Research Projects
LIFE Waste4Growth
The main objective of LIFE Waste4Growth is to strengthen the circular economy by converting insect frass—the primary byproduct of black soldier fly (Hermetia illucens) rearing—into organic, biostimulant fertilizers. According to EU Regulation 2021/1925, insect frass is a mixture of insect excrement, undigested feed substrate, and shed exoskeletons produced during insect rearing. Currently, insect frass is used for biogas production, which means its potential is not fully exploited. By converting insect frass into high-quality organic biostimulant fertilizers, LIFE Waste4Growth supports more sustainable, productive, and climate-resilient agriculture in Europe. The project builds on the results of LIFE Waste2Protein (2019–2023, LIFE18 ENV/DE/000011), which developed the modular, decentralized ReFarmUnits technology for the treatment of bio-waste using insects.
Optimized feed formulations
REPLOID Deutschland GmbH (formerly madebymade GmbH) is developing a data-driven, scientifically grounded process for formulating and optimizing feed formulations based on organic waste streams for black soldier fly (Hermetia illucens) larvae at its Pegau (Saxony) facility. Rather than the trial-and-error approach that has been standard practice to date, the method holistically considers macro- and micronutrients, physical substrate properties, and the nutritional physiology of the larvae. The developed feed formulation products are marketed to operators of decentralized insect farms, improving their bioconversion efficiency, reducing production costs, and enabling the use of a wider range of regional organic waste materials.
Liquid fertilizer made from insect frass
REPLOID Deutschland GmbH (formerly madebymade GmbH) is bringing a novel liquid fertilizer based on insect frass from the black soldier fly (Hermetia illucens) to market readiness at its Pegau (Saxony) facility. The odorless, fast-acting product with biostimulant properties increases plants' resistance to drought stress, heat, and disease, and is aimed at both professional farmers and home gardeners. The project involves developing a regulatory approval strategy, producing a pilot batch, and creating logistics, sales, and marketing concepts — with the goal of increasing resource efficiency and reducing greenhouse gas emissions in crop production.
Valorization of insect frass in a biogas process
REPLOID Deutschland GmbH, in collaboration with DBI – Gas Technology Institute gGmbH Freiberg, is developing a two-stage biogas process for the energy recovery of insect frass from the black soldier fly (Hermetia illucens). The process simultaneously produces biogenic hydrogen and methane, and integrates the legally required hygienization directly into the process – without any additional external steps. In addition to energy recovery, the resulting digestate is assessed for its suitability as a fertilizer. The project further closes the material cycle of insect production and contributes to the circular economy, bioeconomy, and the energy transition.
Innovation Management for Sustainable Insect Production
REPLOID Deutschland GmbH (formerly madebymade GmbH) is establishing a structured, data-driven innovation management system at its Pegau (Saxony) facility to systematically advance process, product, and organizational innovations in insect biotechnology. Interdisciplinary teams spanning production, research, sales, and management are deliberately connected, innovation cycles are accelerated, and agile working methods are embedded throughout the organization. The goal is to develop new marketable products and processes based on the black soldier fly, and to sustainably strengthen REPLOID's competitiveness in the global insect market.
Interreg | foodCIRCUS
foodCIRCUS (Circular Solutions for Keeping Food Waste out of Central Europe's Schools) is an Interreg Central Europe project tackling one of the most overlooked sources of food waste: school and kindergarten canteens, where up to 70% of prepared meals can end up as waste. Bringing together partners from across Central Europe, the project combines prevention, awareness raising, and circular valorisation of unavoidable waste — including insect feeding, biogas, and bioplastics — with the goal of reducing canteen food waste by around 25% across participating sites. REPLOID Group AG contributes as an industrial partner, designing and testing how pre-sorted canteen food waste can be safely integrated into insect-based production processes. The project also aims to deliver practical tools for sustainable school meal management and build a lasting cross-border network for circular school food systems in Central Europe.