Download Bio-based solutions to maximise value generation from

Bio-based solutions to maximise
value generation from biomass
17. April 2013
Klaudija Milos
www.direvo.com
Our Mission
Direvo’s profound know-how and expertise in the development
of bio-based technologies positions us perfectly to
 deliver proprietary solutions allowing the best use of
biomass while maximizing profitability
 create new technologies for the sustainable conversion of
non-food biomass to biofuels and chemicals at lowest
cost
Company
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Clib Conderence 2013
DIREVO Industrial Biotechnology GmbH
History
3
2000
2008
2008
2010
2013
Foundation of
DIREVO
Biotech AG
Spin-off of
Thermostable phytase
developed by Direvo
enters the market
Direvo restructures and
sets new strategy for
growth
Second thermostable
phytase developed by
Direvo enters the
market
DIREVO Industrial
Biotechnology GmbH
2007
2008
2009
2011
Creation of
biopharmaceutical
& industrial biotechnology BU´s
Acquisition of
DIREVO Biotech AG
by Bayer HealthCare
at a transaction
value of € 210m
IBT moves into new stateof-the-art premises
Completion and validation
of technology set-up
Direvo sells its thermostable mannanase to BASF
Animal Nutrition
Clib Conderence 2013
DIREVO Industrial Biotechnology GmbH
Direvo business overview
DIREVO is a leader in biocatalyst optimization for various industrial applications
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
BluServTM covers the technology platform and services offered to the
industry for enzyme engineering, strain development and fermentation
processes.

BluZy® is a line of enzyme based products targeting the US grain and
animal feed industry

BluCon® is a process platform developing new lignocellulose conversion
processes.
DIREVO Industrial Biotechnology GmbH
BluServ
by Direvo Industrial Biotechnology GmbH
DIREVO Industrial Biotechnology GmbH
BluServ: Directed evolution / fee for service
Optimize biomass utilization emphasizing enzymes and microbes
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Process
development
Microbiology
Enzyme
Biochemistry
 Up to 150 L
 Fermentation,
Up-, Downstream
 Strain Isolation
 Genomic
recombination
 Application
relevant assays
 “Factory in a well”
Clib Conderence 2013
Molecular genetics
Screening &
Selection
 Metabolic
engineering
 Recombinant
libraries
 Selection
pressure
 150’000 /day
screening
DIREVO Industrial Biotechnology GmbH
Robotic screening capabilities
Primary screening platform
Two platforms

Multiple unit operations

384 and 1536-well format

Multiple assays on one sample

Automated from library distribution to hit

Homogeneous and heterogeneous formats
picking

Fully automated (24/7) industrial robotics
150.000 Tests/assays per day or 200 site
saturation libraries

Application relevant assays
Confirmation platform

384- and 96-well format

Fully automated 5.000 wells per day
or 15 site saturation libraries

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Application relevant assays
DIREVO Industrial Biotechnology GmbH
Application-relevant HTS assays resembling real
process conditions
Type of assays

Multiple readouts



Use of unlabeled substrates
fluorescence, absorption

Extreme environments
luminescence

Application relevant conditions
Fluorescence based


Multiple types of reading,
Solid substrates (e.g. crystalline
cellulose)
intensity, anisotropy, Förster

Complex technical media
transfer

Surfactants, oxidants etc.

Indirect assays (no surrogate assays)

Direct assays on labeled substrates

Homogeneous and heterogeneous
formats
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Application relevance
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
In the presence of whole cells or cell
lysates

Turbidity acceptable

Milk, waste water, serum etc.
DIREVO Industrial Biotechnology GmbH
Enzymes and optimization parameters
Enzymes of interest
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Optimization parameters

Cellulases

Hemicellulases
surfactants, organic solvant,

Proteases
oxidants)

Phytases, phosphotases

Amylases

Esterases, amidases

Selectivity, specificity

Nitrilases

Inhibitor resistance

Lipases, cutinase

Binding affinity

Oxidases (laccase, peroxidase,

Catalytic activity / specific activity
etc.)

