Executive Summary: Upcycling bovine co-products for sustainable protein

Summary of Project and Key Findings (for public disclosure):
Bovine hide-face pieces are an obligatory co-product which must be rapidly channelled out of the production line. Owing to the lack of ‘food-grade’ further processing technologies available in NZ, the current best alternative for managing such co-products is landfill and rendering. This project investigated the feasibility of developing a scalable process to utilise beef hide/face pieces to produce a beef protein powder as a food ingredient for human consumption.

The investigation started the process development from a bench scale (1- 10 kg). Sample pretreatment methods, tallow by-product, protein extraction via protease hydrolysis were tested out for the selection of processing parameters and overall process protein yield. The best processing conditions were used in the intermediate scale production at 100 kg. Finally, the pre-pilot scale production using 300 kg hide material was run at food grade in Food Innovation Network facility. The scale up production produced better results in final solid yield and consistent functional properties in the final protein powder. In summary, a food grade efficient process was developed which can transform waste bovine hide pieces to a high protein (and collagen) powder, and ready to be taken up to the next pilot run. The extracted protein powder has been characterised to understand its composition, functional properties and potential applications as ingredients for food and beverage producers.

Catalogue of IP Generated by the Project (kept confidential to the BPA):
At this stage, no IP is to be pursued but the developed process for protein extraction from beef hides and faces will be kept as tech know how.

Statement from the industry partner describing the business impact of the project (kept confidential to the BPA):
This project was established to find alternative uses for bovine head pieces, aiming to recover more value, minimize costs, and reduce the environmental impact of handling these co-products. The main output was a proprietary process for creating beef protein isolate, which includes raw material preparation, extraction, and purification. This new capability for Alliance involves enzyme selection and application, precise thermal treatment, and advanced membrane filtration to ensure consistent product yield and quality.

A major challenge from earlier projects—product bitterness—was successfully addressed. While other undesirable flavors were revealed after the bitterness was removed, flavor improvement remains a goal in ongoing product development to increase customer acceptability.

The project enabled a techno-economic assessment (TEA) to determine the required CAPEX and OPEX. It has fully equipped the Business to conduct informed discussions with potential third-party partners, allowing for confident and strategic decision-making regarding the commercialization of enhanced proteins derived from beef co-products. This project has given Alliance a scalable platform for innovation, positioning the company as an industry leader in sustainable by-product utilization and high-value protein production.

TRL at start of project = 2-4
TRL at end of project = 5.0