus on

24

Biological transformation means connectivity

25

ENHANCING THE VALUEOF CROPS FOR THE FARMER –ACTIVE SUBSTANCES FROM THE FIELD

Soil is becoming saltier, nitrogen compounds are accumulating in ground and surface water, and new

Overall concept with the three working levels

pests and diseases are lowering yields. In short, agriculture is facing a host of serious problems. If things
are to change, new ways of thinking are needed. Instead of relying on a few crops, the goal should be totake into account the regional conditions and grow the greatest possible variety of plants. If farmers
switch over to niche crops, that will benefit not only the environment, but their bank accounts, too.

Level 1
Prototypical decision
support system

FurthersourcesMarket datauses data

After all, various active ingredients can be extracted from such crops. Moreover, if farmers process the

GIS

Authorities

Farmers

integrates

plants on their property, they increase their product diversity and are much less vulnerable to market
Prototypical decision support system

fluctuations. Researchers at the Fraunhofer Institute for Molecular Biology and Applied Ecology IME areinvestigating which niche plants are suitable for which soils and what active ingredients can be extracted
from them.

Most crop fields in Germany are covered with maize, wheat

processing tasks such as drying, cleaning and extraction

or rapeseed – the “major crops” as they are known. To havedirectly on their premises. In this way, they increase theira sustainable bioeconomy, however, niche plants are also

product diversity and are less affected by market fluctuations.

important. As we move toward sustainability, we should

Furthermore, the variety of plants reduces the area for pests

therefore take a closer look at the conditions present on

and diseases to attack and ensures that farmers require lessparticular farmland and bring more variety back to these fields

pesticide and less mineral nitrogen as fertilizer.

Level 2
Optimal locations,in silico screening,recommendation for
extraction and use

Level 3
Recommendation
regarding varieties andlocation, pilot system forprimary processing

Activeingredientsfrom the land

Further, regional
value chains

Identification
AVA
OATS

Furthercandidates

in ways adapted to the specific conditions. The main focus ison plants that have been rather neglected in recent times.
Back to niche crops with Fraunhofer
Why niche crops?

Researchers at Fraunhofer IME are working on ways of

cosmetics or health? The researchers identify selected niche

important to bring the providers of different agricultural­evaluating landscape ecology site factors in detail. Are certain

crops with interesting ingredients, describe optimum

products in contact with the buyers, such as the various

But how can we convince farmers to switch over to nichesoils suitable for certain niche crops? What advantages and­cultivation conditions and regions, and reveal their potential

suppliers of processing technologies. If highly specialized

crops? Primarily, as is so often the case, through economic

disadvantages would there be in cultivating them? At the firstuses. Oats are a good example of such an “Active ingredientsprocessing companies are closely connected in a variety of

incentives. Technologies are currently being developed thatlevel, they want to provide land-specific data – regarding, forfrom the field” value chain. After all, oats are a traditional

ways with farming businesses that respond to their needs, thisrender all parts of the plant useful. For example, grain can be

example, the location or the infrastructure – and current

food and animal feed crop which you rarely see growing inwill greatly boost regional value creation. At the same time, aused as food for humans or as animal feed; active ingredientsmarket data. This data will then be analyzed and prepared infields any more. The focus is on so-called avenanthramides

closely interwoven network of different value chains is resilient

can be obtained from leaves, stalks and husks using moderna system designed specifically to support small and medium-(AVA), which can be obtained from oats. How do theagainst crises, because it permits flexible adaptations.

chemical analysis and in silico screening techniques (i.e.

sized farmers in their decision-making. Depending on thecultivation conditions affect the production ofcomputer analyses) to identify them; the residual materials cancultivation conditions and crop species, this will facilitate theavenanthramides (AVA) in various oat varieties? How can the

Dr. Kristina Bette, Prof. Christoph Schäfers

be used as energy sources; and the ashes produced can be

development of new regional cluster locations, whichplant-derived active ingredients be used in crop protection and

Fraunhofer IME, www.ime.fraunhofer.de/en.html

spread over fields as fertilizer. This is known in the sector ascomprise both dual production and processing and thepharmaceutics? These are just some of the questions that

dual or cascading use. New cultivation systems such as­valorization of food, energy and active ingredient crops.

Fraunhofer IME is interested in. In this way, the researchers arecontour and strip farming and adapted crop rotation are

At the second working level, the scientists will study thecontributing to the development of new regional production

designed to ensure that different plant species interact well

“Active ingredients from the field” value chain as an example.

lines – from the breeding objective to the sales market – andwith each other. For farmers this means they can increase theEssentially this will involve analyzing specific plant ingredients.

promoting oat cultivation with the very positive attendant

added value generated on their farms by carrying out primary

What effects do they have in terms of crop protection,consequences in terms of crop r­ otation. For this reason, it is26

27

FUNGI AS PRODUCERS – DETERGENTS
FROM THE FERMENTER

laboratory scale, improvements are still needed for industrial
production. There is scope for improvement in the yields thatcan be obtained from fermentation and also in the productcomposition of the biosurfactants. In addition, yeast fungi
produce interesting molecules, which can be used forT he P a r is C lima te A g re e me n t i s me a n t to put a c hec k on gl obal warmi ng. But how i s the v i rtua lly­synthesizing plastics such as polyesters. Chemically, however,­c a r bon- ne ut r a l e co n o my e n vi s i o n e d b y the agreement s uppos ed to work? The detai l s are s ti l l quit ethese molecules are difficult to manufacture. Fraunhofer IGB

v a gue , but on e th i n g i s cl e a r: I f we ca n produc e c hemi c al s out of renewabl e raw materi al s – that is,has already managed to establish a technique for theby biot e c hno l o g i ca l me a n s – th e n we wi l l hav e taken a bi g s tep toward c arbon neutral i ty. W hen w e­manufacture of dicarboxylic acids with the yeast Candida

bur n oil, w e re l e a s e th e C O 2 th a t h a d b een trapped i ns i de i t for mi l l i ons of y ears i nto the atmosphere –viswanathii, successfully producing octadecanoic dicarboxylic

som e t hing w h i c h d o e s n o t h a p p e n wi th renewabl e raw materi al s . There are no l i mi ts to product diver sit yacid out of oleic acid in commercially significant concentrations

w he n it c om e s to re n e wa b l e ra w m a te ri al s : M other N ature has an i nex haus ti bl e s tore of potent ial

by means of fermentation. To be able to manufacture

1 Cells of the smut fungus Ustilago maydis­p roduc t ion o rg a n i s ms . R e s e a rc h e rs a t th e F raunhofer I ns ti tute for I nterfac i al Engi neeri ng andbiobased chemicals such as the abovementioned surfactants,

at a single cell stage.

1

2­B iot e c hnolog y I G B i n ve s ti g a te th e b i o te chnol ogi c al manufac ture of bi os urfac tants , whi c h are usedfood components and plastics in sufficient quantities for use

2 Cellobiose lipids as needle-shaped crystalsa s ­d e t e r ge nt s , e mu l s i fi e rs , c o s me ti c a n d pharmac euti c al ac ti v e i ngredi ents , and pl ant protec ti o n agent s.

in the various sectors, manufacturing techniques have to be(with structural formula).

To t his e nd, th e y u s e fu n g i – m o re p re ci sel y, y eas ts , s muts and mol ds .

transferred to an industrial scale. At present, the worldwide
production volume of surfactants is around 18 million metrictons per year. Scaling up the processes from kilograms to tons
From the original idea to an application-ready technique

If you find a blue-green layer of mold covering your bread,fuel dilemma does not arise: we do not have to choose

involves a great deal of engineering and computing. How canfruit or some other food, you’ll quite rightly throw it in the

between using land for food or for raw materials to be

you find the perfect balance of mineral salt media? What are

garbage. After all, these fungi are harmful to your health. In

turned into chemicals or fuel.

the best feeding strategies? These questions can be answered

Fraunhofer IGB and Fraunhofer CBP are thus committed to

on a small scale at Fraunhofer IGB.

obtaining chemicals from the widest variety of fungi and to

the laboratories of Fraunhofer IGB in Stuttgart, however, theoptimizing and scaling the requisite processes. In achieving

researchers covet a wide variety of different fungi – including
molds (specifically molds in the genus Aspergillus), smuts

Manufacturing biosurfactants –­(Ustilaginomycotina) and of course yeasts. This is because thefrom renewable raw materials

fungi can be used to manufacture substances in athis objective, Fraunhofer IGB specializes in selecting and
Scaling up:­optimizing the micro-organisms, developing suitable

Fraunhofer pilot plant and biorefinery­conversion processes on a laboratory scale and transferring­carbon-­neutral manner – bringing implementation of the Paris

Smuts can be used to manufacture biosurfactants, which can­Agreement resolutions one step closer. And it is urgent thatbe used in turn to produce detergents, emulsifiers, cosmetic

Subsequently, these processes are implemented on a large

methods. Meanwhile, Fraunhofer CBP is responsible forwe do this, because we are still stuck in the starting blocks

and pharmaceutical active ingredients, and pesticides.

scale at facilities such as the Fraunhofer Center for Chemical­-­implementing production on a large scale. In other words:

when it comes to a carbon-neutral economy.

­Meanwhile, molds can be used to manufacture malic acid, theBiotechnological Processes CBP, where the pilot plant permits

Fraunhofer IGB and Fraunhofer CBP have all the capabilities

market for which is growing rapidly. Among other uses, it

upscaling up to a volume of ten cubic meters. Such hugerequired to take a good idea and create application-ready

Although fungi are just one of the possible ways of producing

gives products such as jams and juices their sour taste andvolumes of biobased chemicals require an enormous amounttechniques in the l­aboratory – which in turn generatechemicals on the basis of renewable raw materials, they are a

improves the shelf life of baked goods. It can also be used asof raw materials; after all, the fungi need something to feedenough of the required substance to manufacture productsvery promising avenue to pursue. A big advantage they offer

a building block for biobased polyesters. The production

on. This is where lignocellulose-based sugar solutions, which

for the market.

is that some fungi – unlike most micro-organisms – are able

process for biosurfactants and malic acid is similar to thealso contain the abovementioned xylose, come in. These

to break down sugar rings containing five-carbon rings.

brewing of beer. Micro-organisms are used to ferment sugars“wood sugars” are added to the growth medium,

Prof. Steffen Rupp, Dr. Susanne Zibek

As such, the fungus is able to utilize xylose, a majoror vegetable oils, transforming them in the process. Whenand can be obtained directly in the Fraunhofer CBP

Fraunhofer IGB, www.igb.fraunhofer.de/en.html­component of wood – and therefore a raw material thatmaking beer, it is yeasts that transform the malt sugar in thelignocellulose biorefinery.

www.cbp.fraunhofer.de/en.html

people do not use as food. Therefore, the food versus

barley. Although fermentation like this works very well on a28

these techniques to a pilot scale using mathematical-technical

29

COMBINING NATURE AND TECHNOLOGY –BIOLOGICAL-TECHNICAL INTERFACES

Where can neuroadaptive interfaces be used?
To date, neuroadaptive interfaces have been used primarily for

Biodegradable electronics for active implants

medical applications – for example, to communicate with
If w e w a nt t o c o mmu n i ca te fro m p e rs o n to pers on, we us e l anguage. But i f we want to c ommu nicat eseverely paralyzed patients. But they also hold great potential

Electronic components that completely dissolve

w it h t e c hnolo g i c a l d e vi ce s , we n e e d s u i t abl e i nterfac es . Before now, thi s has effec ti v el y meant t hat

outside the medical sphere. We could have driver assistanceonce they have completed their work? That may

t e c hnology h a s d e fi n e d th e wa y a n d h u m ans hav e adapted ac c ordi ngl y. Thi s i s s et to c hange i n t hesystems, for instance, that respond to the attentiveness, thesound like science fiction, but it has already been

f ut ure , w he n m a c h i n e s a n d d e v i ce s wi l l l ear n to res pond to the mental s tates of thei r us ers .

mental exertion and the alertness of the driver. Or we could

accomplished in the laboratory. It goes by the

W ha t a re t he p re fe re n c e s a n d i n te n ti o n s of the us er? A re they i rri tated or ev en out of thei r dept h?

have personalized assistance systems for smart living thatname of biodegradable electronics, and it not

N e uroa da pt iv e i n te rfa c e s a re a b l e to re cord thes e s tates us i ng neurophy s i ol ogi c al s ens ors . Res earcher swould adapt contents as well as display and interaction

only ­reduces ecological footprints, but also opensa t t he F­ r a unh o fe r I n s ti tu te fo r I n d u s tri a l Engi neeri ng I A O are worki ng on way s of us i ng thes e int er f aces

­mechanisms to individual needs. Another technology thatthe door to innovative applications in a variety of

t o re nde r t e c h n o l o g y s e n s i ti ve to u s e r n eeds .

would enter the realms of possibility is collaborative robots,­sectors, such as medical implants, biotechnology

which would respond sensitively to user intentions, emotions

and the food industry. In Fraunhofer’s in-houseand attentiveness.

