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Our client, a leader in the circular economy that turns food waste into high value-added insect proteins, took on the challenge of building the largest insect protein production plant in North America. The massive new facility, covering over 100,000 sq. ft., had to be capable of processing 250 metric tons of organic matter per day, resulting in an annual production of 5,000 tons of larvae meal and oil and 15,000 tons of certified organic fertilizer.
Due to the scale of the project and the need to efficiently manage this massive quantity of organic matter, the plant had to be fully automated. Our client therefore called on NEXRUN’s expertise to design and integrate the advanced technological systems that would ensure the performance and efficiency of this innovative facility, thus placing Canada among the world leaders in insect breeding.
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Context
NEXRUN was involved right from the pre-engineering phase of this new plant to ensure the optimal technological choices were made and the processes were fully automated. Support included participation in the various technological choices made, the manufacture of multiple control panels and the entire programming of the systems.
We also provided the client with a high-performance data collection system, essential for monitoring critical parameters such as humidity and temperature, which have a direct impact on plant performance. At every stage of the process, it was crucial to have accurate information to optimize these parameters, because the loss of a production day can never be recovered.
Challenges encountered
One of the main challenges of this project was managing the schedule overruns often associated with the construction of a new plant. In addition, the innovative nature of the insect breeding process required us to quickly adapt to the particularities of this technology. NEXRUN worked closely with the client to find innovative solutions and ensure that all requirements were met. As with any project of this scale, it was crucial to stay in solution mode.
Suggested solutions
NEXRUN provided experienced project managers to meet the complex needs of the project. We provided an advanced data collection system to monitor critical parameters such as humidity and temperature, which are essential for optimizing production. Our proactivity and experience proved invaluable, as did the versatility and size of our team. We explored the various tools that could be implemented to minimize the resources needed and maximize efficiency through cutting-edge technological solutions.
Concrete benefits
Thanks to the automation and innovative solutions implemented by NEXRUN, the plant continues to see a steady increase in productivity. This optimization is part of a broader framework, where other strategies have also been put in place to improve overall operations. Automation has maximized process efficiency, but it has also freed up time and resources for the company to focus on other key initiatives, reinforcing its position as a leader in the sustainable economy.
This collaboration has improved process accuracy and guaranteed product traceability, two key elements in ensuring production quality and efficiency. As Pierre Fitzgibbon, former Minister of Economy and Innovation, pointed out, “With an innovative insect protein meal product and a new state-of-the-art plant, the company is setting itself up for success in a rapidly growing market.”
Our client has thus positioned itself as a model of technological innovation and sustainability, serving as a benchmark for projects in the circular economy.