BioMade | Valorization of insect frass in a two-stage biogas process

About the Project

REPLOID Deutschland GmbH (formerly madebymade GmbH), in collaboration with DBI – Gas Technology Institute gGmbH Freiberg, is developing an innovative process for the energy recovery of insect frass – the waste material from the rearing and processing of the black soldier fly (Hermetia illucens) – using a two-stage biogas process. 

Insect production generates significant quantities of frass, a mixture of substrate residues, excrement, and insect exoskeletons. The BioMade project develops a specially adapted two-stage biogas process that simultaneously produces biogenic hydrogen and methane, and directly integrates the legally required substrate hygienization – without additional external process steps. This efficiently unlocks the energy potential of this waste stream and further closes the sustainable material cycle of insect production. 

The findings generated will create the scientific foundation for broad application of this process across the growing insect rearing industry – contributing to the circular economy, bioeconomy, and the energy transition. 

Objectives

• Develop and scale up a two-stage biogas process for the simultaneous production of biogenic hydrogen and methane from insect frass 

• Integrate the legally required hygienization directly into the thermophilically operated pre-reactor (70 °C) – without an external hygienization stage 

• Characterize and assess the digestate for its suitability as a fertilizer 

• Conduct a technical and economical assessment and prepare for market readiness  and preparation for market readiness