“bioElektron” project, researchers at the

When the sun peeps out from behind the clouds and makes it

peripheral muscle tension and eye movement. If the­Fraunhofer Institutes FEP, ENAS, IBMT, ISC and thesuddenly brighter, modern computer screens adjust their­technology recognizes people’s mental states in this direct

Project Group for Materials Recycling and Resource

brightness automatically. Park assist systems warn drivers if

manner, it can adjust more precisely to them – without thethey get too close to an obstacle while maneuvering into aneed for additional interaction effort on the part of the user.

Fraunhofer at the cutting edge of research

Strategies at Fraunhofer ISC are developing
important components for these electronic

space. And in manufacturing environments, industrial robots

As a research field, neuroadaptive interfaces is still in its

implants that will be able to biodegrade in thework together side by side. As the examples above attest,

infancy. Interdisciplinary cooperation is required if applied

body in the future. These include conductor paths,

research is to advance and if the results are to be transferred

electrode contacts for electrical signal derivation or

to scientific practice. Researchers at Fraunhofer IAO arestimulation, thin-film transistors and circuits, barrier

technical systems are already able to recognize various

Solution: Developing neuroadaptive interfaces­environmental conditions, adapt to different situations and –increasingly as technology advances – operate flexibly and

Neurotechnological interfaces make this possible. Based on

working on freeing the recorded data from interference andcoatings to keep out water and gas, and electricalautonomously. This is not enough, however, if we want smart­activation patterns in the brain or the dynamics of eye

motion artifacts and classifying the states of the user

isolation layers – all biodegradable.

technology to interact with people in an optimal manner that­movements or of excitations in the peripheral cardiovascular­continuously and without time lags. How can the systemyields maximum benefits – it needs to go beyond recording

system, the interfaces make inferences about mental andbehavior – that is, the response of the technical system to theenvironmental conditions to also register the preferences andemotional states. This creates a new field of research:detected user states – be shaped and controlled? This is also

intentions of the user. People will only perceive technology as­neuroadaptive human-machine interfaces that work in asomething that Fraunhofer IAO scientists are researching.

cooperative and “human-friendly” – and accept it as an

human-technology control loop, recording neurophysiologicalBecause if neuroadaptive interfaces are used in the non-­­assistant or even as a partner – when it is sensitive anddata in real time, interpreting the user’s states from it, andmedical sphere, they must be systematically aligned with the­intuitive and responds promptly to their needs. What thisadapting the system’s behavior accordingly. But how do weneeds and ethical values of their users and of society.

means is that the technology should continuously recognize

obtain the requisite data? Brain-computer interfaces (BCIs) are aand take into account mental states, such as the emotions,particularly p­ romising approach, while electroencephalography

Dr. Mathias Vukelić

changes in attentiveness levels, stress and cognitive exertion of(EEG) is a useful measurement technique that directly records

Fraunhofer IAO, www.iao.fraunhofer.de/en

the user. Wherever possible it should register this informationthe ­electrical activity of synchronized neuron populations in theright at the source – namely, the brain.

cortex. Another option is functional near-infrared spectroscopy

Failing that, it should measure the states where they manifest(fNIRS), an optical technique that measures m­ etabolic processes

themselves with the greatest intensity, such as heart activity,

which are related to these neural patterns (EEG).

30

31

ALGAE VERSATILITY IS THE KEY TO
SUSTAINABLE CHEMICAL PRODUCTION

1Microalgae are unique: Basically, all they need is sun, water and carbon dioxide to grow and generate

Process chain for obtaining food ingredients from algae

biomass. The one-cell organisms use sunlight more efficiently than flowers, trees and grasses. These
qualities make algae perfect for producing biobased materials. It is no wonder, then, that they are
currently conquering new, growing markets – for example in the food and pharma industries.

People and many animals can go without food for days andStrain selection

Production

Cell disruption

Cascade extraction

55 % proteins

Process development in laboratory

Mechanical cell
disruption

Scale outdoors

High-pressure
homogenizer

Pressurized
liquidextraction(PLE)

Products

Microalgae have got what it takes

even weeks, provided that they have enough water. In thelong term, however, no living creature can survive without

We should note, however, that microalgae are by no means all

food. It is a similar story in the plant kingdom: trees, flowers

alike. It is estimated that there are more than 100,000 species

and grasses need light and soil with nutrients in order to growof algae, which offer great potential as sources of various

and thrive. But microalgae are different. They build up biomass

substances such as carotenoids, phytosterols and beta-glucans.

in freshwater or seawater out of sun, water, carbon dioxide

These ingredients appear in concentrations about ten times

and anorganic nutrients, making them very interesting as ahigher than in land plants. The composition of algae biomass

biomass source.

can be controlled by means of targeted cultivation conditions.

5 % omega-3 fatty
acid EPA> 3 % carotenoids

Extraction
using supercritical fluids(SCF)

Fucoxanthin
EPA
Biomass withproteins

Stirred media mill

One thing that all microalgae have in common is that they
contain a lot of proteins – more than 60 percent of their dry
Microalgae as a new raw materials source

weight in fact. Depending on culture conditions, however,lipids can also account for up to 60 percent of the cell dry

developed a photobioreactor for algae production in theand transferred them to outdoor production. Success was not

The frugal nature of microalgae is far from the only advantage

weight. If the conditions are set in such a way that algae­laboratory and outdoors, which was subsequently

long in coming: The concentrations of the omega-3 fatty acidthey have to offer. They only need little input to give good

growth is only moderate, many of them also produce oil or­commercialized by Subitec GmbH, a spin-off of Fraunhofer IGB.

EPA and the carotenoid fucoxanthin were the highest yet

biomass yields: microalgae produce up to five times morecarbohydrates as reserves. Other valuable substances such as

There are some substances that algae only develop whenpublished for a long-term production operation. In this way,

biomass than land plants per area and time. In addition, theyvitamins and long-chain polyunsaturated fatty acids can also

­nutrients are scarce. The best-known examples of this are fats

it is possible to produce naturally occurring carotenoids,

do not need fields and pastures in order to grow – marine

be extracted from the algae. Among other applications, theand polysaccharides, and also carotenoids such as beta-­

omega-3 fatty acids, proteins and other healthy ingredients in

microalgae, for example, thrive in seawater, as their namefatty acids are used for health and nutrition or as colorants.

carotene. Nutrient limitation is carried out by the researchers at

a targeted process. These natural extracts will then command

Fraunhofer IGB in a second production stage. This two-stage

substantially higher prices on the market than theircultivation presents particular challenges, as both stages have to­synthetically manufactured equivalents.

indicates. Moreover, their harvests are not tied to specificseasons, so they can be cultivated all year round. They arehomogeneous – in other words, every cell is identical and not

Using algae to produce valuable

be optimized and adapted to each other. In a third stage, thedifferentiated according to leaf, stem and root – and free fromsubstances in photobioreactors

researchers process the biomass to achieve defined qualities

Dr. Ursula Schließmann, Dr. Ulrike Schmid-Staiger

according to the substances that are to be extracted from it.

Fraunhofer IGB, www.igb.fraunhofer.de/en.html

lignocellulose. As lignocellulose content entails higher energy
input for biomass decomposition and processing, this means

None of this is particularly easy, however, as algae need special

that microalgae are easier to extract. A further advantage is

production conditions. Effectively this means closedthat exhaust gases containing carbon dioxide can be used for­photobioreactors. The limiting factor here is light. If the algae

their cultivation.

cultures are dense, they cast shadows over each other.

32

Customized algae production on an industrial scale­Consequently, the algae have to be efficiently mixed in a

To be able to commercially exploit the wide spectrum of algal

1 Outdoor facility attargeted manner, so that all of them get some of the light on

ingredients, we need customized algae production with highFraunhofer CBP for microalgae

the reactor surface. To this end, researchers at the Fraunhofer

process stability on an industrial scale. For this purpose,

production with 180 L-FPA

Institute for ­Interfacial Engineering and Biotechnology IGB­Fraunhofer IGB has developed processes in the laboratory

reactors.

33

GREATER FOOD SECURITY,­BETTER HEALTH WITHRENEWABLES
Tasty foods made of plant or aquaculture proteins are efficient and eco-friendly. Nature’s tools
are opening a window to a whole new world of opportunities, including high-tech medical­applications. The push to make sustainable products for new markets is on.

34

35

HIGH-TECH SILK – OUT OF THE LAB
AND INTO MEDICAL APPLICATIONS

Man-made lacewing silkare equipped with functional groups so that just one of thetwo mirror images can pass through the channel. The

Attempts to manufacture the silk proteins of the green­application potential for these membranes is vast. With more­lacewing in sufficient quantity and purity are yet to succeed.

than half of today’s active pharmaceutical ingredients madeThe researchers at Fraunhofer IAP aim to change that. In a

up of these mirror-image twins, there is a lot of purification

joint research project with AMSilk GmbH, they haveto be done

conscripted bacteria in an attempt to produce large quantities
T he gossa m e r s tra n d s o f a s p i d e r’s we b m ay l ook fragi l e, but appearanc es dec ei v e. O n a s c al edof green lacewing silk proteins in a biotechnological process.

Prof. Alexander Böker­c om pa r ison, th e s e fi b e rs a re s tro n g e r th an s teel c abl es , y et more el as ti c than ny l on. Si l k produced by

The University of Bayreuth’s Department of Biomaterials did

Fraunhofer IAP, www.iap.fraunhofer.det he la c e w ing a l s o e x h i b i ts s u p e rl a ti v e p roperti es , parti c ul arl y i ts tremendous fl ex ural s trength. The

the molecular groundwork, constructing a gene sequence thatindust r y ha s ta k e n a s h i n e to th e s e n e w materi al s , for ex ampl e, l i ghtwei ght pol y mers for us e i nempowers bacteria to produce the silk protein. Fraunhofer IAP­t r a nspor t a t io n a n d b i o c o mp a ti b l e s i l k coati ngs for medi c al i mpl ants . H av i ng di s c ov ered the s i l k prot ein

is fine-tuning the manufacturing process with an eye toof t he gre e n l a ce wi n g a s a s o u rce fo r a new ty pe of bi ofi ber, res earc hers at the F raunhofer I ns t it ut e f or

producing this silk protein at low cost in industrial quantities.

