SciTransfer
SUSTAINEXT · Project

Zero-Waste Industrial Biorefinery for High-Value Plant-Based Ingredients and Botanical Extracts

manufacturingPilotedTRL 6

Imagine a smart factory that works like a master chef, adjusting its recipe on the fly based on the quality of the vegetables coming in. Instead of throwing away peels and stems, it squeezes every bit of value out of plants to make healthy ingredients. It even grows some of its own plants under solar panels to save space and energy.

By the numbers
20,000
tonnes per year processing capacity
46
plant-based healthy extracts delivered
13
extracts totally new on the market
12
extracts newly produced in Europe
271 M€
generated revenue
5,000
new green jobs created
6.8 million
tons of underutilized agricultural biomass annually
The business problem

What needed solving

The botanical extract industry often suffers from high waste, inefficient resource use, and a reliance on non-European imports. Additionally, rural regions face economic decline as traditional crops like tobacco become less viable.

The solution

What was built

A digitalized, multi-product biorefinery (DYANA) capable of processing 20,000 tonnes/year with a zero-waste and zero-emissions strategy.

Audience

Who needs this

Nutraceutical companiesCosmetic ingredient manufacturersAgricultural biomass processorsSustainable farming cooperativesBio-based chemical producers
Business applications

Who can put this to work

Nutraceuticals
enterprise
Target: Health supplement manufacturer

If you are a supplement manufacturer dealing with a lack of diverse European-sourced ingredients — this project developed a route to produce 46 plant-based extracts, including 13 entirely new to the market. This allows you to diversify your product line with sustainable, locally sourced ingredients.

Cosmetics
SME
Target: Natural skincare brand

If you are a skincare brand dealing with high waste in raw material sourcing — this project developed a zero-waste biorefinery model that upcycles agricultural side streams like olive and pomegranate. This ensures your ingredients meet strict circularity and zero-pollution standards.

Agriculture
mid-size
Target: Commercial farming operation

If you are a farmer dealing with declining tobacco profits — this project developed a model to replace tobacco with medicinal plants like rosemary and chamomile. By using agrivoltaics, you can produce renewable energy and high-value crops on the same land.

Frequently asked

Quick answers

What is the industrial scale of the production facility?

The biorefinery is designed for an industrial scale with a processing capacity of 20,000 tonnes per year.

What is the expected revenue from this model?

The project objective states it will generate a revenue of 271 M€.

How is the intellectual property or licensing handled?

Based on available project data, the project focuses on showcasing a replicable and versatile model for the EU bio-based industry, though specific licensing terms are not detailed.

When will the project be completed?

The project period runs from June 1, 2023, to November 30, 2027.

How does the system handle varying raw material quality?

It uses a smart dynamic analytical biorefinery (DYANA) that optimizes processing batch-wise according to the initial composition of the feedstock.

Consortium

Who built it

The consortium is heavily industry-driven, with 17 industrial partners (77% ratio) and 12 SMEs, indicating a strong focus on commercial viability over pure research. With 22 partners across 5 countries (AT, CH, DE, ES, IT), the project leverages a broad European supply chain, specifically integrating 7 partners from the Extremadura region to ensure local feedstock security and regional economic impact.

How to reach the team

Contact NATAC BIOTECH SL in Spain for partnership opportunities regarding the DYANA biorefinery model.

Next steps

Talk to the team behind this work.

Contact SciTransfer to identify similar bio-based industrial scale-up opportunities in the EU.

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