The Process

NewFoss pilot facility
NewFoss stands for 100% useful use of the biomass: the NewFoss process converts 100% of non-woody biomass into fibers and other sustainable and valuable products.

For the commercial production of the lignocellulosic fibers for predominantly the paper- and cardboard industry NewFoss has developed and constructed a first full scale pilot installation in Uden. This production facility has a capacity of 1000 kg/hr fibers (dry solids basis). From this facility Huhtamaki has been provided with raw material for their GreeNest egg boxes since January 2016. In addition the facility is used to produce small and large volumes for developing other applications such as for cardboard (Parenco), substrate (CNC and BVB) and insulation panels (Gramitherm). All based on residual grass and residue streams from agriculture and horticulture.

The NewFoss Biorefining Process
The patented NewFoss biorefining process converts non-woody biomass into two valuable product streams: an inert lignocellulosic fiber (NFF) and an aqueous juice containing the separated minerals, salts, amino-acids, protein and other cell contents; the grass juice. This mild extraction process uses the microbiology already present on the organic feedstock. The process takes place at ambient conditions and does not use any chemicals or other addditives. NewFoss just accelerates and controls a natural process.

The NewFoss process consists of four key steps in producing clean lignocellulosic fibers and aqueous gras juices

(1) Washing of the biomass waste flow to remove heavy components such as sand and stones
(2) Biologically opening of the cell walls (make them permeable) which releases the intracellular components
(3) Rinsing of the opened cells to extract the cell contents
(4) Further processing of the biomass to match the client’s specific wish

Sustainable circular process

The NewFoss NewFoss process not only produces sustainable products, but is also sustainable as a process itself. The grass juice which is a side product with fiber production is rich in easily digestible organic components. When digested in a standard anaerobic digester to biogas this results in enough energy to meet the entire energy demand of the production installation. So, no nett emission of  CO2! And there is even some energy left to supply to adjacent energy consumers such as houses or offices.

Also the water used in the process is cleaned and recycled completely. So both for biomass, water and energy the process is 100% circular! Meeting the demands of tomorrow.

Cooperation in the value chain
To convert residue grass into fiber products, NewFoss cooperates with partners in the entire value chain; from mowing and collection (Waterweg en Zeekanaal, Natuurpunt, Rijkswaterstaat, Natuurmonumenten, composting, provinces, cities and waterboards) until producers (Huhtamaki, Smurfit Kappa Parenco, CNC Grondstoffen, BVB substrates, contractors, building companies). Cooperation is essential to develop this completely new value chain and to value each link in the chain. It important to take into account the different drivers, as these may differ per partner.

  • Sustainability
  • Cost savings
  • Image
  • Consumer wishes and demands
  • Profit
  • Logistical issues
  • Raw materials shortages
  • Security of supply
  • Quality

Where for one image and sustainability are the key drivers, for others security of supply and logistical issues may be more important. To match these in a consortium is not easy, but a vital element for success.