Recovering and processing of high value food and pharmaceutical ingredients from waste egg shells
Lead Research Organisation:
Nottingham Trent University
Department Name: School of Science & Technology
Abstract
Nottingham Trent University (NTU)'s contributions will reflect its expertise in the chemical and biological analysis of
materials at all stages of the process. The research facilities of the Prof. Carole Perry's Biomolecular & Materials Interface
Research Group will be utilised in addition to the facilities within the School of Science and Technology to support the
development of the materials for commercial exploitation. As required, materials will be analysed to ensure that they meet
the requirements for proposed pharmaceutical and healthcare applications (e.g. British Pharmacopeia).
Material Collection and Pre-Processing
1. Evaluation/development of continuous collection methodologies, including:
Determination of variation in process critical factors such as organic content, water content, albumin and yolk
contamination of collected material, particle sizing.
Optimise transit and pre-processing stabilisation of raw material (storage time limits, temperature limits, concentration of
storage solution).
2. Evaluation/development of initial processing approaches:
Determine particle sizing resulting from different milling parameters (time, initial water content, milling speed) and develop
optimised milling parameters and QC methodology.
Determine powder properties resulting from different drying parameters (time, initial water content, drying speed) and develop optimised drying parameters and QC methodology.
Determine and check specification of processing raw materials e.g. site water supply, base and alcohol (trace metals
content, elemental profile and purity) and develop QC methodology for raw materials.
Analytical services to determine effectiveness of initial processing output (testing to British Pharmacopeia grade CaCO3).
Primary Processing
Iterative evaluation of different continuous processing approaches, conditions and materials
3. Evaluation of the influence of processing variables on process output:
Process; NaOH concentration, alcohol concentration/type (ethanol or isopropanol), position of milling in process (before,
during or after).
Process conditions; temperature, volume of treatment: mass of feed material ratio, time and mixing rate.
Materials; continuous monitoring of starting materials and end product in relation to the desired specification (testing to
British Pharmacopeia grade CaCO3). In addition intermediate stages in the process and the extent to which raw materials
can be recycled in the process will be monitored/evaluated as necessary.
QC methodology will be developed for the process.
Secondary Processing - Agglomeration
Iterative evaluation of different continuous agglomeration approaches
4. Evaluating the influence of processing variables on the agglomeration process:
Influence of processing on particle/agglomerate size including coating thickness and structure from the atomic
(crystallography) through to micro and macroscopic scales (microscopy) including particle and coating porosity.
Organic content of particles, influence on formulation pH and general composition (chemical and elemental [e.g. Fe, Al, Pb,
As, Cd, Hg and total heavy metals] analysis, purity of calcium carbonate, moisture content) using relevant analytical,
microscopic and spectroscopy methods.
Determine material compliance to any relevant regulatory standards pre and post-agglomeration.
Comparative studies will be conducted with at least 3 competitor materials.
Combination of process steps to demonstrate process complementarity
NTU will support AvGo in evaluating the process developed to date though analytical testing of product output to check
conformity, e.g. testing to British Pharmacopeia grade CaCO3, and providing guidance in the event of any compliance
issues detected.
NTU will also assist in consolidation of process operations, evaluating opportunities to file for new intellectual property and
composition of the final project report.
materials at all stages of the process. The research facilities of the Prof. Carole Perry's Biomolecular & Materials Interface
Research Group will be utilised in addition to the facilities within the School of Science and Technology to support the
development of the materials for commercial exploitation. As required, materials will be analysed to ensure that they meet
the requirements for proposed pharmaceutical and healthcare applications (e.g. British Pharmacopeia).
Material Collection and Pre-Processing
1. Evaluation/development of continuous collection methodologies, including:
Determination of variation in process critical factors such as organic content, water content, albumin and yolk
contamination of collected material, particle sizing.
Optimise transit and pre-processing stabilisation of raw material (storage time limits, temperature limits, concentration of
storage solution).
2. Evaluation/development of initial processing approaches:
Determine particle sizing resulting from different milling parameters (time, initial water content, milling speed) and develop
optimised milling parameters and QC methodology.
Determine powder properties resulting from different drying parameters (time, initial water content, drying speed) and develop optimised drying parameters and QC methodology.
Determine and check specification of processing raw materials e.g. site water supply, base and alcohol (trace metals
content, elemental profile and purity) and develop QC methodology for raw materials.
Analytical services to determine effectiveness of initial processing output (testing to British Pharmacopeia grade CaCO3).