A pplie d P oly m e r R e s e a rc h I AP a re n o w s eeki ng to mas s manufac ture thi s bi otec h i n the l ab. A dedicat ed

With the benefit of biotech and polymer research capabilities

re se a rc h unit d e p a rtm e n t s e t u p b y F ra u nhofer I A P two y ears ago i s al s o i nv es ti gati ng other prot eins,housed under the same roof, Fraunhofer IAP has the assets

som e of w hic h c o u l d s e rv e a s fi l te rs to separate c hi ral materi al s .

needed to produce lacewing silk fibers. This includes a pilot
wet and melt spinning plant that can process both
solutions and molten material to deliver technical fibers
on a ­near-­industrial scale.

The silk spun by spiders is a fascinating material. Its fibers are

Silk for high-performance fibers and films

more elastic than nylon, yet sturdier than steel cables,
Membranes to separate mirror-image molecules­relatively speaking. They can absorb three times more energy

It is no great surprise, then, that these fine protein fibers alsothan synthetic Kevlar fibers before a strand tears. This

harbor great promise for industrial applications. Spider silk­remarkable tensile strength is attributable to the material’s

could be made to serve many medical purposes, for example,

The researchers at Fraunhofer IAP are not only interested inprotein structures. Other silks also exhibit outstanding

for bandages, surgical sutures, and cartilage and tendon

spider silk; they are also investigating other proteins. Amino­properties. People have been tapping the cocoons of theimplants. Other potential applications include cosmetics,

acids, the building blocks of proteins, and other small

mulberry silk moth, a yellowish grey nocturnal butterfly, forpaper products and adhesives. The rigid fibers of green­molecules often present as chiral combinations.

5000 years. This silk still figures prominently in high-­­lacewing silk would seem an excellent prospect for lightweightThis means that the variants consist of the same atoms,

performance materials such as parachute canopies. The

designs, where they could replace the glass fibers in composite

arranged differently in a mirror image that does not exhibit the­enormous tensile and flexural strength of the lacewing’s silk is­materials. This would certainly simplify recycling. Whilesame chemical properties as its chiral twin. For example, theno less impressive. It has to be strong by nature, as green

conventional glass fiber composites leave glass fiber residue

two variants may not have the same fragrance. Separating­lacewings deposit their eggs on the underside of leaves,when incinerated, products made with rigid lacewing silkthese mirror-image twins is a technically demanding task, andperching their offspring on the tip of silk filaments to keep

proteins can be composted or incinerated in a CO2-neutral

quite expensive, depending on the substance. Fraunhofer IAP

them safe from ground-borne predators. These eggs stalks

way that leaves no residue.

and RWTH Aachen University teamed up to develop a new

are only 15 micrometers thick, yet they easily hold thebreed of membrane that can readily separate theseoffspring’s weight.

­combinations by filtration. To this end, the researchers slotted
natural protein channels that are just three to four nanometers
wide into the ultra-thin polymer membranes. These channels

36

37

1

ALL FLAVOR, NO REMORSE – SUSTAINABLEYET SCRUMPTIOUS VEGETABLE PROTEIN

Cutlets and roasts made of plant fibers

sell animal products. Potential bottlenecks in the commodities
supply line and rising prices for animal foodstuffs pose major

Researchers are striving to develop succulent vegetarianrisks for this industry. New business prospects will emerge for­alternatives that are tasty, juicy and chewy in a way thatthe industry as companies begin to embrace innovative

mimics the texture of meat. Fraunhofer IVV is devising and­products made of plant proteins. Recent studies show thatcharacterizing protein-rich recipes and investigating theirvegan products are going mainstream. Multinationals

behavior in the production process. This is done with a special­dominate this market. If the research efforts outlined above

Our pla ne t ’s p o p u l a ti o n i s o n th e ri s e . T h ere are 7.5 bi l l i on of us today and the forec as t c al l s for t he

extrusion process that allows ingredients to be mixed, kneaded

enable small and medium-sized enterprises in Germany tohe a dc ount t o re a ch 9 .7 b i l l i o n b y 2 0 5 0 . O ne of the great c hal l enges of our age i s to prov i de s a f e,

and rapidly heated under pressure all at once, and then cooled

offer tasty vegan products, these companies could grow their­h igh- qua lit y f o o d to a l l th e s e p e o p l e when res ourc es s uc h as arabl e l and, water and ferti l i z ers are f init e.

in a special nozzle. When the source material is fairly dry, thismarket shares at home and abroad and increase their

Me a t , e ggs, m i l k a n d fi s h s ti l l fi g u re p ro mi nentl y i n today ’s di et, but s us tai nabl e pl ant-bas ed ­a lt er nat ives

produces granules that serve as the base material for foods­competitive edge.

w ill soon be v e ry mu c h i n d e ma n d . M e a t produc ti on i s hardl y effi c i ent, gi v en the v as t quanti ti es ofmuch like minced meat. When source materials containing anut r ie nt s c on s u me d a l o n g th e wa y. I n the i nteres ts of gl obal food s ec uri ty, we wi l l hav e to fi nd

lot of water are boiled and then slowly cooled, this produces

Dr. Peter Eisner­p rot e in- r ic h, n u tri ti o u s fo o d s th a t a re ta s ty al ter nati v es to meat. That i s ex ac tl y what res earc her s at

fibrous protein structures with a meat-like grain and

Fraunhofer IVV, www.iw.fraunhofer.det he ­F r a unhofe r I n s ti tu te fo r P ro c e s s E n g i neeri ng and Pac kagi ng I VV are s tri v i ng to do.

­consistency. This protein may then be processed into productswith the familiar texture of cutlets, roasts and steaks.

Lupin proteins and fibers for vegan cold cuts
These days, when people fire up the barbecue on a hot

Even so, meat-lovers’ fears of a vegan food police aresummer’s day, many also treat vegetarian or vegan family

unfounded; no one will be inspecting barbecues for illicit

Fraunhofer IVV joined forces with ten companies and threemembers and friends to a selection of vegetables. Even so,

non-veggie sausages any time soon. However, meatother research institutes in the PlantsProFood alliance toa lawn party without barbecued beef or Christmas dinner­consumption would have to be halved from the current

produce food ingredients from the seeds of native blue lupin

without roast turkey is unthinkable for many of us. That will

88 kilograms per capita per year to at least hold Germany’sbeans. Their benefits are many: Lupin fibers and proteins’

have to change eventually. Livestock has to eat three to ten

total annual meat production to the current level. That is not

flavor is neutral, they exhibit very good functional properties,

kilograms of vegetable feed such as cereals or soya to produce

going to happen without a tasty plant-based alternative.

and they are nutritious. And that makes them an excellent

one kilogram of animal protein. Consuming meat is anything

Consumers snubbed meat alternatives such as tofu mainlybase material for vegan cold cuts and spreads. With this in

but eco-friendly. Animal husbandry requires a great deal of

because of the products’ texture. To change that, scientists

mind, the researchers set out to develop a suitable extraction

water, energy and arable land, and livestock’s digestive

must come up with quality plant-based alternatives with theprocess and recipes. Their efforts met with success: The

systems produce a lot of greenhouse gases that end up in the

fibrous consistency of meat.

­manufactured products look and feel like the real thing, andatmosphere. More than 60 percent of the vegetables, cereals

they spread and cut well. Even their color is very much likeand the like cultivated in fields end up in feed troughs for thethat of conventional products.

livestock reared to satisfy humankind’s big appetite for meat.
A growing population and rising prosperity is driving theconsumption of meat, eggs, milk and fish; the Food andWhat’s in it for the industry?

­Agriculture Organization FAO of the United Nations (FAO)
expects it to increase 70 percent by 2050. It does not take a

The food industry is the most important sector of Europe’s

degree in higher math to figure that this rate of consumption

manufacturing business; around 40 percent of revenues inis unsustainable.

Germany are generated by businesses that make, process and38

1 An extruder at Fraunhofer IVV.

39

A MEDICAL (R)EVOLUTION –BIOLOGICAL THERAPIES AND IMPLANTS

1

Change is afoot in the world of commerce; principles of nature are making inroads into humankind’s

brought on by cancer. These active substances could also

Designing ecological processes tofactories. A term has been coined to describe this ingress driven by advances in life sciences, andsignificantly reduce the use of antibiotics in factory farming.

make biological products­e specially in biotech – biologization. This word covers quite a lot of ground. Biological processes that takeEver since the Industrial Revolution mechanized manufacturing,place in cells and tissues of natural organisms help scientists develop unprecedented medical therapies.
And artificial neural networks could help improve manufacturing processes.

Artificial neural networks inspired bypeople have been extracting more and more products fromthe nervous system’s connectivity

ecosystems every year. Human interference has thrown off thebiological balance. If we want to redress these imbalances,

Biological models can also teach us a lot about networks.

we must first understand biological systems and then simulate

After all, the neurons in our nervous system do not fire attheir material cycles and causal chains in modern

Like humans who have evolved and adapted over time,

vessels alive and allow organs to be grown outside the body.

random; they are connected to serve a specific purpose. It­manufacturing.

biological systems have also been subjected to nature’s efforts

The human immune system not only protects us fromis due to that connectivity that scientists call this a neuralThis is exactly what the land-based Integrated Multi-Trophic

towards perfection for millions of years. Although we believe­infections; it also inhibits the proliferation of cancer cells.

network. Researchers engaged in computer science,

Aquaculture (IMTA) system developed by researchers at thewe understand some of the basic principles at work here, theMultinational pharmaceuticals and biotech companies haveinformation technology and robotics replicate these structures

Fraunhofer EMB is here to do. An IMTA replicates various

very complex processes that optimize biological systems suchtasked the Fraunhofer Institute for Cell Therapy andin ­artificial neural networks, sometimes in modified forms.

levels of the ecosystem to simultaneously cultivate fish,

as the human brain or highly selective immune systems are­Immunology IZI in Leipzig to develop clinical trial preparations

These neural networks can serve many applications. One

mussels, algae and the like. This has multiple benefits. The

difficult to fathom. If we were to harness the power of suchfor new cell therapies. These treatments reinforce and control

example from the Fraunhofer Institute for Production

water is reused several times; biological waste is repurposed as

evolutionary processes, we could put it to good use forthe healthy immune system’s natural activation strategies inTechnology IPT is milling. Milling machines often direct all theira food source. And the aqua-farmer can bring several products

medical applications, as the following Fraunhofer researchvery specific ways. Genetically engineered receptors areenergy to a short stretch of the blade, where it then wears

to market at once to further boost these recirculation systems’case studies go to show.

inserted into the patient’s immune cells to this end. Thesevery fast. Researchers engaged in the OptiWear project

efficiency.

antigen receptors detect the surface characteristics of cancer

developed an artificial neural network to analyze the sections

cells. When the altered immune cells are injected back intoof the blade expected to endure particularly high levels ofProf. Frank EmmrichRegenerative medicine:the patient’s body, they destroy the mutated cancer cells very

wear. The network learns to precisely predict tool wear

Fraunhofer IZI, www.izi.fraunhofer.de

From wound healing to herbal medicine

effectively. Researchers at the Fraunhofer Institute for Marine

during milling; it then adjusts the blade’s path to distribute

Biotechnology and Cell Technology EMB are devoting their

the wear over a large area of the cutting edge. In the field ofProf. Charli Kruse

Researchers are pursuing remarkably diverse avenues toefforts to yet another field, wound healing.

computational neurosciences, neural networks like this are

Fraunhofer EMB, www.emb.fraunhofer.dedevelop new therapies. Some are technical, such as

They have developed an outpatient procedure to retrieve

used to gain deeper insight into the human brain and develop­unprecedented radiation therapies. Others are mechanical, likestem cells from the sweat glands of patients. When thesebetter medical treatment options. The Federal Ministry ofultra advanced prostheses for joints and extremities. Still

stem cells are applied to the wound, they form skin cells that

Education and Research (BMBF) set up the Bernstein Network

others are biological; these new procedures are based on

manage the healing process. The patient’s body does notas part of the g­ overnment’s high-tech strategy; it now

biological ­functions executed in the cells and tissues of naturalreject its own cells when they are reintroduced. How doencompasses over 200 working groups at more thanorganisms. Recent methodological breakthroughs in gene andplant-derived agents affect human health and the clinical

25 locations throughout Germany. The former Fraunhofer

cell therapy and tissue engineering have given rise to these

expression of diseases? Healers have been seeking answers toInstitute for Computer ­Architecture and Software Technology

advanced therapies. The term regenerative medicine has been

this question for centuries. There is a treasure-trove of

FIRST was one of the working groups looking into intelligentcoined to describe the intended goal, which is to restore­knowledge out there, but the nuggets of wisdom aredata analysis; the Neurolab at the Fraunhofer Institute forhealthy functions with biological means. One variant is to­scattered far and wide. Much has yet to be investigated byIndustrial Engineering IAO was also involved. Scientists at the

deploy enzymes to strip an organ of its cells while preserving

scientists. A research group at Fraunhofer IZI teamed up with

Neurolab deal are seeking answers to questions such as: Are

its structure so it can be colonized with the patient’s bodyscientists from the Makerere University in Uganda tousers comfortable with or stressed out by technology? Howcells. Experienced biologists at the Fraunhofer Institute for­investigate extracts from East African plants used byhigh is the cognitive load at the workplace? What can we do

1 Charting neurophysiological

Chemical Technology ICT are taking this approach to keep

­traditional healers, for example, to treat the emaciation

to design tech that creates a positive user experience?

data.