Stereoselectivity
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

Stability
(pH, protease, temperature,
Activity profile and optimum (pH,
temperature)
DIREVO Industrial Biotechnology GmbH
Direvo’s BluServTM offerings
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
Directed evolution of enzymes, e.g.
stability, selectivity, specificity

Directed evolution of strains, e.g.
production efficiency, yield, inhibitors

Process Development & Contract
fermentation

Conducted as
 Fee-for-service
 Research collaboration
 Contract research
 Public funded project
Clib Conderence 2013
DIREVO Industrial Biotechnology GmbH
Track record in enzyme engineering
Direvo has proven its ability to optimize enzymes to meet customer and market requirements
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Product
Enzyme
Optimized parameters
Application
Customer
Market launch
BP-17 / 111
Phytase
Thermo stability
pH resistance
Protease stability
Specificity
Starch liquefaction
Genencor
since 2008
BP-17/111
Phytase
Thermo stability
pH resistance
Protease stability
Specificity
Animal nutrition
Danisco
2013
PIN K224
Mannanase
Specific activity
thermo stability
pH/protease resistance
Animal nutrition
Sold to BASF
in 2012
CEL 1E
Cellulase
Specific activity
Lignocelluloses
degradation
Proprietary
Patents granted
CEL 2D
Cellulase
Specific activity
Food processing
Proprietary
Patents granted
Protease
Specificity, activity
Biocatalysis
Confidential
Running project
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DIREVO Industrial Biotechnology GmbH
®
BluZy
by Direvo Industrial Biotechnology GmbH
The corn ethanol dry-grind process
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DIREVO Industrial Biotechnology GmbH
Ethanol Market Drivers



Sustainable Demand: US Federal mandates
DDGS is the main co-product of the ethanol industry
DDGS Revenue share: 15%  23% of ETOH
revenue

Margin squeeze:
 Corn cost volatility
 Global oil prices

Industry downtime & consolidation
Historical ethanol operating margins (- Dec 2012)
Volatile ethanol margins
and industry consolidation
are driving process
optimization and
value-added co-products
Ethanol operating margins - nearby future prices
Return
over operating
costs (blue
area) under
pressure
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DIREVO Industrial Biotechnology GmbH
Animal Feed Nutrition Drivers
Co-products in animal production
 DDGS is a desirable source of protein/
energy relative to corn and soybean meal
to optimize feed formulation costs
 DDGS is No.2 feedstock in the US
 DDGS amounts to over 35M tons
annually (~ $10 bn market value)
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DDGS consumption by species 2011*
 Demand for increased use in poultry high
 The quality of DDGS needs to be
improved to enable inclusion of more than
10% DDGS in formulations
*Source: 2013 Ethanol Outlook, RFA:
DIREVO Industrial Biotechnology GmbH
Improving economics from corn ethanol dry-grind
process
Efficiency
Biodiesel
Edible Oil
Fibers
Proteins
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Fish
Phytonutrients
DIREVO Industrial Biotechnology GmbH
Improving economics along the value chain
Efficient processing
• Reduced viscosity
• Improved dewatering
& deoiling
• Less energy
consumption
• More water recycling
Reduced
production cost
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High DDGS quality
• Reduced fibers
• Improved
processability
• Constant quality
High value DDGS
Premium Feed
• High true metabolizable energy
• High amino acid
digestability
• High Inclusion Rates
Lower Feed Cost
DIREVO Industrial Biotechnology GmbH
BluZy®: Improving economics along DDGS value chain
Efficient ethanol process
BluZy®-P
Easy implementation
Less energy consumption
Lower production costs
Premium Feed Product
BluZy®-D
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High Value DDGS
High Inclusion Rates
Lower Feed Cost
DIREVO Industrial Biotechnology GmbH
BluZy®: The biological solution
improving process efficiency and co-product quality
”The major benefits of Direvo´s approach are:
 No additional equipment needed for use, no CAPEX
 Controlled process conditions
 Reproducible and consistent processing
 Quality controlled processes and products
 Enzymes are inactivated during production
Beer Well
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DIREVO Industrial Biotechnology GmbH
BluZy® products in the ethanol process
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DIREVO Industrial Biotechnology GmbH
Enzyme treatment in beer well
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DIREVO Industrial Biotechnology GmbH
BluZy-P for efficient ethanol processes
Improving economics of an existing ethanol production
facilities without any investment in equipment needed.
 Reducing viscosity
 Improving dewatering and drying
 Improving de-oiling
Increasing process
efficiency and improving
co-product quality.
 Safe and consistent processing
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DIREVO Industrial Biotechnology GmbH
BluZy-P Development
The biological solution to increase processing efficiency of DDGS
Lab
Small Pilot
Pilot
Production scale
 Screening of
different enzyme
activities alone
and in various
combinations for
improved
dewatering
 Test performance
on small pilot
scale of 100L
scale
 Further up-scaling
2000 L and
production of
400kg DDGS for
animal trials
 2 - 3 week trial in a
commercial
35MGY ethanol in
April 2013
Selected enzymes were up-scaled and performance confirmed in each scale .
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DIREVO Industrial Biotechnology GmbH
BluZy-P generates value for ethanol processor
The technology is easy to implement, requires a tank/pump, meter, QA (not capital, or engineering
intensive) and offers benefits at different stages of production.
Saving potentials
Value creation for a 100 MGY plant

