Calysta, the company developing and introducing a new protein source based on single-cell organisms - a bacterium called methylococcus – and destined for inclusion in fishfeeds, has built a ‘market introduction facility’ in Teesside, England, with production beginning in this last quarter of 2016.

1. C
alysta, the company developing and
introducing a new protein source
based on single-cell organisms - a
bacterium called methylococcus – and
destined for inclusion in fishfeeds, has
built a ‘market introduction facility’
in Teesside, England, with production
beginning in this last quarter of 2016.
At an opening ceremony prior to
the start of Aquaculture Europe 2016 being held in Edinburgh
in the same week in September, the company said this facility
will enable it to provide commercially-representative samples to
customers for testing from early 2017.
Additionally, Calysta will be pursuing feed trials in warm water
aquaculture species and product registration in jurisdictions
outside the European Union.
The company also announced earlier this year a partnership
with Cargill Corn Milling with an investment estimated at
US$30 million, for production of the FeedKind Aqua protein in
North America and marketing worldwide. A world scale plant is
expected to open in the United States by 2018.
Cargill’s involvement dramatically accelerates the introduction
of commercial production of FeedKind Aqua protein and next
generation products are in active development.
FeedKind Aqua protein can be customized to suit customer
specifications.
Current modifications being pursued include elevating the levels
of individual amino acids, incorporating omega-3 fatty acids and
optimizing the amino acid profile for species-specific dietary
requirements.
FeedKind Aqua protein has proven gastrointestinal benefits to
salmon, including the prevention of soy-induced enteritis. The
company is also researching potential anti-viral and anti-parasite
effects conferred by this new protein product.
Using methanotrophs as a replacement protein source dates
back some 20 years when a Danish company called BioProtein
developed a stable production process for singlecell protein
production. Statoil, the Norwegian oil and gas giant bought into
UK PRODUCTION FACILITY
TO PRODUCE NEW ‘PROTEIN
SAMPLES’ BASED ON SINGLE-CELL
ORGANISMS FOR FEEDS
A NEW PROTEIN
SOURCE FOR FEED
48 | October 2016 - Milling and Grain
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2. the product and process and pursued its potential for inclusion in
fishfeeds before selling the technology in 2014 to Calysta, which
has been further refining it since then.
Critically, both the EU and Norway had approved the use of
Methylococcus-based organisms and the process using them in
fishfeeds during the product's early development.
However, the USA is still to complete its approval of the
product. The company is aiming to have that approval soon and
aims to build facilities in the US by 2018.
Dr Alan Shaw is Calysta President and CEO with its global
headquarters in Menio Park, California. He says, “The opening
of this plant represents the end of a decade of development and
heralds a new era in the race to sustainably feed the world’s
growing population.
“By 2050 the global population is expected to rise from 7.4
billion today to 9.6 billion and require 70 percent more protein
than is currently available.
“Calysta can help meet this need by supplying the aquaculture
industry with a naturally produced, sustainable and traceable feed
alternative to replace conventional ingredients based on fishmeal
and soya. Calysta’s proprietary technology enables retailers and
consumers to have increased confidence in the integrity of their
food.
“Our first focus is the salmon farming industry and we were
very pleased to welcome representatives from a number of key
producers. FeedKind protein has been shown to improve growth
rates, nitrogen retention and gut health in Atlantic salmon.”
Anna Turley, the UK Member of Parliament for Redcar,
“BY 2050 THE
GLOBAL
POPULATION IS
EXPECTED TO
RISE FROM 7.4
BILLION TODAY
TO 9.6 BILLION
AND REQUIRE 70
PERCENT MORE
PROTEIN THAN
IS CURRENTLY
AVAILABLE"
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3. officially opened the facility adjacent to the Centre for Process
Innovation (CPI). She was joined by Dr Shaw and Nigel Perry,
CEO of CPI.