40

41

LOCAL, SMART, URBAN –THE FUTURE OF FOOD PRODUCTION

A pple s f rom Ne w Z e a l a n d , to ma to e s fro m Spai n – we hav e the gl obal di v i s i on of l abor to thank f or our

researchers are jointly developing an inFarming® prototype

f re sh- f ood su p p l y c h a i n . H o we v e r, th e a mount of arabl e l and that c an be managed s us tai nabl y is f init ewith their US partner BrightFarm Systems at the Fraunhofer

on t his pla ne t, a n d i t i s i n p a rti cu l a rl y s hort s uppl y ami d the urban s prawl near megac i ti es . This is w hy

inHaus Center in Duisburg.

ur ba n a gr ic ul tu re i s l i fti n g o ff i n to th e t hi rd di mens i on wi th v erti c al farmi ng i n mul ti -s tory bui ldings.

The first application center for building-integrated inFarming®

On t he r ise in u rb a n s e tti n g s a ro u n d th e worl d, v erti c al farms are an attempt to us e energy andhorticulture is going up now in Oberhausen with around 1200

re sourc e s m o re e ffi c i e n tl y, fo r e x a m p l e , by maki ng the mos t of materi al c y c l es . A c ti v e pharmaceut ical

square meters space.

ingre die nt s so u rce d fro m p l a n ts ma y a l s o bec ome a v erti c al s uc c es s s tory. F raunhofer res earc he r s are
Prof. Görge Deerberg, Hans-Jürgen Körner

c e r t a inly w or k i n g o n s o l u ti o n s to ma k e t hat happen.

Fraunhofer UMSICHT, www.umsicht.fraunhofer.de
Downtown vegetable farming? Many people are warming to

There is plenty of room for urban farms. The space available

Dr. Johannes Buyel, Andreas Reimann

the idea of growing vegetables and herbs sold in theon the flat roofs of Germany’s non-residential buildings alone

Fraunhofer IME, www.ime.fraunhofer.de­supermarket on the roofs or facades of neighboring officecomes to more than a trillion square meters. About a third ofbuildings rather than trucking or shipping them in from afar.

it can be used to cultivate plants in rooftop greenhouses. This

Ideally, these foods will be harvested in the morning to be

could bind around 3.5 million metric tons or carbon a year,

offered fresh off the shelves with the flavors and vitamins

which is roughly ten percent of the CO2 emitted annually byintact and the transportation costs negligible.

industrial enterprises in Germany. It all sounds very simple on

Next-generation vertical farming at Fraunhofer IME

paper, but urban agriculture’s production speed, costs andassessing horticultural methods. This new vertical
farming system at Fraunhofer IME will enable researchers

scalability will have to be optimized for maximum economic

What will it take to make vertical farming work? Experts

to evaluate and develop innovative, sustainableefficiency. One intriguing way of doing this is to grow plantsfrom the Fraunhofer Institute for Molecular Biology andconcepts under real-world c­ onditions to make aand make high-quality products with their pharmaceutically

Applied Ecology IME teamed up with their counterparts

valuable ­contribution to t­ omorrow’s organic-­

With time, the importance of locally sourced food will rise. ­active ingredients, as this creates a lot more value per squareat the Fraunhofer Institute for Production Technology IPT

based production economy.

On one hand, the world’s population is growing; experts fear

meter of cultivated area.

to answer this question. An automated plant production

Vegetable farming in the city, for the citythat a food shortage could occur as early as 2050. On thesystem with a central vertical farming unit is serving asother, customers are increasingly demanding local products.

their high-tech test field.

But there is not enough arable land in and around

Urban farming:

This vertical farming unit consists of eight levels with an­metropolitan regions and megacities to meet today’s demand

Fraunhofer UMSICHT’s inFarming® concept

effective cultivation area of some 550 square meters.
It yields up to 100 kilos of plant biomass or up tofor local fruit, vegetables and cereals. If we want tomorrow’s
food supply chain to be sustainable we will have to adopt

Researchers at the Fraunhofer Institute for Environmental,

10,000 plants per week depending on the species andmore innovative farming systems. Urban farming, where

Safety and Energy Technology UMSICHT are busy developing­production mode. An automated logistics system is in­vegetables are cultivated in rooftop greenhouses, is one

the inFarming® concept, a set of building-integrated

place to sow, cultivate and harvest plants continuously

approach; vertical farming, where vertical plants and­agricultural methods, and are optimizing the technologies andor in batches. Active ingredients may be extracted from­vegetables grow on facades or over several floors, is another.

farming methods needed to do this. This concept calls for a

the plant material and fed into two 100-liter

Both are hot topics in many countries. Everything plants needvegetable greenhouse to be built on the flat roof of a­homogenizers for purification. Integrated scanners fromto grow – light, water, heat and nutrients – is available in­five-story office building. Moss will cover the entire facade to

the Fraunhofer Institute for Integrated Circuits IIS

1 Cultivation of tobacco plants.

urban areas. The savings potential is considerable, especiallybind particulate matter. This system uses and treats water inmonitor various parameters throughout the plant’s

2 Winter wheat in the vertical farming prototype underwith smart systems that link (residual) material and energy

closed cycles. It taps waste as a source of nutrients or for­lifecycle to track how they grow and flourish, providing

LED lighting in a plant growth chamber.

flows with the building’s ­infrastructure.

energy to light and heat the greenhouse. UMSICHT

the information needed for assuring quality and

42

1

2

43

CELLS AND STEEL –AUTOMATED CELL PRODUCTION

requires many people and costs a lot of money. Attempts toadopt automation technologies and processes from consumer
product manufacturing failed because humans are moresophisticated than machines by nature. These manufacturing
plants are far less efficient than lab staff. It will take a different

In t he pha r m a ce u ti c a l i n d u s try, i n b i o te c h s tartups , i n hos pi tal s - wherev er medi c al res earc hers are

breed of autonomous system to do this job; a learning system

st r iv ing t o de ve l o p a n d o b ta i n a p p ro va l for new drugs , they need model s y s tems to prov i de meaningf ulthat is able to acquire and tap an experienced scientist or

da t a . Inf or m a ti o n s o u rce d fro m a n i ma l tri al s are of l i mi ted v al ue and therefore l es s s ui tabl e fo r

­technician’s implicit knowledge to make context-based­e la bor a t e de v e l o p me n t p ro j e c ts . S o ci e ty wants fewer ani mal ex peri ments ; pol i c y makers hav e p ledged

predictive decisions.

t o c ur b t he se tri a l s . I t wo u l d a p p e a r th a t pati ent-s pec i fi c c el l s – or more ac c uratel y, prec i s i on-induced
plur ipot e nt s te m c e l l s – wi l l p l a y a l a rg e rol e i n the future of medi c al res earc h. A s i t s tands no w,
t hough, sc ie n ti s ts l a c k th e te ch n e e d e d to automate c el l propagati on. The F raunhofer I ns ti tute f orStrides towards automation

Biom e dic a l E n g i n e e ri n g I B M T i s l o o k i n g to c hange that.
Researchers at Fraunhofer IBMT have developed the­technologies required for these autonomous systems. Their
A new drug has to pass a battery of approval tests before it

patient’s skin, for example. Introducing specific genetic factors

predecessors were as big as entire rooms and could only

earns a rightful place on pharmacy shelves. Does it produce

into these cells conjures something akin to a miracle: These

execute tasks sequentially. Fraunhofer researchers shrunk thethe intended effect? And most importantly, is it safe for

specialized cells acquire abilities that nature has reserved for

footprint and added smarts with a system that is small, parallelpatients? Researchers tasked to answer questions like thesecells from an embryo – they can divide indefinitely andand redundant. Scientists recruited stem cells that adhere welland bring medicines to market need model systems on whichdevelop into any type of cell found in the human body. They

to certain bioactive materials to create conditions like those in

to test drugs. The long-term objective here is to tailor

may even be endowed with the properties that cells would

the human body. This also marks the first time microscopes­therapies as precisely as possible to the patient and to be

exhibit in various clinical expressions. The pharmaceutical

can automatically identify simple processes such as dividing

able to track the course of this personalized therapy.

industry has found this type of cell type to be an excellent

cells and beating cardiac muscle cells.

vehicle for testing active ingredients in their R&D activities.

In their next step, the researchers aim to integrate artificial

The ethics of animal experiments are controversial; the value

intelligence (AI) enabled by artificial neural networks. Theseof the information they provide is limited. They are also
­expensive. The push to bring down the number of animal trials

technologies are readily available, but not the lessons andA bio-economic bottleneck

is on for all these reasons. Cell systems like those used in labs

examples AI needs to learn before it can serve to help produce
human cells. An autonomous cell production system needs

are ineffectual in personalized therapies. These cells are altered

The European Commission and the European Federation ofthis information like a self-driving car needs archived maps

in the lab to extend their longevity so they can grow in

Pharmaceutical Industries (EFPIA) has launched two majorand driving situations – without data to guide them, thesecultures for prolonged periods – experts call thisprograms – StemBANCC and European Bank for induced

machines are going nowhere. It will take a joint effort to ­­immortalization. The problem is that once cells are

pluripotent Stem Cells (EBiSC) to make this cell sourcegen­er­ ate this data. And Fraunhofer IBMT has started­immortalized they no longer behave like the bodily cells.

­available for biomedical research. These programs provide thedoing its part.

infrastructure for producing and distributing stem cells.
Patient-specific cells – that is, human induced pluripotent stem

However, labs have to produce many lines of stem cells in

Prof. Heiko Zimmermann

cells – would appear to be a far more promising alternative.

sufficient quantities to meet industrial needs, and convert

Fraunhofer IBMT, www.ibmt.fraunhofer.de

Stem cells can become any type of cell in an organism.

them into the required target cells such as cardiac muscle cells.