Primary Processing
Iterative evaluation of different continuous processing approaches, conditions and materials
3. Evaluation of the influence of processing variables on process output:
Process; NaOH concentration, alcohol concentration/type (ethanol or isopropanol), position of milling in process (before,
during or after).
Process conditions; temperature, volume of treatment: mass of feed material ratio, time and mixing rate.
Materials; continuous monitoring of starting materials and end product in relation to the desired specification (testing to
British Pharmacopeia grade CaCO3). In addition intermediate stages in the process and the extent to which raw materials
can be recycled in the process will be monitored/evaluated as necessary.
QC methodology will be developed for the process.
Secondary Processing - Agglomeration
Iterative evaluation of different continuous agglomeration approaches
4. Evaluating the influence of processing variables on the agglomeration process:
Influence of processing on particle/agglomerate size including coating thickness and structure from the atomic
(crystallography) through to micro and macroscopic scales (microscopy) including particle and coating porosity.
Organic content of particles, influence on formulation pH and general composition (chemical and elemental [e.g. Fe, Al, Pb,
As, Cd, Hg and total heavy metals] analysis, purity of calcium carbonate, moisture content) using relevant analytical,
microscopic and spectroscopy methods.
Determine material compliance to any relevant regulatory standards pre and post-agglomeration.
Comparative studies will be conducted with at least 3 competitor materials.
Combination of process steps to demonstrate process complementarity
NTU will support AvGo in evaluating the process developed to date though analytical testing of product output to check
conformity, e.g. testing to British Pharmacopeia grade CaCO3, and providing guidance in the event of any compliance
issues detected.
NTU will also assist in consolidation of process operations, evaluating opportunities to file for new intellectual property and
composition of the final project report.
Planned Impact
Project beneficiaries
The project aims to generate >£30m in direct revenues for the project partners within 5 years of project completion,
creating >50 direct jobs and significantly reducing the negative economic and environmental issues associated with current
disposal of waste egg shells (~15,000 tonnes disposed/year in the UK, costing >£500k/year in landfill/haulage). The project
will also lead to ~£1.6m in further UK investment in R&D/manufacturing.
Beneficiaries outside of the project consortium
In addition to commercial benefits to Avgo and its project partners, other beneficiaries from this project include (within 5
years of project completion):
A) Local Suppliers: anticipation that project outputs will contribute to ~£1.6m in additional revenue (incl. distribution) for
local, E.Midlands suppliers with the creation of ~12-15 additional roles
B) Egg processors: ~£950k cost savings for egg processors, enhancing their European competitiveness and supporting
further investment.
Also, it's expected that processors' compliance with key customers' corporate social responsibility policies with lead to
~£2.4m/year in additional revenues
C) Food and Pharmaceutical product manufacturers: In addition to reduced raw material transportation costs, potential UK
manufacturer benefits include a reduction in downstream process costs e.g. ~15-20% reduction in "filler- binder"
ingredients required to form quality tablets via direct compression due to use of customised ACC grades.
D) Employees: the improved, sustainable processing of waste egg shell material will improve employee health and safety at
both primary (reduced biohazard) and secondary processors (reduced processing dust; exposure to contaminates
associated with alternatives e.g. Precipitated Calcium Carbonate (PCC)).
E) Consumers: the end product will use a higher purity raw material with improved bioavailability, benefitting the consumer.
Displacement of inorganic PCC by egg shell ACC will also lead to reduced consumer exposure to heavy metal
contamination and product quality issues that have been associated with PCC.
This has the potential to improve consumer confidence, driving product adoption through repeat sales and improved
product compliance/use, leading to consumer quality of life improvements and reduction in conditions associated with
insufficient calcium intake, including osteoporosis: Calcium supplementation/fortification with eggshell-derived CC has been
proven to improve bone health (bone mineral density (BMD) and resistance to fractures).
F) Environmental beneficiaries: the consortium anticipates halving the UK costs and volumes of current waste egg shell
disposal within 5 years of project completion (and, through technology licensing, also significantly reducing EU volumes). It
also expects to displace PCC production from mined limestone (negative environmental impact including aesthetics and
generation of waste gas, effluent streams and CO2).
The project aims to generate >£30m in direct revenues for the project partners within 5 years of project completion,
creating >50 direct jobs and significantly reducing the negative economic and environmental issues associated with current
disposal of waste egg shells (~15,000 tonnes disposed/year in the UK, costing >£500k/year in landfill/haulage). The project
will also lead to ~£1.6m in further UK investment in R&D/manufacturing.
