MSc Thesis M.G.

Assessing the potential for large scale production of insects

A study on the quality attributes that can influence a large scale production of Yellow mealworm (Tenebrio molitor).

Student: Maria Giakoumelou Supervisors: dr.ir. JJA (Joop) van Loon

dr. JLF (Geoffrey) Hagelaar

Background information

• Growing world population and wealth - Approaching 9 billion people in 2050 (FAO, 2009) - Increasing demand for food the coming decades (Gahukar, 2011)

• Insect production creates less pollution than the common animal (cow/pig) production

- Yellow mealworms produce much less GHG’s (Greenhouse Gases) than pigs, chickens and cattle (Oonincx & De Boer, 2012)

• Insects as alternative protein sources- Entomophagy is the practice of eating insects (FAO, 2013)- Rich nutritional value (Sirimungkararat et al.,2010)- Especially rich source of protein (Ramos-Elorduy et al., 2012)

But- Nutritional value of edible insects can vary (Van Huis, 2003)- Depending on their developmental stage and diet (Van Huis, 2003)- Depending on environmental factors such as temperature (Sonmez & Gulel, 2008),

humidity (Nedved & Kalushkov, 2012). - Such factors can cause changes in development and rate of growth (Toba et al.,

1967)

Background information

Yellow mealworm

• Larvae phase• 8-10 weeks to reach the size for

harvest(NVWA, 2012)• Rich in protein and fatty acids

(Finke, 2008)• In the EU, insects fall within the

definition of novel food as food ingredients isolated from animals. Parts of insects also fall within this definition (Regulation PE-CONS 38/1/15)

• Demarcation- focus on the Quality Design function in order to analyze the diverse

technological and managerial aspects that can influence the outcome.- focus on the mass production system of Yellow mealworm (Tenebrio

molitor) - more precisely focus on the up-scaling step from pilot step of the quality design, because it is expected higher requirements take place regarding capital, equipment and facilities from small to large scale production (Smit, 2000)

Introduction to the research

• Aim of study- is to highlight the key factors relevant to upscaling of insect production upscaling, how they contribute to the large scale production and how these influence the quality outcome on safety, and nutrition value.

• The research objectives are to gain insight in

• 1. The technological (mass rearing and processing) and managerial (consumer orientation) requirements for insect mass production during the quality design process.

• 2. The rearing conditions that influence and are important for the insect production upscaling.

• 3. What influences the quality attributes of a Yellow mealworm production.


• Research questions- 1. Which factors in the up-scaling step can influence the consumers’ perception of quality of an insect product?- 2. Which conditions and activities during the mass rearing and processing of insects can influence the quality of the final product (from the consumer viewpoint) and the production volume of edible insects? - 3. What is the influence of these factors on the quality and possibly interaction effects between the quality attributes.


Insect mass rearing- production techniques- production conditions

Insect mass processing

- heat treatment - freeze-drying

- drying- preservation techniques

Quality (nutritional value, safety) of insect

products for human consumption through large scale production

The up-scaling step of quality design process for the production of Yellow mealworms as food.Realizing optimum production process for product quality, product yield, process control and costs

Mass rearing of insects

-Degree of insect welfare during the rearing process.-Apropriateness of ambient conditions during insect rearing.

Technological Factors

Mass processing of insects

-Knowledge on processing methods.

-Appropriateness of application of HACCP principles.

Managerial factorConsumer Orientation

-Adequacy of information acquired, shared, interpreted and utilised about consumers.

Theoretical Framework

Hypothesis• If welfare and technical requirements (ambient conditions) on the

insect rearing facilities are met, safety requirements during processing are performed and high level of consumer orientation is achieved, then successful large scale insect production and quality insect products for human consumption will be possible.