­Pluripotent stem cells are produced by removing highly

And these cells must reliably perform their natural function in

specialized adult cells with very specific functions from thea technical environment. This work is done by hand, which

44

45

AQUACULTURE – ANOTHER PIECE IN THE
SUSTAINABLE FOOD PRODUCTION PUZZLE

Cells as a biological commodity

Cyclic process control

Cells figure most prominently in biological

Step 1: Preparation

Step 2: Encapsulation­transformation. They are the key building blocks ofPrepare cells (top) and theTransfer cell suspension

many biotechnological processes, molecular-biologicalmedium + cross-linking agent

with a dropper to form

F ish f a r m ing i s g o i n g s wi mmi n g l y. Fo re c as ts s ugges t that the v ol ume of fi s h produc ed worl dwi d e w ill

diagnostic procedures, and cell therapies. And they are(stirred tank bioreactor)

capsule carriers

m ult iply ne a r l y 2 0 -fo l d fro m 4 .6 mi l l i o n metri c tons i n 1980 to 73.8 mi l l i on i n 2020. A nd the fact is t hata renewable resource. Researchers at Fraunhofer EMB

t he f a r m e d f i s h h a rve s t a l re a d y e xc e e d s the gl obal wi l d c atc h, as s tudi es hav e c onfi rmed. The p ot ent ial

have developed a universal platform technology forf or sust a ina b l e g ro wth , h o we ve r, i s l i m i ted: fi s h farms need hi gh-qual i ty water, fi s h s eeds , feed andpropagating adherently growing cells. More than

he a lt hy st oc k . O th e r i n te re s ts c o mp e te for the bes t s pots . I nv es tments i n i nfras truc ture are l ag ging.

90 percent of all cell types are adherent, which means

A nd t he re a re o th e r ch a l l e n g e s th a t d i m i ni s h the potenti al . But i f s c i enti s ts manage to dev el op newthat they need a surface to multiply and perform theira qua c ult ure t e c h n o l o g i e s , to m o rro w’s m arkets c oul d benefi t. The F raunhofer I ns ti tute for M arine­function.

Step 3: Expansion

Step 4: Capsule dissolution

Grow cells in capsule carriers

Dissolve the capsule carriers;

with a multiplication factor

expose and wash the cells

Biot e c hnolog y a n d Ce l l Te c h n o l o g y E M B i n L übec k i s worki ng towards thi s end.
In this Fraunhofer process, cells are first encapsulated ina hydrogel. When they multiply often enough to fill thecapsule, it is dissolved and a suspension with the cells
Today most aquacultures are out in open waters, for example,

the most of available resources, new measurement and control

grown in this capsule is transferred to other capsulesin open-net cages in the sea. This limits the choice of location

techniques, probes and other technologies. Another important

where they can proliferate. Fraunhofer EMB patented

to large bodies of water where there is nothing to stop

field of research in aquaculture is the wellbeing of farmed

this process. When cells can be produced inexpensively­wastewater and chemical pollutants such as excrement, feed

animals. Scientists have a long way to go before theyand in large quantities at high densities, this will give riseand medication from escaping. Fish-borne parasites thrive in­understand aquatic organisms’ comfort zones – merely

to new lines of business and markets not only for thethis sort of environment. One alternative is to breed organisms

measuring animals’ stress levels with suitable indicators isfood industry, but also in cosmetics and medicine.

in land-based plants using closed water circuits where just fiveno mean feat. The research case studies outlined above are

Cell-based model systems could be used to characterize

to ten percent of the process water per day has to be replaced

just pieces of a bigger puzzle. However, these efforts are

new substances and assure their product safety.

by fresh water. Enabling farmers to rear fish without exposing

contributing to the optimized, ecologically and economicallythem to harmful substances, they may be located anywhere­sustainable development of aquaculture as an important partAnd these complex cell systems can serve many

water is available, even near megacities. These plants areof future global food security. Entire branches of aquaculture

other purposes, for example, to create personalizedeasier to protect than open installations or net cages in theindustry are sure to emerge – some to farm and look after the­immunotherapies or tissue therapies. These model

Step 5: Re-suspension

Phase 6: Cell harvestingsea. Looking to nature for inspiration, scientists are now

health of fish, others to design and build plants, and others

systems will also help reduce the number of animalRe-suspend the cells inTransfer cells for­developing eco-friendly alternatives for farming fish and otherstill to develop feedstuff.

experiments.

the gelling agent

reuse in step 1

flows to boost efficiency. One approach is to cultivate fish,

Dr. Marina Gebert

Dr. Daniel Rapoport

algae and mussels collectively. Many challenges have to be

Fraunhofer EMB, www.emb.fraunhofer.deFraunhofer EMB, www.emb.fraunhofer.deof around 10, depending on
the cellaquatic organisms that make the most of cycles and byproductsurmounted to keep such radically streamlined ecosystems
viable and many questions remain to be explored. Fraunhofer
EMB has the largest research facility for land-based­multifunctional aquacultures in Germany at its disposal. The
people who work here find answers to questions about­material flows, combinations of different organisms to make46

47

HEALING NATURE’S WAY WITH
BIO­- INSPIRED WOUND DRESSINGSA GREENER WAY OF
KEEPING SURFACES SLEEKBe t t e r w a y s o f tre a ti n g wo u n d s wo u l d b e mos t wel c ome i n a worl d wi th an agi ng popul ati on a nd r isingfrequency of pH value changes around the ship.
The hull paint is also manufactured with theeco-friendliness of its components in mind. It
contains ecological products made of lignin, ac ost pre ssure i n h e a l th c a re . M e d i ca l s c i e nc e has y et to fi nd a remedy for poorl y heal i ng s ki n i njur ies

Seawater-borne microorganisms require stable

paper industry waste product, rather than fossil

suc h a s c hron i c a n d e x te n s i v e wo u n d s . And doc tors need dres s i ngs that i ns tantl y c l os e wounds t oliving conditions to thrive. They grow in a certain

materials.

c ount e r inf e cti o n s , s te m fl u i d a n d e l e c trol y te l os s , rel i ev e pai n, and prev ent amputati ons for m ore t han

pH range determined by the salinity of the sea andsix m illion sev e re b u r n s th a t o cc u r a ro u nd the worl d ev ery y ear. Bi ol ogi c al wound dres s i ngs c an m eet

form what is called biofilm on the hulls of ships.

Prof. Andreas Heilmannt his pre ssing m e d i ca l n e e d .

Known as biofouling, this accumulation of organic

Fraunhofer IMWS, www.imws.fraunhofer.delife is a problem for vessels. As the surface getsrougher, it creates frictional drag that impedes aship’s forward motion.
Skin tissue of human and animal origin to redress wounds is in

Their mechanical properties are not the only upside;

Engines have to work harder. They burn a lot morevery short supply. And there is always the risk of infection with­bio-inspired wound dressings can also be endowed with

fuel and emit more greenhouse gases, all of which

donor tissue. Today’s scaffolding structures that serve to cover­functions modeled on nature. These lab-made skin fibers

makes lasting protection against biofouling an

wounds are made of synthetic polymers. These materials havecan bind excess enzymes that have the undesirable effect of

economic and ecological imperative. Fraunhofer

their drawbacks: they can only remain on the wound for abreaking down newly formed tissue. The fibers also support

IMWS has developed a sustainable method ofshort time. Lacking the intact skin’s elasticity, they cause

new tissue formation by enabling skin cells to colonize theaffording hulls permanent protection that involves

causes contractions and put the skin under tension. This

wound bed.

no toxic paints or varnishes. Its researchers put
their knowledge about the realities of marine

distresses the patient and often impairs the healing process.
The Fraunhofer Institute for Microstructure of Materials andProduced using biotech in the lab or purified from animallife to work: Microbiologists know that saltwater

Systems IMWS is developing new biomaterials for dermal

tissue, these proteins are then processed into fibers. Scientists

microorganisms do not flourish in fresh water;

applications. These materials are biocompatible andare working on a method that uses electrical force to spin

they stop growing and eventually die. However,­immunocompatible. They have the biological and mechanicalproteins into nanofibers. It could serve to produce composites

other microorganisms will quickly encrust the samestability required for the given application. And they arein form of nonwoven meshes. The great advantage of thissurface in fresh water, and vice versa.

inspired by nature, particularly by the biological fiber proteins

method is that it yields vast quantities of fibers.

This is attributable to the change in pH value,
which correlates with the water’s salinity. Scientists

elastin and collagen. The fact that the skin, lungs, bloodvessels and cartilage are elastic, robust and hard-wearing

Dr. Christian Schmelzer

capitalized on this insight into biofilm formation toenough to withstand a lifetime of rigors is mainly down to the

Fraunhofer IMWS, www.imws.fraunhofer.dedevelop an electrochemical antifouling system thatinteraction of these two proteins. Collagen fibers’ tremendous

cyclically changes the pH value and makes local life

tensile strength lends tissue its mechanical stability.

a lot harder for microorganisms.

Elastin exhibits complementary properties. As the main

The pH value has to change only on the hull’scomponent of elastic fibers, it enables fabrics to stretch andsurface to significantly reduce biofilm formation.

then snap back into shape. These wound dressings are fully

An electronic control unit can serve to set thebiodegradable – the body can break them down – yet theyhold up very well under physical stress.

48

49

THE CIRCULAR ECONOMY –SUSTAINABLE CONSUMPTION
AND CLIMATE PROTECTION
Trash, garbage, refuse... It’s a problem entirely specific to Homo sapiens. No otherspecies produces waste that does not get recycled in some way or other. Our only
hope of reducing our ecological footprint is by learning to modify our products andprocesses in such a way that any waste material gets used more effectively. For a start,
we can take some inspiration from nature, which offers many good examples of­recycling: organic waste such as waste wood and milk residues – and, of course,
carbon dioxide.

50

51

ORGANIC WASTE –VERSATILE COATINGS FROM FRUIT FIBER

production of coatings and can also be incorporated as a

Smart processes for closed-loop recycling systems

module in small agricultural biorefineries and biogas plants.
Alongside the development of new materials, researchers from
Fraunhofer ISC and the IWKS project group are also working
bioORMOCER®:

on smart recycling processes. Enhanced design of easily

a coating with wide applications­recyclable materials and products together with an innovative
pilot plant for sorting waste and a highly selective separation

Product packaging made of plastic has never been particularly green. Yet in terms of hygiene, durability
and availability, we have still to come up with anything better. Researchers from the Fraunhofer Institute

Biodegradable coatings also offer numerous benefits in otherprocess are now paving the way for the future development

for Silicate Research ISC and its project group for Materials Recycling and Resource Strategies (IWKS) areareas. For example, they can endow organic, cellulose-based,of simple and profitable recycling systems that will help

now working on some alter natives. Their work focuses on the development of biologically degradable“vegan” fibers – i.e., cotton or viscose – with new andconserve resources.

packaging materials, some of which are produced using biogenic waste. By analyzing how these materials­attractive properties, making them water repellent, forwill be recycled, their aim is to create a circular economy.

example, or good bonding agents in biocomposites and able

Dr. Stefan Hansteinto block UV radiation. And there are many other associatedFraunhofer IWKS project group www.iwks.fraunhofer.defields of research that could lead to the development ofUnpack your groceries after a visit to the supermarket, and theand paper-based packaging become more environmentally

trash can is soon overflowing. There have long been moves tofriendly in the future.

­innovative materials and products for a sustainable

Dr. Sabine Arnberg-Schwab­management of resources.

Fraunhofer ISC, www.isc.fraunhofer.de

replace hydrocarbon-based plastic packaging with biodegradable

For example, Fraunhofer ISC researchers have alreadymaterials. These, however, are permeable to oxygen, moisturedeveloped a fabric coating by the name of InnoSolTEX®. Thisand aromas. As packaging for food – particularly for moist

Food waste for biodegradable packaging

delivers a variety of properties in one single formula, making
textiles antimicrobial, antistatic, flame-retardant, hydrophobic

products such as fish, meat, cheese and cold cuts – they areunable to guarantee a comparable shelf life.