Beneficiaries outside of the project consortium
In addition to commercial benefits to Avgo and its project partners, other beneficiaries from this project include (within 5
years of project completion):
A) Local Suppliers: anticipation that project outputs will contribute to ~£1.6m in additional revenue (incl. distribution) for
local, E.Midlands suppliers with the creation of ~12-15 additional roles
B) Egg processors: ~£950k cost savings for egg processors, enhancing their European competitiveness and supporting
further investment.
Also, it's expected that processors' compliance with key customers' corporate social responsibility policies with lead to
~£2.4m/year in additional revenues
C) Food and Pharmaceutical product manufacturers: In addition to reduced raw material transportation costs, potential UK
manufacturer benefits include a reduction in downstream process costs e.g. ~15-20% reduction in "filler- binder"
ingredients required to form quality tablets via direct compression due to use of customised ACC grades.
D) Employees: the improved, sustainable processing of waste egg shell material will improve employee health and safety at
both primary (reduced biohazard) and secondary processors (reduced processing dust; exposure to contaminates
associated with alternatives e.g. Precipitated Calcium Carbonate (PCC)).
E) Consumers: the end product will use a higher purity raw material with improved bioavailability, benefitting the consumer.
Displacement of inorganic PCC by egg shell ACC will also lead to reduced consumer exposure to heavy metal
contamination and product quality issues that have been associated with PCC.
This has the potential to improve consumer confidence, driving product adoption through repeat sales and improved
product compliance/use, leading to consumer quality of life improvements and reduction in conditions associated with
insufficient calcium intake, including osteoporosis: Calcium supplementation/fortification with eggshell-derived CC has been
proven to improve bone health (bone mineral density (BMD) and resistance to fractures).
F) Environmental beneficiaries: the consortium anticipates halving the UK costs and volumes of current waste egg shell
disposal within 5 years of project completion (and, through technology licensing, also significantly reducing EU volumes). It
also expects to displace PCC production from mined limestone (negative environmental impact including aesthetics and
generation of waste gas, effluent streams and CO2).
Organisations
Publications
Belton DJ
(2019)
Traditional materials from new sources - conflicts in analytical methods for calcium carbonate
in Food Additives and Contaminants: Part A
Hickman G
(2019)
Barriers to adoption of biogenic carbonates in the food, pharmaceutical & supplement sectors
in NFS Journal
| Description | A COLLECTION PROCESS HAS BEEN IDENTIFIED TO COLLECT, DECONTAMINATE AND TRANSPORT EGGSHELL BY-PRODUCTS TO A SITE OF PROCESSING. SEPARATION AND ISOLATION OF CACO3 FROM BIOLOGICAL MATERIALS HAS BEEN CARRIED OUT ON A SIGNIFICANT SCALE - 150KG OF MATERIAL BEING PROCESSED AT A TIME, RECOVERING MATERIALS SUITABLE FOR RESALE UNDER CONTROLLED CONDITIONS, USING A MECHANICAL MIXING AND HEATING REACTION VESSEL. PROCESS AND WASH LIQUERS HAVE BEEN FILTERED AND A PROCESS IDENTIFIED TO RECYLE THIS MATERIAL TO REDUCE THE USE OF RAW/NEW REACTION MIXTURE. A MECHANISM HAS BEEN IDENTIFIED TO CONCENTRATE THIS LIQUER, RICH IN BIOLOGICALS SUITABLE FOR FURTHER DOWNSTREAM PROCCESSING. METHODS TO DRY AND MILL THE MINERAL COMPONENT HAVE BEEN IDENTIFIED AND TRIALLED AT THE 1000 KG SCALE AND MATERIALS TESTED FOR THEIR SUITABILITY FOR AGGLOMERATION. USES FOR PARTICLES HAVING A RANGE OF SIZES HAVE BEEN IDENTIFIED AND SAMPLES ARE CURRENTLY WITH CUSTOMERS. TABLETS HAVING A RANGE OF SHAPES HAVE BEEN PREPARED AND ARE OUT FOR CUSTOMER EVALUATION. |
| Exploitation Route | AVGO INTEND TO TAKE THE CACO3 TO MARKET AS A FINISHED AND SELLABLE PRODUCT IN THE HEALTHCARE SECTOR - AS A FINE POWDER THROUGH CHRYSALIS AND AS A UNMILLED OR COARSER MATERIAL THROUGH OTHER CHANNEL LEADERS. ADDITIONAL WORK IN THE MARKET SUGGESTS THAT THE EGGSHELL RAW MATERIAL WILL SELL IN VARIOUS FORMS IN THIS MARKET AND IN OTHER ALLIED MARKETS. AVGO AND NTU ARE IN DISCUSSION TO FIND A WAY FORWARD TO EXPLOIT THE BIOLOGICAL STREAM - THROUGH FURTHER FUNDING AND COLLABORATIONS WITH POTENTIAL CHANNEL PARTNERS. THIS PROJECT HAS ALSO INSPIRED THE MEMBERS TO LOOK AT PRODUCTS REQUIRED IN THE HEALTHCARE AND ALLIED INDUSTRIES AND SEE IF THEY CAN ALSO BE SOURCED FROM FOOD INDUSTRY BY-PRODUCTS. |
| Sectors | Agriculture, Food and Drink,Chemicals,Environment,Healthcare,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology |
| Description | The project outcome was that a good quality material was produced, though this did not meet the specification of the human supplements market, regulated by European Food Standard E170. Where the required specification for Magnesium and biologicals was not reached work had been carried out, within the project, to remove the Magnesium. This was successful however the process was regarded as being too expensive for the market we were addressing and was put aside. The Perry group published 2 papers on the back of the project 1. "Barriers to adoption of biogenic carbonates in the food, pharmaceutical & supplement sectors". NFS Journal 16 (2019) 1-8 2. "Traditional materials from new sources - conflicts in analytical methods for calcium carbonate". Food Additives & Contaminants: Part A DOI: 10.1080/19440049.2019.1571288 They have led to a number of responses, in particular from the USA Regulatory bodies suggested that further work was needed to take this understanding further. This has been precluded due to a lack of funds. Moving Forward Market engagement by Avgo led to the identification of a real opportunity to look at purity of the calcium carbonate that could be produced. The need was for material with low heavy metals, within the pharmaceutical market, for ante acids etc. This is a market with higher end user pricing than the human supplements market, making the magnesium removal process viable. Taking the previous ideas about reducing Magnesium - a chemistry and engineering solution was developed - the RecEgg process. This produced calcium carbonate with low biologicals, low magnesium and low heavy metals, in a very economic and completely circular process. Avgo pursued funds over the ensuing years - a number of applications were made to gain support from the EU which unfortunately were not successful. • Avgo received a commendation for the idea and concept at the 2019/20 Rushlight awards. • Pitch Finalists in the 2020 Midlands Pitchfest • Winners in the 2020 Taming the Dragons Pitch event run by Lincolnshire Business Angels SIF - 91752 - RecEgg. An application was made to the Innovate SIF3 fund to undertake a small industrial scale proof of concept - project 91752. This was successful. RecEgg 91752 output This project was designed to bring together the magnesium removal chemistry, from NTU, under 102402 and the engineering concepts of Mike Keast the chemical engineer working with Avgo. The project was taken from TRL 3 -> 4 / 5 whilst also providing the opportunity to file a Patent based upon 91752 and that carried out in 102402 (UK Patent Application Number 2106141.1). We were successfully able to take shell through the complete process and repeatedly produce pharmaceutical standard calcium carbonate, while selectively dropping out contaminating materials including, magnesium, heavy metals and biologicals. Our own waste recycling has been demonstrated by the equipment supplier, in their own laboratories. The project proved that the chemical and engineering concepts that we started with worked and has taken Avgo to TRL 4/5. Current position and going forward Working with NEDs from the AngelsGroup Avgo is currently going through legals for a substantial fund raise. Funds due into company by the end of March 2022. Active exploitation discussions: UK based Supermarket A UK based vertically integrated supermarket, owns many of its suppliers in the food sector. Discussions on a 5,000 tonne/year facility (at TRL5/6 through to 9) to take all of their eggshell waste, their seashell waste (cockles/ scallops). Also looking at sourcing shell from other UK processors. Discussions are taking place to look at other food waste streams. This company want to use the output in their own products - supplements, pet food and animal feed. The impacts of this relationship are expected to: 1. Increased employment at the supermarket - directly 10FTEs at the processing plant, indirectly 6 FTE's at "satellite" facilities. 2. Reduced costs for landfill of approximately £500,000 3. Reduction of Environmental Impact a) directly from landfill - 250kgCO2/tonne CaCO3.Total 1,250 tonnes CO2 , and b) indirectly from elimination of mining and transport carbon footprints - 750kgCO2/tonne CaCO3.Total 3,750 tonnes CO2) 4. Reduced manufacturing costs - on the premise that the results of recycling are going to be used in the company's other operations. It is expected that those product lines taking the recycled calcium carbonate will have reduced costs and improved margins. 