Research methods

• Exploration of the research topic• Using tools (boolean operators, synonyms, and

wildcards)• Using databases (ScienceDirect, Scopus,

WurLibrary)• Using journal articles and books relevant to the

topic of study.• Assessment of factors for the identification of

indicators.• For greater accuracy, use of levels (defined by

Luning et al., (2008)) to analyze the present situation of the given indicators and the current level of insect companies.

• Completing of questionnaire by experts of insect companies

• The questions are divided in 4 main parts: 1. General questions about the expert 2. Questions about the consumer orientation 3. Questions about the mass rearing of insects 4. Questions about the mass processing of insects

Part A: SYSTEMATIC LITERATURE REVIEW Part B: STUDY ON THE RESPONSES OF QUESTIONNAIRE

Results• The most of the potential respondents showed little willingness to

participate and share their experiences.

• Only 3 of 10 Dutch companies participated.

ResultsFactor Indicator Current Level*

Consumer orientation 1) Adequacy of information about the consumer. Level 3

Mass rearing

1) Degree of insect welfare during the rearing process. Level 2/3

2) Appropriateness of ambient conditions during insect rearing. Level 2/3

Mass processing

1) Knowledge about processing methods of insects. Level 2

2) Adequacy of application of HACCP principles. Level 3

*The optimal situation is always characterized by the reference situation level 3.

Conclusions

Number Bottlenecks

1 Lack of legislation on welfare of insects.

2 Lack of deeper technical knowledge in insect rearing and processing.

There are no specific welfare regulations for insects and the current legislation on welfare of animal production typically refers to Brambell’s five freedoms, but excludes invertebrates (Jönsson & Wätthammar, 2013).Although some successful processing methods are used for the production of insects, not all methods are currently reproducible at the industrial scale and more research in this area is needed (Veldkamp et al., 2012).

- Filling of the existing legislation gaps about insect welfare - Filling of the existing research gaps through multidisciplinary approach

Conclusions• Insect rearing companies are involved in activities to enhance the insects’

welfare and more specifically, in the absence of specific welfare regulations for insects, insect farmers have individually developed their own production practices and they are generally hesitant to share their expertise.

• Technical requirements, such as ambient conditions (humidity, temperature) have not been performed on a widely known and ideal level, but their range is determined by the company’s experience.

• Safety requirements during processing are performed to a certain extend and awareness of this aspect is present.

• High level of consumer orientation through data collection.

Conclusions• Overall, it can be concluded that the initial hypothesis is partially

proven.

If welfare and technical requirements (ambient conditions) on the insect rearing facilities are met, safety requirements during processing are performed and high level of consumer orientation is achieved, then successful large scale insect production and quality insect products for human consumption will be possible.

Recommendations for further research

- Specific research on insect welfare during the rearing processes and the standardization of regulations and safety guidelines for their production.- Research on the industrial development of insect products, focusing on welfare issues, processing, product commercialization and alignment of market with supply and demand of insect products.- Specific marketing research about advertising of insect products and how to overcome acceptability barriers.- Research on the up-scaling of insect production in other countries in order to compare the major problems and acquire deeper knowledge that is necessary for the solution of problems.

Thank you for your attention!

Questions and comments?

Consumer Orientation

Mass Rearing- welfare requirements- ambient conditions requirements (humidity, temperature)

Mass Processing- required knowledge on

processing methods- HACCP requirements

Rearing Processing

Quality (availability, safety, health, nutritional value) of yellow mealworm products for human consumption through large scale production

Theoretical Framework

Evaluation of the research

Literature Analysis

Theoretical Frameworks

Developing research methodology/approach

Data Collection

Questionnaire preparation

Completing the questionnaire

by experts

Data Analysis

Results and Discussion

Analysis and examination of the hypothesis.Acceptance or rejection

Thesis Plan

Explanations• Brambell’s Five Freedoms (Brambell, 1965):

the freedom from hunger and thirst,

the freedom from discomfort,

the freedom from pain, injury and disease,

the freedom to express normal behavior and the freedom from fear and distress.

