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Purpose <p>Tilapia skin, a filleting by product, can be used to extract collagen (CTS) for bio-based films and hydrogels. This study performs the first ex-ante environmental and economic assessment of CTS, evaluating two pathways for these applications, with the aim of guiding the selection of one of these pathways for future investments in pilot plants or their redesign.</p> Methods <p>Two pathways for extracting 1 kg/year of CTS were modeled at a pilot scale using laboratory data in SuperPro Designer: acid-soluble (ASC) and pepsin-soluble (PSC). Total costs and the Product Environmental Footprint were combined in contribution and scenario analyses, considering the mass and economic allocation in tilapia production and filleting. The contributions of unit processes to the impacts and costs of CTS were shown in a proportionality graph with a threshold line of relevance; only the critical points above it were prioritized to identify alternatives to reduce environmental and/or economic impacts. An optimal pathway was selected, considering uncertainty. The impacts of CTS (optimal pathway) were then compared to those of cellulose, starch, and polyacrylamide, used in films and hydrogels. The minimum selling price (MSP), calculated as annual costs per production, was also compared to surrogate market prices. These comparisons included sensitivity and uncertainty analyses.</p> Results and discussion <p>The CTS performance study shows that collagen has greater environmental and price impacts than cornstarch, cellulose, and polyacrylamide, even with 90% less CTS, in both allocation criteria and in most impact categories. The comparison between ASC and PSC after improvements reveals that ASC outperforms PSC, leading to its selection. In both pathways and criteria, the main critical points above the relevance threshold and close to the proportionality line are sodium chloride, ultrapure water, acetic acid, and ethanol. For these points, the most effective alternatives are replacing dialysis with diafiltration and adjusting the acetic acid concentration, along with reducing reaction time, temperature, and yield.</p> Conclusions <p>Recommendations were provided for redesigning the CTS production process and its targeted application, highlighting potential improvements such as the use of electrodialysis in the purification stage, the removal of the lipid extraction step or the replacement of ethanol with butyl alcohol, as well as the evaluation of applications in the biomedical sector. Learnings from this study allowed the proposition of a novel integrated framework for improving technological pathways and targeting product application based on techno-economic and environmental impact criteria at technology readiness level 5. This framework may be applied to assess and improve other technologies on a laboratory scale.</p>

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Ecodesign of collagen extraction from tilapia skin: an integrated economic–environmental framework for process and product improvement at the laboratory scale

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月16日

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  • Johnny David Gomes de Queiroz,
  • Ednaldo Benício de Sá Filho,
  • Maria do Livramento Linhares Rodrigues Menezes,
  • Gabriela Ibiapina Figueiredo Câmara,
  • Men de Sá Moreira de Souza Filho,
  • Raimundo Marcelino da Silva Neto,
  • Renato Carrha Leitão,
  • Maria Cléa Brito de Figueirêdo

摘要

Purpose

Tilapia skin, a filleting by product, can be used to extract collagen (CTS) for bio-based films and hydrogels. This study performs the first ex-ante environmental and economic assessment of CTS, evaluating two pathways for these applications, with the aim of guiding the selection of one of these pathways for future investments in pilot plants or their redesign.

Methods

Two pathways for extracting 1 kg/year of CTS were modeled at a pilot scale using laboratory data in SuperPro Designer: acid-soluble (ASC) and pepsin-soluble (PSC). Total costs and the Product Environmental Footprint were combined in contribution and scenario analyses, considering the mass and economic allocation in tilapia production and filleting. The contributions of unit processes to the impacts and costs of CTS were shown in a proportionality graph with a threshold line of relevance; only the critical points above it were prioritized to identify alternatives to reduce environmental and/or economic impacts. An optimal pathway was selected, considering uncertainty. The impacts of CTS (optimal pathway) were then compared to those of cellulose, starch, and polyacrylamide, used in films and hydrogels. The minimum selling price (MSP), calculated as annual costs per production, was also compared to surrogate market prices. These comparisons included sensitivity and uncertainty analyses.

Results and discussion

The CTS performance study shows that collagen has greater environmental and price impacts than cornstarch, cellulose, and polyacrylamide, even with 90% less CTS, in both allocation criteria and in most impact categories. The comparison between ASC and PSC after improvements reveals that ASC outperforms PSC, leading to its selection. In both pathways and criteria, the main critical points above the relevance threshold and close to the proportionality line are sodium chloride, ultrapure water, acetic acid, and ethanol. For these points, the most effective alternatives are replacing dialysis with diafiltration and adjusting the acetic acid concentration, along with reducing reaction time, temperature, and yield.

Conclusions

Recommendations were provided for redesigning the CTS production process and its targeted application, highlighting potential improvements such as the use of electrodialysis in the purification stage, the removal of the lipid extraction step or the replacement of ethanol with butyl alcohol, as well as the evaluation of applications in the biomedical sector. Learnings from this study allowed the proposition of a novel integrated framework for improving technological pathways and targeting product application based on techno-economic and environmental impact criteria at technology readiness level 5. This framework may be applied to assess and improve other technologies on a laboratory scale.