AS Metrosert is establishing a state-of-the-art synthetic biology and biorefining pilot plant in Estonia as part of the national Applied Research Centre (RTO). Our goal is to address a critical gap in Estonia’s innovation system by serving as a trusted partner for researchers and businesses during the product-development scale-up phase and helping turn laboratory discoveries into industrial production.
Synthetic biology and bioprocessing make it possible to produce raw materials, chemicals, materials and food products sustainably. However, scaling from laboratory level to industrial volumes is expensive and technologically risky for companies. Metrosert’s pilot plant provides the necessary infrastructure, expertise and testing systems, significantly reducing development risks for businesses.
What do biorefining and synthetic biology make possible?
Biorefining means fractionating and processing biomass, such as wood, agricultural residues and algae, into high-value products and energy while minimising waste generation. Through precision fermentation and synthetic biology, wood-derived sugars or plant-based raw materials can be converted into high-value end products.
- Novel foods and plant-based proteins: Replacing animal protein with plant-based or microbial protein helps meet the world’s growing food demand while reducing greenhouse gas emissions.
- Environmentally friendly bioplastics and materials: Petroleum-based plastics can be replaced with biodegradable materials. Cellulose nanofibres can be used to produce materials that are stronger than steel.
- Advanced chemicals and healthcare solutions: Bio-based chemicals, cosmetic ingredients and drug-delivery systems for personalised medicine.
State-of-the-art equipment and infrastructure
Our testing systems are designed to be flexible and to meet the requirements of different technologies at technology readiness levels TRL 5 to TRL 7. Unlike many pilot facilities in the region, our pilot plant is fully automated and digitalised from the outset. It provides complete process support, from raw-material preparation to the separation and drying of the final product.
Our main equipment and testing systems include:
- Fermentation and bioprocessing — upstream
- Fermenters with capacities of 5 m³, 0.5 m³ and 50 litres
- Enzymatic reactor with a capacity of 4 m³
- Media-preparation, feed and collection tanks, with and without high-shear mixers, in various capacities of up to 1 m³ and 4 m³
- Separation and downstream processing
- Nozzle or disc-stack separator
- Chromatography skid
- Tangential-flow filtration system and filter press system
- High-pressure homogeniser
- Drying and forming
- Falling-film vacuum evaporator
- Spray dryer
- Final dryer and multipurpose fluidised-bed dryer
- Lyophiliser, or freeze dryer
- Yeast extruder for dry yeast
A collaborative value-chain model
We do not work in isolation. Instead, we bring together all parties in the product-development value chain, including researchers, agricultural producers, processors and retailers. This co-creation model ensures that the developed product meets market and consumer expectations in terms of both taste and price.
[Farmers / Raw materials] ➔ [Researchers / R&D] ➔ [Metrosert Pilot Plant / Scale-up] ➔ [Industry and Retail]
- The farmer knows exactly which varieties to grow and has a guaranteed buyer.
- Industry receives an optimised, energy-efficient processing technology and a reliable supply of raw materials.
- The consumer receives a tasty, healthy and affordable end product.
Project funding and official information
The establishment of Estonia’s synthetic biology and biorefining pilot plant is a strategic national investment. The total cost of the project is approximately 19 million euros.
The project is supported by the Estonian state and the European Union through the following measures:
- Estonian Business and Innovation Agency (EIS): EIS is supporting the purchase of equipment and the construction of infrastructure with 4 170 000 euros under the activity “Support for R&D infrastructure of companies providing research and development services”, established by Regulation No. 23 of the Minister of Entrepreneurship and Information Technology of 21 March 2022, “Regulation on Applied Research by Enterprises”.
- Agricultural Registers and Information Board (PRIA): PRIA is supporting the purchase of equipment with 343 266,38 euros under Regulation No. 48 of the Minister of Rural Affairs of 19 August 2022, “Investment Support for the Valorisation of Bioresources”.