Explanations• It takes 8 to 10 weeks at a temperature of 28–30 °C and 60 % relative

humidity for mealworms (Tenebrio molitor) to reach the size for harvest (NVWA, 2012)

• The optimal growth rate for mealworms at 25 °C is attained at 70% RH (Machin, 1975)

ExplanationsThe proposed by Luning et al. (2008), general grid is presented below:- Level 1: is characterized by lack of scientific evidence, use of company history/experience, variable, unknown, based on common-material equipment and not adapted to the production system.- Level 2: is related to best practices knowledge and equipment, sometimes variable, not always predictable and based on generic information in the production industry. - Level 3: is associated with scientifically underpinned (accurate, complete), stable, predictable and tailored information and technology for the specific food production situation. For the large scale production of insects the indicators will be determined in levels and the reference situation (optimal situation for a given indicator) will be proposed based on scientific literature. The assessment of the level based on the indicators will determine which areas are currently being operated closely or further from the reference situation, which will give insights into the positive and limiting aspects for large scale production of insect for human consumption.

Explanations

Indicator: Adequacy of information about consumer• Level 1: is characterized by lack of information about

consumers, in which the acquired information do not follow the next steps in order to be acted upon. This level is characterized by companies with very low level of interest in consumer’s concerns and low level of knowledge about their consumers;

• Level 2: is characterized by presence of acquisition and sharing of information about consumers but the information is not specific to the product and not further interpreted and acted upon. This level is characterized by companies which do not examine information to identify trends or patterns that may be significant to the company;

• Level 3: is characterized by presence of acquisition, sharing, interpretation and utilization of information about consumers. This level is characterized by companies which design their decisions and strategies based on knowledge about the consumer marketplace.

Indicator : Degree of insect welfare during the rearing process• Level 1: is characterized by lack of any welfare

standards regarding the rearing of insects. The unnatural, stressful environment and unnatural density of animals can lead to health issues and extensive medication provided than more space.

• Level 2: is characterized by moderate use of welfare standards. Some of the five freedoms are followed.

• Level 3: is characterized by large use of welfare standards. The insect farms respect the five freedoms, action that is proven economically beneficial and produce healthy and safe products as well.

ExplanationsIndicator : Appropriateness of ambient conditions during insect rearing• Level 1: is characterized by companies which are

unaware about the optimal temperature of Yellow mealworms and the correlation of that with the growth rate and nutritional value of insects.

• Level 2: is characterized by companies which have information about the optimal temperatures that could lead to high growth rate and high protein content of insects.

• Level 3: is characterized by companies which have the knowledge about the optimal temperatures that could lead to high growth rate and high protein content of insects. Finally, these companies apply that knowledge and produce according to that.

Indicator : Knowledge about processing methods of insects• Level 1: is characterized by lack of knowledge both in

laboratory scale as in industrial scale for all the following methods that could be applied for insect processing: e.g. extraction of fat, extraction of protein, browning reactions.

• Level 2: is characterized by existing knowledge which may be primarily in laboratory scale or tested in pilot plants of the following methods that could be applied for insect processing: e.g. extraction of fat, extraction of protein, browning reactions.

• Level 3: is characterized by existing knowledge which is developed and applicable in industrial scale for all the following methods that could be applied for insect processing: e.g. extraction of fat, extraction of protein, browning reactions.

ExplanationsIndicator : Adequacy of application of HACCP principles

• Level 1: is characterized by no application of HACCP principles in the processing of insects. No information about identified CCPs, tolerances and monitoring and any verification procedures or record keeping.

• Level 2: is characterized by the use of HACCP principles based on hygiene codes or on advices of specialized consultants, but not tested for specific food production systems characteristics of insects. Identification of CCPs, tolerances and monitoring program determined by microbiological tests, historical data and by general hygiene codes but not tailored for the specific production system. Verification and record keeping procedures based on international standards but not specific for the insect production system.