5. Environmental and Corporate Responsibility - it is expected that there will be a positive impact from implementing the circular recycling process. Improving: a) Ease to raise finance b) Image in front of the customer 6. Reduction of export duties associated with import/export from China / to Europe improving ease to export , imp 7. Increased "positive" image of the product lines carrying circular recycled ingredients European Based engineering company A European based egg process engineering company are offering large facilities in Europe and Asia as big demonstrator facilities to address a global market. They have the engineering expertise to manufacture and sell an efficient piece of process equipment and also through global connections bring cost down. They know the global egg processing market and have reach to access this market as an engineering supplier. The impacts of this relationship are expected to: 1. Licensing income to Avgo, from access fees 2. Demonstration on a global stage 3. Reach and sales of equipment to the global egg processing market, providing equipment toll licensing fees 4. Sales of calcium carbonate from equipment buyers, providing license fees, toll 5. Increased income to a UK based company from global markets, 6. Positive benefits to UK PLC through appropriate taxation Providing, on a global scale: 7. Reduced landfill 8. Improved environmental footprint 9. Improved image of the egg industry 10. Provision of a high quality, heavy metal and pesticide free, raw material for the supplements and pharmaceutical industry Calcium Carbonate Customers 1. UK based OTC ante acids supplier - Material has been sampled to this company. They are looking for cGMP so the lead times will be lengthy before we realise sales - 500 tonnes pa 2. UK based distributor into the supplements, food and pharmaceutical markets. Using/Selling substantial volumes of agglomerated calcium carbonate. They are experiencing supply issues from China - both timings and also cost of transport. Bought into the sustainability and circular concept - 400 tonnes pa 3. Large UK based manufacturer. Supply "white label" products to the food supplements market. Having issues with the supply of calcium carbonate, timing costs of delivery, quality (heavy metals and pesticides). Ideally looking for agglomerated material - 600 tonnes pa A number of enquiries from India and Bangladesh about eggshell calcium carbonate for inclusion in new products (Bangladesh market 1500 tonnes). This has come without marketing activity. |
| First Year Of Impact | 2018 |
| Impact Types | Economic,Policy & public services |
| Description | Foodwastenet POC Sourcing protein from the cat. 3 waste of the liquid egg processing industry |
| Amount | £15,873 (GBP) |
| Organisation | Biotechnology and Biological Sciences Research Council (BBSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 11/2017 |
| End | 02/2018 |
| Description | Innovate: The use of Nano MIPS to extract valuable compounds from waste streams |
| Amount | £100,000 (GBP) |
| Funding ID | 133175 |
| Organisation | Innovate UK |
| Sector | Public |
| Country | United Kingdom |
| Start | 03/2018 |
| End | 02/2019 |
| Description | viability of obtaining biopharmaceuticals from eggshell waste |
| Amount | £50,000 (GBP) |
| Funding ID | PoC15_06 |
| Organisation | Biotechnology and Biological Sciences Research Council (BBSRC) |
| Sector | Public |
| Country | United Kingdom |
| Start | 07/2016 |
| End | 01/2017 |
| Title | Method for analysis of calcium carbonate |
| Description | As per research paper published in Food additives and Contaminants A. We suggest an analytical approach involving centrifugation that improves analytical efficiency (up to 85% time reduction), especially for calcium carbonate of biological origin. |
| Type Of Material | Technology assay or reagent |
| Year Produced | 2019 |
| Provided To Others? | Yes |
| Impact | None as yet though our published method does suggest that some of the methods set as 'standards' for the analysis of calcium carbonates for use in pharmaceuticals/ foods should be reconsidered. |
| Title | APPARATUS AND METHOD FOR PRODUCING PURIFIED CALCIUM CARBONATE |
| Description | as per title. |
| IP Reference | PCT/EP2022/061358 |
| Protection | Patent / Patent application |
| Year Protection Granted | 2022 |
| Licensed | No |
| Impact | funds being sought for commercial scale up |
| Description | conference- jointly organised by Food waste net and Ad net |
| Form Of Engagement Activity | A talk or presentation |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Professional Practitioners |
| Results and Impact | One day conference bringing together people from a range of different industries, some research council representation and 2 academics (myself as the only senior academic) to talk about how the research and how this is being taken forward. The most important aspect of impact relates to informing new audiences of the opportunities with this waste stream. Contact with other organisation post meeting. Too early to tell if other contacts will lead to implementation o=r otherwise. |
| Year(s) Of Engagement Activity | 2018 |