Proteo
Single Cell Protein
Build versus Lease
AACE Class 4
Proteo makes single cell protein from yeast by continuous fermentation, for human and animal nutrition. In about six weeks, Roebling built a techno-economic model of its process, resulting in a scale-up plan that showed the smallest facility to meet its price target and whether to build new or lease existing space.
67%
reduction in engineering time
60+ scenarios
across facility scales, build versus lease, and sensitivity inputs
6 scales
of facility compared on the same cost basis, across fermentor sizes and counts
Challenge
Proteo needed a scale-up strategy for its global manufacturing plans. That strategy depended on three answers: what a commercial facility would cost, how large it had to be to reach Proteo's price target, and whether to build a new facility or lease existing building space.
Solution
Roebling did FEL-1 engineering and built a live techno-economic model of Proteo's process, covering a range of facility sizes, process performance, and operating modes. The team used the model to run facility scale cases, find the minimum size that supports the target price, and compare building new against leasing.
Results
Proteo used the scale and build versus lease results to shape its manufacturing strategy. The sensitivity results showed which process variables had the largest effect on cost, so Proteo could focus process development on those inputs.
Deliverables
Process & Engineering
Block Flow Diagram
The full process from fermentation through drying.
Mass & Energy Balance
Material and energy flows at each scale.
Sized Equipment List
Equipment sized across facility scale cases.
Utility Summary
Utility demand for each case.
Labor Model & Staffing Plan
Staffing needs for commercial operation.
Cost & Economics
Techno-Economic Model
A live model covering facility size, process performance, and continuous and semi-continuous operation.
Class 4 CapEx Estimate
Estimated at +/-30%, broken down by process area.
COGS Breakdown
Direct COGS and fully loaded COGS for each case.
Pro Forma Financial Model
Sources and uses, with fully loaded COGS that includes the cost of capital.
Scenario Analyses & Tornado Diagrams
Stacked upside and downside cases at three scales, with tornados for direct and fully loaded COGS.
Scale & Planning
Build versus Lease Analysis
A new facility compared with leased existing building space on CapEx, direct COGS, and fully loaded COGS.
Facility Scale Analysis
Six configurations across fermentor sizes and counts, with the minimum size that supports the target price.
TEA Executive Summary Report
Findings to support Proteo's manufacturing strategy.
"On Proteo's journey, it was essential to have the guidance and coordinates that the Roebling team provided us to ensure that the course had viability and a clear destination. The internal effect on Proteo was comprehensive in having advisors of great depth and in giving us all the necessary variables to validate our course, and to navigate with certainty in this industry, having a radar like the TEA, without which it would have been impossible. We are convinced it was a great decision! Having Roebling's advice was the best decision we could have made."
Ernesto Cevallos Coppel
CEO, Proteo
The Approach
One model for every scale and siting question.
Every scale, operating mode, and build versus lease case ran through to CapEx, direct COGS, and fully loaded COGS.
Every comparison used the same basis, so Proteo did not need separate studies for each question.
Stacked upside and downside cases at three scales identified the cost drivers to guide process development.
Roebling delivered the model and executive summary on a short timeline.
What the team says
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