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ETSA, a subsidiary of Semapa Group, has been dedicated to rendering—transforming food by-products into value-added products—for over 50 years. This activity converts inedible parts of animals into ingredients for animal feed, biofuels, and industrial products, playing a crucial role in promoting sustainability and the circular economy.
Preparing for the next 50 years, ETSA has been strengthening its commitment to R&D to develop higher value-added products. Recently, ETSA ProHy project was recognised in the second edition of the National Innovation Award (PNI) in the Business segment, subcategory Agriculture and Industry. This is the largest initiative for recognising innovation in Portugal, with Nova SBE as a knowledge partner.
André Almeida, New Business and R&D Director at ETSA and leader of this project, explains that “this recognition is very important for the Group, as ProHy technology is the result of internally developed innovation that involved several years of research. This distinction reinforces that we are moving in the right direction”.
ProHy technology represents a turning point in ETSA’s history and strategy. Until now, the focus was on producing high-quality but undifferentiated products (commodities). The new positioning, which is being implemented gradually and involves training for employees and attracting new talent, focuses on manufacturing differentiated and high-value-added products, such as ProHy. This project, which has been under development for six years, involves close collaboration between ETSA’s R&D department and academic institutions, particularly Universidade Católica, in Lisbon.
ProHy is a natural product. To date, the production process for hydrolysed animal proteins available on the market required the addition of enzymes. This new technology developed by ETSA is innovative because it dispenses with any type of chemical reagent; in this case, hydrolysis is done through pressure and high temperatures.
ProHy offers several advantages: it has a protein content exceeding ninety-three percent and, due to its very high digestibility, is especially suitable for feeding animals in their early stages of development. Additionally, it has antioxidant properties that combat and slow cellular aging and possesses a high hypoallergenic potential.
The factory being built at ETSA’s Coruche complex is intended for ProHy production for pet food, aquaculture, or veterinary pharmaceutical products. The completion of this manufacturing unit is expected by the end of 2024 and has been designed to later develop ProHy for human consumption. This will be a “soluble ingredient that enters our daily lives as a protein dietary supplement. For this, we need to work upstream with our suppliers and establish very well-defined raw material control mechanisms so that we can operate in this market,” emphasises André Almeida.
ProHy adopts an innovative approach by using materials that have no value in the food market as raw materials. This practice promotes the reintroduction of waste and by-products into the value chain, preventing them from being discarded and allowing for a reduction of about 90% in greenhouse gas emissions that would occur if traditional landfill deposition methods were followed, contributing to a more circular and efficient economic model.
André Almeida notes that “sustainability has been part of ETSA Group’s DNA since its founding 50 years ago when there was still no talk of circular economy and sustainability”.
The development of the ProHy Project can be divided into three main stages. The first stage involved conducting studies that validated the feasibility of the new product. For this, a diverse team of scientists from ETSA and other partners worked together. We are currently in the second stage, which involves constructing the new factory. This phase requires considerable investment in various areas, including construction work, equipment acquisition, and hiring skilled labour. The third stage concerns the operational start-up of the factory. Additionally, this phase will involve a broad network of suppliers, preferably local ones, which will not only support factory operations but also bring benefits to Coruche region by creating new jobs.
The technological innovation developed for ProHy opens a range of possibilities, serving as a catalyst for future projects and innovative products. A concrete example of this technology’s potential versatility to create innovative solutions across various areas is spray-drying—a highly specialized and differentiating technique.
This method enables the development of a microencapsulation system where hydrophobic liposoluble ingredients (which do not absorb or retain water) are enveloped by protein capsules.
Regarding expansion strategy, ETSA aims to replicate ProHy’s production model in other geographical locations, particularly within the European market, expanding this innovation’ potential.
The National Innovation Award won by ProHy also represents recognition given to a project entirely developed in Portugal and reflects the commitment to always making it better that characterizes companies under Semapa Group.