The plant is supported by a conditional Exceptional Regional
Growth Fund (EGRF) award and represents a total potential
investment of UK£30 million. When completed, the facility is
expected to provide employment for 35 to 40 people.
“It was an honour to open Calysta’s market introduction facility
today,” says Ms Turley MP.
“As well as generating investment and employment in Teesside,
this facility puts the UK at the forefront of the race to address
the world’s growing protein demand with novel technologies. I
am really pleased that Calysta have chosen to base their biotech
project here and look forward to seeing the facility develop
further.”
The official opening at the Wilton Centre was followed by a
conference hosted by Calysta to discuss the increasing worldwide
demand for fish protein, traceability and sustainability.
Representatives from Marine Harvest, Sainsbury’s and
Rabobank took part in a panel discussion at the event.
Based in Menlo Park, California and established in 2011,
Calysta brings together experts in biotechnology and product
innovation to focus on commercialising disruptive, sustainable
technologies.
In February 2016 Calysta announced US$30 million in Series
C funding including an investment from Cargill. To date, the
company has raised approximately US$50 million.
Calysta, Inc of Menlo Park in California is an innovator
in sustainable products. Calysta Nutrition develops and
commercialises fish and livestock nutritional products improving
food security worldwide.
CEO Shaw says the goal isn’t to replace conventional fish feed
but to provide alternative sources of protein to supplement the
fast-growing market.
While FeedKind requires no agricultural land, fertilisers or
pesticides and little water – and has a ready feedstock of easily-
cultured methylococcus bacteria - its one drawback is its reliance
on methane which has been partly overcome with the recent
developments of the fracking industry in the US.
The company is, however, aiming to rapidly scale production
once a US plant is in operation and estimates production the first
year at 15,000 tonnes with a target of 200,000 tonnes by 2020.
www.calysta.com
Table 1: Histopathology Scoring of Shrimp
Treatment Shrimp
Number
EMS
Grading1
Sampling
Status
Control (no EMS) 6 G0 Survivors
EMS Control 7 G2 Moribund
EMS + Calibrin-Z 8 G0 Survivors
1
Grading system based upon severity of EMS from G0 (not detected) to G4
(severe infection). Survivors were assumed to have healthy status - U of
Arizona
AREPLACEMENTPROTEINANDITSCARBONFOOTPRINT
FeedKind Aqua protein is a sustainable,
cost-competitive alternative to fishmeal.
On the EU catalogue of feed materials, it
is a single cell protein approved for use in
all aquaculture species.
FeedKind Aqua protein is produced
via natural fermentation with non-GM
organisms and contains 71 percent crude
protein with an amino acid composition
superior to vegetal sources. Ten percent
crude fat content consisting primarily
of short-chain, saturated fatty acids
contributes to fish fillets with a firm
texture.
Replacing fishmeal with FeedKind
Aqua protein improves nitrogen retention
and increases growth rates in Atlantic
Salmon.
It is a protein source that is traceable
from production to the plate, has
a shelf life of over one year and
is produced to high standards of
production – ensuring consistency of
composition batch-to-batch and year-
to-year.
Additionally, FeedKind Aqua protein
has a sustainability profile not found in
other ingredients:
• No animal-based ingredients or
additives
• No mercury content
• Production is independent of weather,
climate variability and fishing
regulations
• It does not compete with the human
food chain
• There is no agricultural land use and
minimal water is required
Calysta has sponsored an impartial
analysis and report by the Carbon Trust
‘Assessment of Environmental Impact
of FeedKind Protein' to look at carbon,
water and land use of the new process.
It should be noted that FeedKind protein
is not currently in commercial production,
says the report.
“This product footprint is based on data
from a decommissioned facility that had
a production capacity of approximately
10,000 tonnes per annum. The location
for the new facility is assumed to be
Mobile, Alabama, USA for the purposes
of this study.
“Commercial production is expected
to begin in 2018, with an expected
production rate of at least 20,000 tonnes
per annum,” it adds.
50 | October 2016 - Milling and Grain
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