Abstract

In the NextVegOil project, an innovative and sustainable production of a palm oil alternative using corn stover, was successfully developed. This groundbreaking, multidisciplinary approach is characterized by the integration of plant biology, microbiology, biochemical engineering, and economic analysis to provide a viable solution to reduce reliance on conventional palm oil. In the scope of the project, we utilized the fungus Ustilago maydis to convert corn biomass into a palm oil substitute.
Small-scale fermentation techniques were established to compare various pretreatment methods for corn stover, with enzymatic hydrolysis identified as particularly effective, enhancing process efficiency. The established technology was further used to identify potential enzymes, which could be introduced into the fungus, to enable a more efficient process without the need for enzyme addition. In parallel, the performance of U. maydis on different soluble sugar backgrounds of maize variants was tested and used to identify genetic regions in maize associated with favorable bioconversion traits.
On the microbial front, U. maydis was further engineered as a chassis for oil production. A fluorescence sensor was developed to monitor lipid accumulation in real-time, and comprehensive RNA sequence data were generated under producing and non-producing conditions. From this data, new strategies and gene candidates were identified to boost yield and enable a more precise fatty acid tailoring.
From a process development perspective, key parameters such as growth conditions and pH management were refined, allowing successful scale-up of the bioprocess for industrial application. A cost estimation model revealed that upstream biomass pretreatment is the main cost driver for an industrial scale process, highlighting areas for future optimization.
Beyond technological development, market dynamics and consumer perceptions of microbially derived oils were examined. Strong support was indicated by studies due to their environmental benefits; however, careful communication and pricing are crucial for maintaining public acceptance. Investment trends suggest that moderate innovation in business models can effectively attract early-stage funding.
In conclusion, an integrated pathway towards producing sustainable palm oil alternatives from corn stover could be demonstrated within the NextVegOil project with significant scientific contributions published in six peer-reviewed publications so far. Not only is bioeconomy advanced through this work but promising solutions for sustainability challenges in NRW are also offered.

BOOST FUND 2.0 Coordinator

Dr. Marcel Mann
AVT - Biochemical Engineering
RWTH Aachen
email: marcel.mann@avt.rwth-aachen.de

Partners

Prof. Dr. Pauly & Dr. Vicente Ramirez, Plant Cell and Biotechnology, HHU Düsseldorf
Prof. Dr. Feldbrügge & Dr. Kerstin Schipper, Mikrobiology, HHU Düsseldorf
Prof. Dr. Büchs & Dr. Kira Kauffmann, AVT - Biochemical Engineering, RWTH Aachen
Prof. Dr. Bröring, ILR - Technology and Innovation Management in Agribusiness, University of Bonn

Funding period

01.06.2022 - 31.08.2025

Funding

NextVegOil is part of the NRW-Strategieprojekt BioSC and thus funded by the Ministry of Culture and Science of the German State of North Rhine-Westphalia.

Publications

Grebe, LA, Richter, P, Altenkirch, T, Mann, M, Müller, MJ, Büchs, J and Magnus, JB (2025). Sampling-free investigation of microbial carbon source preferences on renewable feedstocks via online monitoring of oxygen transfer rate. Bioprocess and Biosystems Engineering 48(3): 413-425.

Richter, P, Panchalingam, J, Miebach, K, Schipper, K, Feldbrügge, M and Mann, M (2024). Studying microbial triglyceride production from corn stover saccharides unveils insights into the galactose metabolism of Ustilago maydis. Microbial Cell Factories 23(1): 204.

Robertz, S, Philipp, M, Schipper, K, Richter, P, Miebach, K, Magnus, J, Pauly, M and Ramírez, V (2024). Monitoring corn stover processing by the fungus Ustilago maydis. Bioresources and Bioprocessing 11(1): 87.

Bröring, S and Thybussek, V (2023). Understanding the business model design for complex technology systems: The case of the bioeconomy. EFB Bioeconomy Journal 3: 100052.  

Wang, S, Robertz, S, Seven, M, Kraemer, F, Kuhn, BM, Liu, L, Lunde, C, Pauly, M and Ramírez, V (2023). A large-scale forward genetic screen for maize mutants with altered lignocellulosic properties. Front Plant Sci 14: 1099009.