Less Fresh Water consumption:
improved dewatering allows to recycle more
water and can reduce the fresh water
consumption by 10%

Less Fresh Water consumption:
200.000 $

Energy reduction by using less:
Gas : 2,5 to 5%
Electricity: 12 – 15%
Steam: 5%

Energy reduction by using less:
Gas : 0,5 – 1 M$
Electricity: 0,6 M$

Oil seperation
Replacing surfactants: up to 4000$ per day
Separation of 50% more oil:

Oil separation
Replacing surfactants: 1.4 M $ per year
More oil: 4 M$

Reduced maintenance:
Less fouling, cleaning, etc.
2 days @ $50,000 (fixed cost of asset) +
lower equipment repair = $250,000

Reduced maintenance:
$250,000
total value of up to 5 M$ per
100 MGY plant
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DIREVO Industrial Biotechnology GmbH
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DIREVO Industrial Biotechnology GmbH
BluZy-D reducing feed costs in poultry production
Enzymatic removal of fibers from DDGS improves
nutritional profile of DDGS, and enables increased use in
broiler diets.
 High metabolizable energy
 High Fiber digestibility
 High Protein digestibility
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Lowering Feed cost by
replacing corn, soy bean
meal and phosphate.
DIREVO Industrial Biotechnology GmbH
DDGS from BluZy-D production reduces feed costs
~ 50$/ton
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DIREVO Industrial Biotechnology GmbH
BluZy-D
The biological solution in production of high value DDGS for monogastrics
1.
Optimized nutritional contribution
Improved feed digestibility
2.

Increases the metabolizable energy of DDGS by 6-8%

Improves the lysine digestibility of DDGS by 3,5%
Excellent performance
Improved weight gain

Increases live weight by 3,5% in the starter period

Improves feed conversion by 2%
3. High value product
Higher inclusion rates
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
10% inclusion rate already in starter period possible

Dryer litter
Clib Conderence 2013
DIREVO Industrial Biotechnology GmbH
BluZy® - Improving overall economics of the corn-toethanol industry by increasing production efficiencies,
improving value capture on the main by-product
DDGS and generating new co-products.
BluZy®-P
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BluZy®-D
BluZy®
DIREVO Industrial Biotechnology GmbH
Thank you for your attention.
Danke für Ihre Aufmerksamkeit.
17.4.2013
Klaudija Milos
[email protected]