• Level 3: is characterized by the use of HACCP principles using own knowledge and experience, additional scientific literature and or expert knowledge and according to Codex guidelines. CCPs identification, tolerances and monitoring program determined by microbial product tests, modelling of hazard behavior and/or challenge tests, from process parameters derived from legal requirements, hygiene codes, literature, and tested and tailored for the specific production system of insects. Verification and record keeping procedures based on international standards but and specific for the insect production system.

Questionnaire (1/6)1. Question about the expert: 1) Which organization/company do you work for?2) Is this an organization/company that produces mealworms for feed or food?3) Does your organization/company produce other insects?4) What is your current job position?5) How long have you had experience with insect production in this organization/company?

2. Consumer orientation: Adequacy of information about consumer:1) Please give your opinion about your company’s consumer orientation. Do you think your company is aware of trends and events, opportunities and/or threats that may be significant to its production? (A) Not aware at all (B) Aware but they can improve (C) Very much aware.

2) Do you think that your company feels the need to keep updated regarding its customers/consumers’ needs? (A) Yes (B) No

Questionnaire (2/6)3) If so, how does your company attempt to learn about the customers/consumers?

(A) Complaints or requests (B) Surveys (C) Consumer panels (D) Other 4) In case that your company acquires information from its customers/consumers, based on your experience, how does it utilize such information?

(A) Developing a strategic plan of the company (B) A decision-making on what and how to produce based on customer/consumer demands(C) Other…

3. Mass rearing of insects: Insect welfare during the rearing process:1) Is insect welfare part of policy of your company?

(A) Yes(B) No 2) How important is the insect welfare for your organization/company?

(A) Not at all(B) Important(C) Very important 3) If insect welfare is to some degree of importance, could you give a short example which is typical for how important this topic is.

Questionnaire (3/6)4) Based on your experience with rearing of insects, do you classify your company at Level 1, Level 2, or Level 3? Level 1: is characterized by lack of any welfare standards regarding the rearing of insects. The unnatural environment and density of animals can lead to health issues.Level 2: is characterized by moderate use of welfare standards. Some of the five freedoms* are provided. Level 3: is characterized by explicit use of welfare standards. The insect farms respect the five freedoms*, action that is proven economically beneficial and produce healthy and safe products as well.* Brambell’s Five Freedoms (Brambell, 1965): the freedom from hunger and thirst, the freedom from discomfort, the freedom from pain, injury and disease, the freedom to express normal behavior and the freedom from fear and distress.

Appropriateness of ambient conditions during insect rearing: 1) Do you use humidity control in your company’s rearing facilities? Is it automated? 2) Do you use temperature control in your company’s rearing facilities? Is it automated? 3) How did you determine the specific range of temperature and humidity that you apply? On which information this decision is based?4) Do you take into account the optimal temperature and humidity of mealworms and their effects on the nutritional value of the insects produced?

(A) Yes(B) No

Questionnaire (4/6)5) How these factors influence growth and nutritional value? Based on your experience with the ambient conditions of insects during the rearing process, do you classify your company at Level 1, Level 2, or Level 3? Level 1: has information about the optimal temperature of mealworms and the effect on growth rate and nutritional value of insects but control technology not affordable. Level 2: has information about the optimal settings of temperature and humidity that could lead to high growth rat+e and high protein content of insects but only limited control options to regulate these.Level 3: has the knowledge about the optimal settings of temperatures and humidity that could lead to high growth rate and high protein content of insects, applies the knowledge and have tight control over ambient conditions.

6) By which means does your company acquire such knowledge?

(A) Own research (B) Literature(C) Non-public information from others (D) Combination of A, B and C.

7) Does your company expect variation in the growth rate of insects applying different ranges of temperature and humidity?

(A) Yes(B) No

8) If yes, how do you work with that knowledge?

9) Does your company experiment with different ranges of temperature and humidity, to reduce the cost of production?

10) If yes, how do you do that and what are the results from that?