New ideas are needed to keep materials in the recycling chain.

or hydrophilic, and washable. Research will now concentrate

For example, researchers from the IWKS project group are now

on the use of such coatings with natural fibers fromusing renewable materials to produce bioORMOCER ­coatings

renewable resources. This will provide fabrics that remain

for biodegradable packaging. These materials can be extracted

biologically degradable, despite boasting a range offrom waste matter in the food industry, including fiber-richs­ ophisticated properties.

®

Barrier properties with bioORMOCER® coatings
Researchers at Fraunhofer ISC have developed biodegradable

byproducts from processing food – especially fruit. These

coatings that endow bioplastics with the properties required

byproducts contain long, branched sugars from the highlyfor packaging foods. These bioORMOCER® coatings arediverse group of substances known as hemicelluloses, which­inorganic–organic hybrid polymers – a class of materials thatare not broken down by the human digestive tract

provides a good barrier against gases and vapors. They

and therefore not metabolized so as to yield energy.

­therefore offer an ideal material basis for developing­Hemicelluloses have good barrier properties against air and­biodegradable packaging. Suitable for combination with either

aromas. The project group is currently identifying suitablebioplastics or paper, bioORMOCER coatings will also meansource materials and processes for extracting hemicelluloses.

that coated paper packaging for takeout products will fulfill its

The aim is to obtain molecules that can compete with thetrue environmental potential. These coatings are therefore thepetroleum-based raw materials currently used to produce

key to making bioplastics an attractive option to industry as a

coatings. A pilot plant has now been set up in order to help

packaging material. This will pave the way to a successfuladvance the development of this technology. This ensuresmarket launch, the ultimate goal being to make plastic ­sufficient quantities of the branched sugar molecules for the

®

52

53

MORE FOR LESS –BETTER MANAGEMENT OF SOIL NUTRIENTSEveryone knows that plants need nutrients to grow. Yet mineral fertilizers, when applied too liberally or

Flow chart for sustainable management of soil nutrients

indiscriminately, are a burden on the environment. The same is true of liquid manure. In either case,organic or inorganic, the real problems begin with overfertilization. What then happens is that the surplus
nutrients end up in ground and surface water, where they accumulate and damage the local ecosystems.

Replenishment of soil nutrientsby addition of fertilizer

Removal of soil nutrientsby harvesting of crop

Processing forfoodstuffs/animal feed,bioenergy, biomass

Consumption

If we are to continue improving the standards of nutrition for the world’s growing population, withoutharming the environment in the process, we must therefore restore nature’s own cycles. This means thatnutrients removed from the fields along with the crop at harvest time must be retur ned to the ground in

Solid and liquid waste

a controlled manner and form that is available to plants. It is this problem that researchers at the­F raunhofer Institute for Interfacial Engineering and Biotechnology IGB are currently investigating.

What could be more idyllic than the sight of a field of barleynitrogen is available in virtually unlimited quantities. This cangently waving in the breeze? To grow and flourish, cereal andbe converted into ammonia as a source material for thevegetable crops need to absorb nutrients from the soil, such assynthesis of nitrogen-based fertilizers. But here, too, there is anitrogen, phosphorus, potassium, calcium and sulfur. Afterproblem: an enormous amount of energy is required for the

harvesting, the crop may be used as animal feed, as food, as a

production of synthetic ammonia – the equivalent of aroundraw material for industry or even as a feedstock for bioenergy.

two percent of the world’s primary energy production. In fact,

But whatever the use, the nutrients stored in the crop are
removed from the ground. Yet only some of these nutrients

Partial loss during
disposal

The problems of overfertilization

Sustainable management of soil nutrientsthe production of nitrogen fertilizers accounts for around fiveIn areas with intensive livestock rearing, there is often a

If we are to continue improving standards of nutrition for thepercent of the world’s annual consumption of natural gas.

surplus of nutrients in the soil as a result of the excessive

world’s growing population, while respecting the integrity offind their way back into the soil in the form of organic­application, often over many years, of liquid manure. By thenature, we must restore nature’s own cycles and return to the­fertilizers – farmyard manure, liquid manure or compost.

same token, when mineral fertilizers are applied in the wrong

soil the nutrients that are removed at the time of harvest.

way or in excessive quantities, they are simply washed out of

To this end, Fraunhofer IGB is working hard to develop andthe soil and end up in ground or surface water, where they

implement sustainable, cost-efficient technologies andBesides, given the environmental problems associated with

Nutrients are lost from the soil

overfertilization, this process is also strictly regulated. A further
complication is that arable farms and livestock holdings are

The nutrients that are removed from the soil together withaccumulate and impact local ecosystems. Similarly, the use of­strategies designed to provide an integrated management ofoften in different areas, which means that the ready availability

crops end up, by and large, in wastewater-treatment plants or

fermentation residues from biogas plants as a fertilizer canresources. This work focuses on new and innovativeof organic fertilizer can vary strongly from region to region. In

waste-disposal sites. Municipal sewage plants, for example,

also be problematic, since the precise composition of nitrogen,­technology and processes to enable the extraction of soil

areas of intensive cultivation, farmers must therefore resort totend to use biological nitrification and denitrification processes

phosphorous and potassium in this waste never corresponds

nutrients from wastewater and organic waste such as liquidindustrially produced mineral fertilizers in order to replenish

to remove nitrogen compounds such as ammonia or nitrates

to the needs of the crop. In practice, fermented waste only

manure and fermentation residues.

their soil with the necessary nutrients.

from wastewater and then convert them – in a highly

meets the needs for one specific soil nutrient, usually nitrogen.

­energy-intensive process – into gaseous nitrogen, which isThis means that the other nutrients are applied in excess,Today, some of these processes are already in commercial

then released into the atmosphere. Phosphate, as a rule, iswhich in areas with intensive livestock rearing can lead to aoperation, with our industrial partners now extracting andprecipitated from wastewater using aluminum or iron salts.

glut of nutrients in the ground, with negative consequences

marketing soil nutrients in such a form that they can be

The resulting phosphate salts end up as landfill, since they arefor the environment.

directly used in agriculture. These products are produced andConventional production of inorganic fertilizers
There are currently no industrially produced mineral fertilizers

not in a form available to plants and can release iron andmarketed in both solid and liquid form. They can be tailored tothat are made of renewable materials. Phosphate fertilizers,

aluminum in concentrations that are toxic to plant life.

specific applications and mixed according to soil properties

for example, are mainly produced from rock phosphates,­Estimates indicate that each year around 4.3 million metricand crop type.

which are mined from deposits around the world. More andtons of phosphorous are lost as a result.

more of these deposits are contaminated with heavy metals

Dr. losif Mariakakis

such as uranium or cadmium. By contrast, atmosphericFraunhofer IGB, www.igb.fraunhofer.de

54

55

MORE THAN MILK –CHEMICALS FROM WHEY

from mozzarella production. In the substance produced, CMP

Functional principle of EMF

accounted for 81 percent of the total protein content. This iscomparable with commercially available formulations, in which
the proportion of CMP is between 75 and 85 percent. In other– CATHODE –words, the process is suitable for producing a commercially
W he y is a m a j o r b y p ro d u ct o f c h e e s e p roduc ti on. Yet onl y around 40 perc ent of thi s s ubs tanc e get s

viable product. Moreover, it can also separate out uncharged

re use d in a ny wa y. T h e o th e r 6 0 p e rc e n t , al ong wi th al l the v al uabl e pepti des and protei ns i t cont ains,

molecules such as lactose and could therefore be used tois w a st e d. T h i s i s l a rg e l y th e fa u l t o f to d ay ’s frac ti onati on tec hnol ogy, whi c h i s c os tl y and i nefficient .

produce lactose-free foods for allergy sufferers.

In ha rd c om m e rc i a l te rms , i t i s s i m p l y n ot worth proc es s i ng the remai ni ng whey. Res earc hers at t he
­F r a unhof e r In s ti tu te fo r I n te rfa c i a l E n g i n eeri ng and Bi otec hnol ogy I G B are now worki ng on a c om pact

Electromembrane filtration makes use of two different forms

a nd e ff ic ie nt te ch n o l o g y c a p a b l e o f s e l ec ti v el y s eparati ng c ompl ex mi x tures of thi s ty pe. Thei r aim is t oof separation: a mechanical membrane and an electrical field.

ha r ne ss t he b e n e fi ts o f fi l tra ti o n wi th thos e of el ec trophores i s . They hav e al ready ac hi ev ed prom ising

Each of these can be individually controlled, which means thatre sult s w it h e l e ctro m e mb ra n e fi l tra ti o n , whi c h prov i des an ec onomi c means of ex trac ti ng prev iously

the process as a whole can be tailored to a customer’s specificunre c upe r a t e d s u b s ta n ce s th a t c a n th e n be us ed i n hi gh-grade produc ts for the medi c al , ­p harm aceut ical,

requirements. This technology has huge potential: oncef ood a nd biop ro ce s s i n g i n d u s tri e s .

neglected substances can now be retrieved and turned into
raw materials, which in turn can be used to make high-grade

OH –

OH –
Permeate

UF or MF membrane
Mixtureof
substances

Retentate

H+

H++ ANODE +products for the food, animal feed, medical, pharmaceuticaland bioprocessing industries.
Promising applications for proteins­chemicals and energy, which in turn can damage or evenand peptides from whey

destroy the protein structure.

Indeed, whey has a lot to offer. In addition to lactose andIn the diagram, where the cathode is on the permeate side,

Having completed basic investigations at the laboratory scale,the electrical field prevents negatively charged substances

researchers at Fraunhofer IGB are now developing an EMF­passing through the filter, even when their molecular size

system based on an EMF cell. The system is currently operating

is smaller than the pore size of the filtration membrane.

minerals, it also contains high-grade proteins and peptides,

Electromembrane filtration:

in semibatch (“feed and bleed”) mode, with feed rates of up

This enables a higher degree of selectivity than withwhich could be used in the bioprocessing and food industries.

the key to efficient fractionation

to 1000 liters per hour, depending on which transmembrane

conventional ultrafiltration.

Furthermore, a number of these peptides, including the caseinpressure is selected. At present, researchers are working tomacropeptide (CMP), are also of interest for medical applications,Electromembrane filtration (EMF) is an efficient way of

scale up the process, get it operating continuously andsince they inhibit bacteria and viruses as well as alleviate theextracting useful substances from whey. This process separates­validate it for other source substances.

symptoms that these cause. CMP, for example, inhibits thethe peptides and proteins by means of a mechanicalformation of plaque and caries. Other substances from whey

membrane and an electrical field. In other words, substances

Dr. Carsten Pietzka, Dr. Ana Lucía Vásquez-Caicedo,

are suitable for preparing products for infant, sports andare separated according to not only their molecular size but

Siegfried Egner­clinical nutrition. Whey proteins can also be used as natural,also their electrical charge. The degree of selectivity is

Fraunhofer IGB, www.igb.fraunhofer.de

environmentally friendly substitutes for synthetic foaming­therefore very high – which in turn makes the process very

agents, emulsifiers, gelling agents and water-retention

effective in economic terms. It is moreover very attractive fromagents. The processes currently used for fractionating andan ecological point of view, since no chemicals are required.

concentrating proteins involve several steps and are therefore
costly and time-consuming. A further problem is that many of

Researchers at Fraunhofer IGB have already demonstrated thethe individual stages require high temperatures and, in certain

potential of electromembrane filtration. Using a demonstration

cases, the addition of acids, solvents or buffer solutions. In

unit not yet optimized for commercial operation, they

other words, such processes involve the use of a lot of

extracted casein macropeptide (CMP) from whey left over

56

57

TOO VALUABLE TO BURN –WASTE WOOD AS A RAW MATERIAL

thereby making it fit for transport, storage and further

the products they yield are being defined with a view toprocessing. Using a flexible torrefaction process, the biomass­developing new business models.

is heated for a specific time in an inert atmosphere of pure,superheated steam at ambient pressure. The temperature ofthis process is below the value at which carbonization

High-grade chemicals from low-grade wood­(pyrolysis) takes place. The torrefaction process developed at
A t pre se nt , w o o d a n d l i g n i fi e d b i o m a s s s uc h as s traw are us ed i n a v ari ety of way s : for generat ing heat ,­Fraunhofer IGB is based on the established method of drying

Long before wood was used to make paper or furniture,

in t he c onst r u c ti o n i n d u s try, fo r m a k i n g fur ni ture and i n agri c ul ture. Yet they c oul d al s o prov i de awith superheated steam at atmospheric pressure.

people burned it to provide heat. Yet from a bioeconomic
perspective, wood is much too valuable to throw on the fire.

