Kerala man's wonder business of transforming waste into protein

We know that organic waste can be converted into compost. But what if kitchen waste could also yield high-value protein powder, chitin, and chitosan, besides compost? K.C. Anoop's Black Fly Technologies, a company in Kattangal, Kozhikode, is literally implementing the concept of 'waste to wealth'.

Anoop's journey started with poultry farming and progressed into waste management and then a protein startup. While working as an electrical engineer, Anoop raised black chickens at home, unknowingly taking the first step towards a startup that would attract even global interest. Even while working at Keltron and ONGC, he continued his poultry farming in his Kattangal home.

When the market for black chickens crashed, Anoop started raising black soldier fly larvae (BSF larvae) to reduce feed costs. Until the Covid pandemic, the black chicken business was booming, with each batch yielding around a thousand birds, each fetching Rs 500. However, post-Corona, demand plummeted, with prices falling to Rs 100 per bird. Even with home deliveries, there were no buyers. To maintain profitability, he had to reduce feed costs. The BSF technology, which also helped manage household waste, caught his attention. Anoop realized that supplementing the larvae with cheaper grain leftovers was sufficient for the chickens. These larvae, an excellent protein source, were a hit with the chickens. The startup was launched as part of an effort to commercially produce BSF as feed for poultry and fish. The Kozhikode NIT's Technology Business Incubation (TBI) Center supported Anoop.

The aim was to develop BSF technology as a new model for source waste management. Initially, they developed a technology to produce BSF larvae on a large scale, dry them, and store them as powder. In the next phase, protein-rich oil was extracted from this powder. This protein oil reportedly fetches up to ₹1000 per liter. It is mixed with other feed ingredients to prepare chicken and fish feed. Anoop points out that much of the plant-based protein oil imported from China and elsewhere is made from insects.

A visit to Israel as part of a Kozhikode NIT startup initiative proved to be a turning point for Anoop. Seeing the research at the Galilee Institute in Israel on utilizing insects as a valuable protein source convinced Anoop that his work was on the right track. This boosted his confidence after having initially worried about abandoning a good job to raise insects. Israeli soldiers reportedly consume grasshopper-based jelly candies, containing only 30% protein, in war zones. One serving reportedly keeps them full and energized all day. Anoop questions the potential of BSF larvae, which contain 40% protein. He has secured Israeli support for further research.

Anoop is working on commercially raising BSF larvae and marketing value-added products. He received funding under the Central Government's Nidhi Prayas scheme. A team including microbiology researchers is working on this startup. Anoop believes that with government support, BSF waste management can become a model for the nation. For three months, they have been processing food waste from the Kozhikode Civil Station. Anoop highlights that they can scientifically compost using just four double-ring composting bins.

Black Fly Technologies is ready to install BSF waste management systems in flats, resorts, and other institutions. The system has been functioning effectively for two years at a resort in Wayanad and a Kozhikode District Cooperative Bank tower. Two units with a processing capacity of one ton each can be installed in the space of a car parking spot. One unit costs ₹100,000. The advantages of this system are its lack of odor and the absence of the need to stir the waste. Besides BSF larvae, high-quality organic fertilizer is obtained as a byproduct. The company collects the larvae.

Challenges faced:
Despite being a beneficial initiative, Black Fly Technologies has faced significant challenges since its inception. When trying to raise the larvae with necessary safety measures, a neighbour complained about pest infestation and odor. The complaint came after hearing that the larvae were doing the processing, despite the unit having operated for four years without any issues. When applying for a license from the panchayat, mentioning black soldier fly larvae turned out to be problematic. Anoop points out that the aversion and prejudice associated with the word 'larvae' are the reasons for the opposition.

Even farmers in remote hill areas demanded high rental fees for operating BSF units, prompting Anoop to seek alternative solutions. He took over the operations of the Kozhikode Corporation's waste processing plant in Njeliyanparambu, hoping to produce BSF larvae as needed from the organic waste there. Black Fly Technologies has developed supplementary techniques for odorless operation. However, the corporation has not yet provided the necessary infrastructure. The compost shed is currently in a dangerous condition, hence the license for organic fertilizer production is not obtained. Anoop points out that if the corporation's promise to build a new 40,000 sq ft shed is fulfilled, they can obtain a license and start production.

Ten months after the council's approval, construction has not begun, preventing the larval composting. Anoop, who hoped to sustain the startup through organic fertilizer production, is now facing a severe financial crisis. He has invested his savings and assets in the larval composting venture and is heavily in debt.
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