Questionnaire (5/6)4. Mass processing of insects:Application of food and feed safety measures:1) How important is for your company to be able to ensure safety of insect products for the large scale production of insects.

(A) Not important (B) Important, but not critical(C) Very important 2) What could cause safety problems and how your company deal with those possible causes? Could you give a short example? 3) How great is the risk that something happens?

(A) Little risk (B) Medium risk (C) High risk 4) And then what is the impact?

5) Which are the most common safety guidelines and/or hygiene codes used to guarantee the safety of processed insects? (Please mention the ones most common in your opinion.)

6) How would you describe your insect company’s commitment to safety aspects? Based on your experience with the safety guidelines of insects during the rearing process, do you classify your company at Level 1, Level 2, or Level 3?

Level 1: No application of HACCP (Hazard Analysis Critical Control Points) principles in the processing of insects. No information about identified CCPs (Critical Control Points), tolerances and monitoring, verification procedures or record keeping.

Level 2: Use of HACCP principles based on hygiene codes or on advices of specialized consultants, but not tested for specific insect food production system characteristics. Identification of CCPs, tolerances and monitoring program determined by microbiological tests, historical data and by general hygiene codes but not tailored for the specific production system. Verification and record keeping procedures based on international standards but not specific for the insect production system.

Level 3: Use of HACCP principles using own knowledge and experience, additional scientific literature and or expert knowledge and according to Codex guidelines. CCPs identification, tolerances and monitoring program determined by microbial product tests, modelling of hazard behavior and/or challenge tests, from process parameters derived from legal requirements, hygiene codes, literature, and tested and tailored for the specific production system of insects. Verification and record keeping procedures based on international standards but and specific for the insect production system.

Questionnaire (6/6)7) Is it a typical activity of your company to apply HACCP (Hazard Analysis Critical Control Points) principles in the processing of insects?

(A) Not at all.(B) Customarily but we can improve.(C) We always apply HACCP principles. 8) Does your company have an HACCP (Hazard Analysis Critical Control Points) person or team, present in the company?

(A) Never (B) Sometimes (C) Always 9) If HACCP is implemented is that done by internal people or external? (A) Internal (B) External 10) Are these people experienced or have a HACCP background?

(A) Yes (B) No

11) How does your insect company identify the CCPs (Critical Control Points) in the company?

(A) Management knowledge (B) Tests (C) Consultants (D) Other…

12) Are there monitoring programmes for the control of CCPs?

(A) Yes (B) No

13) If so, how are they checked? (Please mention the most common method).

14) Does your company has verified processes and record keeping in place? If so, how are they done? (Please mention the most common method).

Which organization/company do you work for?

Marba Apeldoorn B.V. Topinsect bvba Kreca Ento-Feed BV

Is this an organization/company that produces mealworms for feed or food?

Feed for feed and for food both

Does your organization/company produce other insects?

No Many other insects yes

What is your current job position?

CEO Manager assistent manager

How long have you had experience with insect production in this organization/company?

30 years in the family for 90 years

30 years 40 years

Please give your opinion about your company’s consumer orientation. Do you think your company is aware of trends and events, opportunities and/or threats that may be significant to its production?

Aware but they can improve Aware but they can improve Very much aware.

Results

Do you think that your company feels the need to keep updated regarding its customers/consumers’ needs?

Yes Yes Yes

If so, how does your company attempt to learn about the customers/consumers?

Contact with other producers

Consumer panels Complaints or requests

In case that your company acquires information from its customers/consumers, based on your experience, how does it utilize such information?

A decision-making on what and how to produce based on customer/consumer demands

A decision-making on what and how to produce based on customer/consumer demands

Developing a strategic plan of the company

Is insect welfare part of policy of your company?

Yes Yes Yes

How important is the insect welfare for your organization/company?

Important Very Important Important

If insect welfare is to some degree of importance, could you give a short example which is typical for how important this topic is.

Good welfare means high production of healthy mealworms

The better an insect feels, the better it breeds.