­v a lua ble sourc e o f ra w ma te ri a l fo r th e c hemi c al i ndus try. U nl i ke c or n or rape, for ex ampl e, they are notpot e nt ia l sou rce s o f fo o d , a s th e y c a n n o t be di ges ted by humans . Yet l i gni fi ed bi omas s , when f reshly

Fraunhofer IGB has already been able to demonstrate the

A better solution is a process known as cascading. Here, theha r v e st e d, is d i ffi c u l t to tra n s p o rt e ffi ci e ntl y. There are s i mi l ar probl ems wi th l ow-qual i ty s c rap w ood:

process in a variety of pilot plant projects. Unlike conventional

wood is first used in a high-grade product or process. Only ther a t he r t ha n b e i n g u s e d a s a p o te n ti a l l y v al uabl e s ourc e of raw materi al s , i t tends to get bur ned f or

torrefaction processes, the biomass is not contaminated bymaterial that is unsuitable for this purpose is burned toe ne r gy. T he re h a v e l o n g b e e n me th o d s f or i s ol ati ng c el l ul os e and l i gni n (i n the form of s ul fonat ed

exhaust gases or degraded as a result of oxidation by

produce energy. In the chain to exploit the full potential of thelignin) f rom w o o d s o th a t th e y c a n b e u s ed as raw materi al s . Yet wood has other c omponents such as­atmospheric oxygen. This ensures that the biomass and any

wood, however, other valuable substances can be obtained

hemicellulose and lignin (not in its sulfonated form), which are also valuable raw materials with manifold

substances extracted from it are extremely pure and therefore

upstream by means of, for example, the organosolv process,applications. Fraunhofer researchers are therefore working on ways of exploiting these substances.

suitable for high-quality applications. The process can run

whereby wood is fractionated into its basic constituents using

continuously and is flexible enough to be used for different

heated organic solvents in a lignocellulosic biorefinery. Thesetypes of biomass, according to season. The technology can be

can then be used to produce important feedstock materials forscaled either up or down, which makes it suitable both forthe chemical industry, including lactic acid, furfural, aromatic

small units for specific applications and for plants capable ofcompounds and fibrous matter for new materials.

Regions close to equator, such as northern Brazil, are blessed

Preconditioning biomass by drying or torrefaction

with abundant sunshine. Here, it is perfectly possible tohandling a large throughput of material. The torrefaction

produce chemicals from biomass cheaply and sustainably all

Current research tends to focus on the question of how

process converts the biomass into a hydrophobic material withThe Fraunhofer Institute for Chemical Technology ICT, thethe year round. The challenge facing the chemical industry

residual and lignified biomass – for example, straw – can besta very high calorific value in terms of mass. It can therefore be

Fraunhofer Center for Chemical-Biotechnological Processes

back in Germany and the rest of Europe is therefore to lever its

be used either as a source of energy or as raw material. The

transported economically. Furthermore, the material can be

CBP and the Fraunhofer Institute for Wood Research,know-how and develop efficient and sustainable production

first problem, however, is how to transport this material in an

ground into a powder, which makes it easy to create a large

Wilhelm-Klauditz-Institut, WKI are all working on suchprocesses that will enable it to compete. In turn, this will

economic and sustainable way. The regions that are capable ofreaction surface for the purposes of further processing. In­production processes right up to the pilot scale. Using data

enable it to reduce its dependency on fossil fuels and shift toproducing a requisite supply of lignified biomass –addition, any volatilized substances are specifically condensed.

acquired from such projects, researchers can then draw up asustainable alternatives. Increasingly, too, this is the wish of­Scandinavia, for example, or countries in eastern Europe – ­As a rule, these are valuable organic acids, which can be­comprehensive analysis of the economic efficiency andconsumers, who today have a growing influence on theare a considerable distance away from the major industrial

directly used as platform chemicals.

sustainability of these processes. At the same time, they are­chemical industry. They want products made of ingredientslocations where this biomass can be processed and used.

that do not negatively impact the environment – products, inAt present, there is no viable method for preconditioning

The key aim of researchers here is to establish a commerciallyanother secondary feedstock for biorefinery processes.

other words, made of sustainable raw materials. A viable

damp and easily perishable biomass at the place of production

exploitable technology platform. For the SteamBio project,

Fraunhofer WKI is conducting an ecological evaluation of the­alternative to crude oil is wood. Treated in a biorefinery, thisso that it may then be efficiently transported for processing.

they constructed a semi-mobile demonstrator capable ofmaterial flows in which scrap wood is used either as a source

can be broken down into its principal constituents: cellulose,

also investigating the potential of scrap wood to provide

processing around 150 kilograms of lignified biomass perof material or for generating energy. Fraunhofer ICT is involved­hemicellulose and lignin. These fractions can then be further

Researchers at the Fraunhofer Institute for Interfacialhour. This unit is now in operation at various locations inin the development of pulping, separation and extraction

refined and used for a variety of applications. This would not­Engineering and Biotechnology IGB are now looking to solve

Germany and Spain, where it is being used to torrefy at least

processes on the pilot scale. And Fraunhofer CBP is collating

only help meet the growing demand for chemicals and otherthis problem. Their idea is to use mobile units to treat

six different types of agricultural or forestry waste, including

laboratory findings on pulping and fractionation for different

materials but also contribute toward mitigating the effects­lignocellulosic biomass – for example, residual material fromconifer, oak and grapevine cuttings. The economic andgrades of wood and advancing them on a pilot scale. The pilotof climate change.

agriculture and forestry – in the region where it is produced,­material characteristics of the various feedstock materials andplant also produces samples on the multi-kilogram scale,58

59

which can then be used to test applications in the areas offermentation and the utilization of lignin.

Isolation of lignin and hemicellulose
The only substance the pulp industry currently extracts fromwood is cellulose. To date, there are no suitable processes for
obtaining lignin or hemicellulose. As a result, both of thesevaluable components are simply burned to generate energy.
Researchers at Fraunhofer CBP have now adapted the­organosolv process for the separate extraction of both lignin
and hemicellulose in a form suitable for further use. The
processes required for this purpose are already established on
the pilot scale at Fraunhofer CBP. Researchers are now busy
optimizing individual process stages. In particular, they arelooking at ways of reducing the amount of process medium
required and at further integration of the individual process
stages. Further processing of these fractions yields biobased
platform chemicals. Lignins, for example, have huge potential
as intermediates for the production of polymer components –an area in which Fraunhofer Institutes are also carrying out
research. Examples here include polyurethane adhesives and
EPI adhesives, both of which are now being developed intofunctional products in joint projects with industry. A further
project focuses on the development of lignin-based inks foroffset web printing.
Siegfried Egner, Dr. Antoine Dalibard
Fraunhofer IGB, www.igb.fraunhofer.de
Dr. Stefan Friebel
Fraunhofer WKI, www.wki.fraunhofer.de
Gerd Unkelbach, Dr. Moritz Leschinsky, Dr. Katja Patzsch,
Dr. Daniela Pufky-HeinrichFraunhofer IGB, www.igb.fraunhofer.de
A lignocellulosicbiorefinery.

60

61

FROM CLIMATE KILLER TO RAW MATERIAL –CO2 IN CHEMICAL PRODUCTION

In other words, much research, development and demonstration

Prof. Gorge Deerberg, Dr. Torsten Müller

work will be required over the next 20 years. This is the focus

Fraunhofer UMSICHT, www.umsicht.fraunhofer.deof the collaborative project Carbon2Chem®, in which involves
the Fraunhofer Institute for Environmental, Safety and Energy
Technology UMSICHT is a partner. Rather than attempting to
optimize individual parts of a process or types of plant –If t he t a r ge t s a g re e d u p o n a t th e U n i te d N ati ons Pari s C l i mate C onferenc e are to be ac hi ev ed, it w ill

specific chemical processes or blast furnaces, for example –t a k e m ore t h a n j u s t a s wi tch o v e r to re n e wabl e energy and el ec tri c v ehi c l es . I n addi ti on, i ndus tr y m ust

the project is taking a holistic view of the entire constellation.

m a k e it s prod u c ti o n p ro c e s s e s mo re s u s tai nabl e – i n parti c ul ar, thos e proc es s es that emi t l arge am ount s

One option here is a return to coal-based chemistry.

of C O 2 int o t h e a tmo s p h e re . A p ro m i s i n g approac h i s to us e thi s C O 2 as a feeds toc k for the c hem ical
indust r y, t he re b y i m i ta ti n g th e ca rb o n cy c l e i n nature. Thi s has two adv antages : a maj or greenh ouse gas
is pre v e nt e d fro m e n te ri n g th e a tmo s p h ere, and C O 2 repl ac es petrol eum as a raw materi al .

Cooperation between different sectors of industry
If this venture is to succeed, it will require close cooperation
between the steel industry, chemical industry, process industry

Humans and animals exhale CO2 into the atmosphere with

From waste product to raw material

and the plant and equipment industry. For example, in order
to convert CO 2 into chemical products, large quantities ofevery breath they take. In the long run, this would spelldisaster, were it not for the existence of plant life. Plants

Consider the steel industry. Here, plants are operating close tohydrogen are required. This can be produced by theremove CO2 from the atmosphere by breaking it down into

the technically feasible optimum. In other words, there is little­electrolysis of water, using environmentally friendly electricity

carbon and oxygen. They use the carbon to grow and, forscope for any further reduction in CO2 emissions from thisgenerated from renewable sources. Preliminary research

example, to produce lignin, while the oxygen is expelled backsector. Simple thermodynamics dictate that a substantial

carried out by thyssenkrupp AG has already shown ways ininto the air, where we can breathe it.

amount of coal must be used in order to produce steel withwhich the company’s steel works in Duisburg might cooperate

the requisite properties. However, even with this traditionalwith chemical plants. In other words, this form of

In other words, there is a functioning carbon cycle in nature.

method of steel production, there is still a way to reduce CO2­collaboration is viable.

Is it therefore possible to apply the same principle to industrial

emissions: by catalytically converting carbon gases from steel

emissions and thereby counteract climate change? Specifically,

production into chemical products. In turn, this would reduce

In order to promote cooperation of this kind, companies

is it possible to use the CO2 emitted by industry as a feedstock

the carbon emissions of the chemical industry, for whichfrom the relevant industries are also participating in thefor other uses? The answer is yes. To do so, however, willaround 90 percent of the feedstock is still derived from fossil

Carbon2Chem® project. The aim is to establish joint locations

require the use of energy as well as new developments in gas

fuels. Indeed, CO2 could serve as a feedstock for a host ofthat combine steel and chemical production and use

treatment and process and system engineering. The

chemical products, in the process partially replacing fossil fuels­renewable sources of energy. In order to facilitate Germany’s

chemical industry already has experience in a similar field. Insuch as crude oil. For example, the gases produced duringsmooth transition to a new energy economy and thereby

the 19th century and the first third of the 20th century, coalsteel production and electricity generation – blast furnace gas,

reduce CO 2 emissions, project partners will be looking to

was an important feedstock for the chemical industry.

coke gas and converter gas – contain CO2. Instead of releasing

advance the technologies required to develop sustainable

Synthesis gas, produced by the gasification of coal, was turned

this greenhouse gas into the atmosphere, it would be possiblemodes of production and implement these on an industrial

into a whole range of chemical products by means of

to convert it almost entirely into chemical products.

scale. This way, we should be able to get a little closer to theprocesses that the industry developed to varying degrees of

Before we can create a closed carbon cycle in industry,carbon and other cycles in nature and thereby come to regard

technological maturity.

however, we must first develop new forms of gas treatment,

CO 2 as a raw material rather than a waste product.

new catalytic processes and new process technologies.

