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Description
In the egg production industry, large percentage of eggs (approx. 32% in United States, close to 25% in Europe) are diverted to breaker operations - to produce liquid egg products. The by-products of these operations are the eggshell and associated membranes, which constitute approximately 6g/egg. In the US expenses for one breaker plant can exceed even $100,000 per year to dispose the eggshell waste into the landfills. Therefore, egg-based processing companies are highly interested to extract products with potential commercial application from the eggshell waste. During the project we will verify that the technologies for turning the waste (chicken eggshells) into high added value products are available and need to be further developed. We aim to develop a novel concept for conversion of eggshells into the next generation biomaterials for bone regeneration.
While there is a rich literature on conversion of eggshells to calcium phosphates (CaP) such as hydroxyapatite and tricalcium phosphate, conversion to amorphous calcium phosphate (ACP) has received little attention that is mainly related to ACP metastability. Within the current project we will use chicken eggshells as a raw material to synthesize ACP with improved stability, that will be for the first time further applied to produce novel porous, bone-like ACP ceramic scaffolds. Moreover, to fully recycle the proposed waste – chicken eggshells into the high added value products, proteins from eggshell membranes will be extracted as they have a high content of bioactive components possessing antibacterial effects and can be further explored as coatings for porous ACP ceramic scaffolds.
Summary of project results
The EGGSHELL project was initiated to address the dual challenges of sustainable waste management and the need for advanced biomaterials in bone regeneration. Eggshells, an abundant waste product, are a valuable source of high calcium content, which can be used to develop calcium phosphate-based biomaterials. The project aimed to transform eggshell waste into valuable biomaterials, specifically, macroporous amorphous calcium phosphate ceramic scaffolds, while advancing research-based knowledge development in Latvia and Estonia. Scientific groups from Riga Technical University (RTU, Latvia), Tallinn University of Technology (TALTECH, Estonia), University of Oslo (UiO, Norway), and Reykjavik University (Ru, Iceland) collaborated to reach the project’s goals.
Within the project, chicken eggshells were used as a source of calcium for the synthesis of amorphous calcium phosphates. Subsequently, porous ceramic scaffolds were fabricated from the synthesized material, with potential applications in bone regeneration. Amorphous calcium phosphate has excellent biological properties, but due to its metastability, it is particularly challenging to produce it in a bulk ceramic form. Furthermore, within the scope of the project, proteins possessing high bioactivity and antibacterial properties were extracted from eggshell membranes to fully optimize the utilization of the eggshells. The obtained proteins were then applied for coating the developed amorphous calcium phosphate ceramic scaffolds, enhancing their unique properties.
After optimizing the synthesis process, the project team successfully scaled up production to obtain large quantities of amorphous calcium phosphates. The synthesized material demonstrated excellent bioactivity under in vitro conditions. Dense and porous ceramic scaffolds were fabricated from this material and are currently being investigated under both in vitro and in vivo conditions. The project partners have published several peer-reviewed papers based on the findings and have collaborated on several joint project proposals to further advance the research.
During the implementation of the project, the project team encountered several challenges that required innovative solutions. One of the challenges was related to the scale-up of the amorphous calcium phosphate synthesis. After careful optimization of the synthesis parameters, it was possible to obtain amorphous calcium phosphate in quantities exceeding several tens of grams. The initially selected method for densifying amorphous calcium phosphate was unable to produce ceramics with the desired properties. However, through collaborative efforts among the project partners, an alternative densification method was developed, successfully yielding dense and porous amorphous calcium phosphate ceramic scaffolds.
The EGGSHELL project results hold significant socio-economic potential for the Baltic states and the surrounding region. By converting eggshell waste into advanced biomaterials with superior bone regeneration ability, the project addressed waste management issues. This innovative approach can reduce healthcare costs associated with bone healing and regeneration, making treatments more accessible and affordable. Additionally, the project promoted sustainable practices for biomaterial fabrication, contributing to environmental conservation. By providing a sustainable alternative to conventional methods of developing biomaterials, the EGGSHELL project supported the transition to a circular economy, that can enhance the region''s environmental and economic sustainability.
Indicators achieved in the project: 6 scientific publications have been prepared,4 joint project applications for further funding were submitted, 11 researchers were supported.
Summary of bilateral results
To reach the goals of the EGGSHELL project, a collaborative effort was undertaken. Scientists at RTU utilized chicken eggshells as a calcium source for the synthesis of amorphous calcium phosphate. Researchers at TALTECH developed procedures for creating macroporous amorphous calcium phosphate ceramic scaffolds. Meanwhile, scientists at the UiO and RU characterized the developed materials and assessed their biocompatibility to ensure they meet the standards required for bone regeneration applications. The project results demonstrate that waste material – eggshells – can be used to produce high-value-added products. The implementation of the project allowed the project partners to expand their knowledge and acquire new skills, which will be useful in developing new research directions and forming new collaborations. It is expected that the project results will generate interest among companies specializing in biomaterials development. The developed materials could promote faster bone regeneration, thereby potentially improving patient treatment outcomes and quality of life.