You have to explain to your customers how insects live and what the can handle. If we want a success in the food industry insect welfare is important.

Results

Based on your experience with rearing of insects, do you classify your company at Level 1, Level 2, or Level 3?

Level 3: is characterized by explicit use of welfare standards. The insect farms respect the five freedoms*, action that is proven economically beneficial and produce healthy and safe products as well.

Level 3: is characterized by explicit use of welfare standards. The insect farms respect the five freedoms*, action that is proven economically beneficial and produce healthy and safe products as well.

Level 2: is characterized by moderate use of welfare standards. Some of the five freedoms* are provided.

Do you use humidity control in your company’s rearing facilities? Is it automated?

yes Yes yes

Do you use temperature control in your company’s rearing facilities? Is it automated?

yes Yes yes

How did you determine the specific range of temperature and humidity that you apply? On which information this decision is based?

experience Experience experience of 40 years breeding

Do you take into account the optimal temperature and humidity of mealworms and their effects on the nutritional value of the insects produced?

Yes Yes Yes

Results

How these factors influence growth and nutritional value?

controlling that we control production

yes if you don't use the correct parameters, your breeding is not going well

Based on your experience with the ambient conditions of insects during the rearing process, do you classify your company at Level 1, Level 2, or Level 3?

Level 2: has information about the optimal settings of temperature and humidity that could lead to high growth rate and high protein content of insects but only limited control options to regulate these.

Level 3: has the knowledge about the optimal settings of temperatures and humidity that could lead to high growth rate and high protein content of insects, applies the knowledge and have tight control over ambient conditions.

Level 3: has the knowledge about the optimal settings of temperatures and humidity that could lead to high growth rate and high protein content of insects, applies the knowledge and have tight control over ambient conditions.

By which means does your company acquire such knowledge?

Combination of A,B and C Own research Combination of A,B and C

Does your company expect variation in the growth rate of insects applying different ranges of temperature and humidity?

Yes Yes Yes

If yes, how do you work with that knowledge? I use that to manage my production

flexibility Those facts have influence on the hole rearing aspect.

Results

Does your company experiment with different ranges of temperature and humidity, to reduce the cost of production?

No No No

If yes, how do you do that and what are the results from that?

Does your organization/company process insects?

No Yes Yes

How important is for your company to be able to ensure safety of insect products for the large scale production of insects.

Very important Very important

What could cause safety problems and how your company deal with those possible causes? Could you give a short example?

HACCP procedure problems with the feed, diseases

Results

How great is the risk that something happens? Medium risk Medium riskAnd then what is the impact? HACCP procedure depends on what went wrong, but worse case:

breeding downWhich are the most common safety guidelines and/or hygiene codes used to guarantee the safety of processed insects? (Please mention the ones most common in your opinion.)

HACCP procedure haccp/ breedingbook of the VENIK/ cooperation with Eurofin

How would you describe your insect company’s commitment to safety aspects? Based on your experience with the safety guidelines of insects during the rearing process, do you classify your company at Level 1, Level 2, or Level 3?



Results

Is it a typical activity of your company to apply HACCP (Hazard Analysis Critical Control Points) principles in the processing of insects?

We always apply HACCP principles

Customarily but we can improve

Does your company have an HACCP (Hazard Analysis Critical Control Points) person or team, present in the company?

Always Sometimes

If HACCP is implemented is that done by internal people or external?

Internal External

Are these people experienced or have a HACCP background?

Yes Yes

How does your insect company identify the CCPs (Critical Control Points) in the company?

All three mentioned above

Management knowledge

Results

Are there monitoring programs for the control of CCPs?

Yes Yes

If so, how are they checked? (Please mention the most common method).

Analysis on all products and process.

-

Does your company has verified processes and record keeping in place? If so, how are they done? (Please mention the most common method).

Yes, system agreed bij FAVV Belgium.

yes

Results

MSc Thesis M.G.

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