62

63

PROTEIN FROM INSECTS – POTENTIALLY
A MAJOR NEW SOURCE OF ANIMAL FEED

organic waste, of which there is an abundant supply – notProf. Andreas Vilcinskas

least in the tropics, where, for example, the palm oil industry

Fraunhofer IME, www.ime.fraunhofer.de/en.html

produces huge amounts. In addition, the excrement of theinsects is an excellent organic fertilizer. Moreover, insects do
not transmit any diseases harmful to humans or livestock. Nor
do they pose any danger to biodiversity. Both small farms andindustrial-scale operations can benefit from insect farming.
This is because it can be scaled up or down to whatever theWe ha v e now re a ch e d th e p o i n t wh e re c attl e and hogs eat more than we c an grow i n fodder. The result

size of operation required.

is t ha t m ore a n d mo re ra i n fo re s t i s b e i n g c l eared to c ul ti v ate s oy beans for ani mal feed. Yet there is ana lt e r na t iv e : i n s e cts . T h i s wo u l d s o l v e s e v eral probl ems . I ns ec ts c an proc es s organi c was te s uc h as

There are also advantages to feeding cattle and hogs withpom a c e or m a rc , wh i ch mu s t o th e rwi s e be di s pos ed of at s ubs tanti al c os t. A nd when tur ned i n t oinsect protein: not only does it have a high nutritional value,

prot e in, insec ts c a n p ro v i d e a s u s ta i n a b l e – and heal thy – s ourc e of feed for l i v es toc k.

but it also has a positive impact on the animals’ health. In
other words, industrial-scale solutions to commercially exploit
insect protein could help resolve global problems as well as
create new value chains.

Steak, ham or pork loin? Whatever the cut of meat that lands on

Filling feed troughs with insect proteinyour plate, its production has caused a host of problems. One
Pioneering role in insect technology

reason is that cattle and hogs require much more food, measured

Insects could offer a solution to all these problems.

in nutritional value, than they actually produce in the form of

Biotechnology is now busy developing ways of turning insects –meat. In order to satisfy the growing hunger for meat, large

or, more precisely, their organs, cells, molecules or any

The Bioresources project group at the Fraunhofer Institutetracts of rain forest around the world are being cleared to growassociated microorganisms – into products. Literally tons offor Molecular Biology and Applied Ecology IME is playing aanimal feed. In Brazil alone, some 156,000 square ­kilometersinsects such as the black soldier fly (Hermetia illucens) arepioneering role in the development of new technologies

were lost to soybean production between 2002 and 2012.

being bred. Fed on organic waste, these insects will yield

involving insects. Together with industrial partners such as­Moreover, there is an increasing shortfall between the projected

proteins, lipids and other valuable substances that can be

Alternative Protein Corp., the group is now pursuing research

production of protein and the amount of protein required forused to feed livestock or fish reared in aquaculture. This insect

in the area of insect farming. For example, the AIM Biotech

animal feed – a shortfall sometimes referred to as the “protein

farming business is already thriving worldwide and holds huge

project, which is jointly sponsored by the Fraunhofer-­gap.” Experts estimate that by 2025 there will be a shortfall of

economic potential for the future.

Gesellschaft and the Max Planck Society, is investigating
possible industrial uses for the microbes that are associated with

100 million metric tons between the amount of protein actuallyinsects. Similarly, the Bioresources project group is i­nvestigating

available and the amount required to feed the human populationand livestock reared for meat. What’s more, this shortfall is

Insect protein offers big benefits – for the environment,

whether crop yields can be increased by the use of organic­forecast to grow by 300 million metric tons by 2050.

agriculture and livestock rearing

fertilizer based on the excrement of black soldier flies.

Similarly, the need for oils and fats exceeds the amount that

Insect farming is cost-effective, energy-efficient and therefore

It is, however, early days to be talking about new technology

can be sustainably produced. The most important source ofhighly sustainable. Insects offer big advantages compared toand the commercial exploitation of insects on an industrial­vegetable fats is now palm oil. Yet the large-scale cultivation of

the agricultural cultivation of animal feed. A big factor is thescale. First of all, research must continue to focus on

oil palms has devastated swathes of rain forest in Indonesia andamount of land required: it takes one hectare to produce

enhancing the reactors used for the industrial breeding of

Malaysia. This not only poses a huge threat to biodiversity but

around one metric ton of soybean – or as many as 150 metricinsects and on the development of industrial, automatedalso aggravates climate change.

tons of insect protein. The insects can furthermore be fed withprocesses for handling the raw materials that insects provide.

64

65

COATINGS AND PAINTS FROM ­VEGETABLE OIL – PUTTING A SHINEON SUSTAINABLE CONSUMPTION
1

C onsum e r pre fe re n ce s a re c h a n g i n g , wi t h more and more peopl e now opti ng for green, s us tai nable

Ecological adhesives with ideal properties

different reactive resin systems

produc t s. In th e ca s e o f s o me co n s u ma b l es , i t i s rel ati v el y eas y to c hange ov er to wood, c ork o r som eot he r e c ologi c a l ma te ri a l . Ye t i t i s a d i fferent s tory when i t c omes to pai nts and gl ues , for ex am ple, orResearchers at Fraunhofer IMWS are now busy investigating

insula t ion. H e re , i t i s n o t s o e a s y to me e t the demand for s us tai nabi l i ty. A ttempts hav e al ready been

the precise characteristics of these newly developed biogenic

m a de t o prod u c e e p o x y re s i n s – th e b a s i c materi al for s uc h produc ts – from v egetabl e oi l . Yet t heresins – on the micro as well as the macro level. Once theyc om posit ion o f th e s e n a tu ra l o i l s c a n vary greatl y. Res earc hers at the F raunhofer I ns ti tute forhave determined what effect feedstock variations have on the­M ic rost r uc t ure o f M a te ri a l s a n d S y s te m s I M W S are therefore taki ng a c l os er l ook at the ex ac t p roper t ies

resins, they can then set about enhancing and adapting themof e nv ironm e n ta l l y fri e n d l y re s i n s a n d d ev i s i ng s us tai nabl e s trategi es for the us e of s uc h mater ials.

to specific types of processing. Partners from industry will thentransfer these processes from the laboratory to the industrial
scale. At the same time, Fraunhofer researchers are busy

Our climate is changing. The environment is polluted. Each

The sustainable alternative:

developing new formulas for adhesives based on theseyear we produce more garbage than ever. For many people,

vegetable oil-based epoxides with natural additives­vegetable oil epoxides. Which hardeners are best for which

the time has come to try and reverse this trend. Their answer

Increase of biogenic share in five

100 %
90 %
80 %
70 %
60 %

­applications? And which fillers and additives can be used to

50 %
40 %

is to buy goods that are more sustainable. Manufacturers, too,Yet it is also possible to produce epoxy resins fromdeliver specific properties? A particularly useful property would

are responding to this new mindset. It is not enough, however,­environmentally friendly materials. Adhesive manufacturers,

be high electrical conductivity. Through the application of an

merely to replace plastic with materials such as wood or cork.

for example, are already investing much time and effort in theelectrical current, it would then be possible to heat the

30 %For products to be genuinely sustainable, manufacturers must

research and development of alternatives that are not only

­adhesive layer from within, thereby ensuring that it hardens

also use adhesives, paints and foamed plastics that are madesustainable but also of a better quality and better value thanin a fast and precise way. Another advantage of these new

20 %of biobased feedstocks.

the products they replace. In their quest to come up with a­adhesives is that they are entirely solvent-free.

new generation of solvent-free dispersion adhesives, they havealready discovered a promising area of research.
Epoxy resins:the classic material for adhesives and foamed plastics

The Fraunhofer IMWS is also working on alternatives toconventional foamed plastics used, for example, as insulation

Epoxides based on vegetable oils offer the prospect of anfor buildings. Just like adhesives, they can also be made from

10 %
0%
1

2

3

4

ecological alternative to traditional epoxy resins. Here,plastics based on vegetable oil. Here, it is important to find out

Inorganic additives

LigninThe standard raw material for paints, adhesives and foamed­vegetable oils with a high proportion of unsaturated fats arewhich resins are best for a specific production process.

Petrochemical hardener

Linseed oilplastics is thermosetting epoxy resin – synthetic resins that are

epoxidized – which sees the unsaturated fats turned into

Together with partners from industry, Fraunhofer IMWS is

Biobased hardeners

irreversibly hardened after heating. The feedstock for epoxy

three-atom rings comprising two carbon atoms and one

working to develop finely tuned formulas for epoxidized fineresins are monomers. Once a hardener is added, these

oxygen atom. These vegetable oil epoxides are combined withoils and hardeners, ensuring short hardening times and low

individual molecules bind together to form a permanently solid

harmless natural additives to produce highly durable plastics.

viscosity. Here, the challenge is to increase the biogenic

plastic, which can no longer be melted. Through the addition

By varying their composition, these resins can be adapted forshare while also improving the material’s workability and itsof further substances, the properties of the epoxy resin can bea great many applications. In theory, at least, this makes

properties. The foamed plastics produced by the Fraunhofer

tailored to specific applications. For example, it can be colored,­sustainable adhesives, paints and foamed plastics a realistic

researchers currently have a biogenic share by weight of ­protected against heat and sunlight, made flameproof oralternative. Yet there is still one problem: the chemical

80 percent. Here, the chief additive is lignin, a waste productgiven properties that make it easier to manipulate. In addition,­composition of natural materials can vary considerably. In

from the pulp industry. An estimated volume of aroundfillers can be added in order to cut the material costs.

this case, for example, the raw material is extracted from the

20 billion metric tons of this substance is produced each year.

5

seeds of oil plants. The challenges facing producers are­therefore considerable.

66

Andreas Krombholz

1 Foamed linseed oil

Fraunhofer IMWS, www.imws.fraunhofer.de

epoxide, pigmented.

67

Editorial notes

Editorial teamDr. Patrick Dieckhoff (V.i.S.d.P.), Roman Möhlmann,
Janine van Ackeren
Design, layout
Silke Schneider
Contact
Fraunhofer-Gesellschaft
Dr. Patrick Dieckhoff
Anna-Louisa-Karsch-Strasse 210178 Berlin
Phone +49 30 6883 759-1603
patrick.dieckhoff@zv.fraunhofer.de
Gender-neutral pronouns have been used throughout,unless specifically referring to a man or a woman.
Photo acknowledgements
Front cover, back cover: Gettyimages
Page 5: K. C. Wong
Page 7: Zeitz / Fraunhofer
Pages 13, 25, 31, 37, 41, 45, 46, 59 and 65: Fraunhofer
Page 25: Shutterstock
Page 34: Pixabay
Page 39, left: Ludmilla Parsyak / Fraunhofer IAO
Page 43: Wolf-Dieter Gericke
Page 46: Shutterstock
All other photos: iStockphotoklimaneutral

natureOffice.com | DE-141-065815

gedruckt© Fraunhofer-Gesellschaft zur Förderung derangewandten Forschung e.V., München 2018www.fraunhofer.de

68

69

70