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On-Site Enzyme
Production for Large-Scale
Biorefineries

Bring enzyme production on-site to support independent, large-scale biorefinery operations

With global bioethanol production projected to exceed 150 billion liters in the coming years, biorefineries are processing greater volumes of biomass and increasing reliance on enzymes. On-site enzyme production provides an independent, localized way to keep pace with these operational demands.

A Smarter Approach with
On-Site Production

On-site enzyme production enables CRESCENTISTM to be produced and applied directly within the biomass processing workflow. This allows enzyme systems to be adjusted based on feedstock characteristics and operating conditions, supporting saccharification and cellulose hydrolysis under site-specific conditions. It also reduces reliance on external supply, helping streamline logistics and operational planning.

Onsite enzyme production scheme for direct use at a biorefinery plant

Why On-site Enzyme Production?

Biochemical facility with corn biomass for onsite enzyme cost reduction

Reducing Costs Associated with Enzymes

For large-scale operations, the supply of industrial enzymes involves transportation, storage, and handling across multiple stages. These steps add cost and require coordination across supply chains, particularly as production volumes increase.

Onsite enzyme testing for lower-carbon biomass residue processing

Reduced Carbon Emissions Through Local Production

Traditional enzyme supply can contribute to carbon emissions, due to reliance on external supply and logistics. Producing enzymes on-site reduces these requirements, resulting in lower carbon output while fostering a more independent production approach.

How Does It Work?

Kao offers a flexible on-site enzyme production model designed for each facility’s engineering capabilities, cost targets, and operational preferences.

Turnkey Delivery from Design to Operation

Turnkey delivery onsite enzyme production workflow from design to operation

A complete on-site enzyme production system is delivered through leased microbial strains and a Kao engineering partner, covering industrial enzyme production from design through construction. The customer commissions the project and receives a finished facility upon completion—helping reduce the burden on internal teams and simplify execution. This approach is ideal for facilities seeking a fully managed, ready-to-operate plant.

A Customized Model That Works for You

Not every operation starts from the same place. We work with each customer to assess internal capabilities and recommend an approach that fits your specific requirements.

How Will This Scheme Work for You?

Example 1

A large-scale bioethanol producer in the United States processing corn stover and forestry residues, operating continuously with high enzyme demand

Solution

For facilities with strong engineering capabilities, on-site enzyme production can be managed entirely in-house. Kao leases microbial strains, making it easier to integrate enzyme production into existing systems while maintaining full control over design, scale, and cost. This keeps production closely aligned with process needs and site-specific conditions.

Example 2

An integrated biorefinery in France producing bioethanol and bio-based chemicals from cereal residues and forestry biomass

Solution

Implementing on-site enzyme production requires specialized expertise in process design and equipment integration. With a hybrid approach, Kao provides microbial strains while engineering partners support key aspects of system design and equipment. This helps reduce implementation complexity while allowing facilities to retain control over construction and operations.

Example 3

A biorefinery in Thailand expanding capacity, increasing throughput of bagasse, rice straw, and cassava pulp, requiring more enzymes

Solution

As production scales, on-site enzyme production can grow alongside operations with support from Kao’s engineering partners. This approach balances external expertise with internal control, supporting expansion without adding unnecessary complexity. It also allows facilities to adjust production levels more easily as throughput and operational needs change.

Example 4

A bioethanol producer in Brazil processing sugarcane bagasse, seeking to implement on-site enzyme production without managing design or construction

Solution

For facilities prioritizing ease of implementation, a turnkey model enables full deployment—from design to construction—managed by engineering partners. This makes it easier to introduce on-site enzyme production with minimal internal involvement, while maintaining operational continuity and supporting a smoother transition from external supply.

Find the Model for Your Needs

Not Ready for On-Site Production?

For facilities not yet ready for on-site enzyme production, Kao offers ready-made enzyme solutions. CRESCENTISTM is a saccharification enzyme for biomass conversion, supplied conventionally with the option to transition to on-site production.

Our Global Presence

Kao operates globally across Asia, the Americas, and Europe, guided by sustainability and innovation. Its chemical business supports materials, energy, and bio-based production, contributing to advanced industrial and bio-based applications.

About
Kao Global Chemicals Japan

Kao is a Japan-based company with a long history in chemicals and research development. Drawing on expertise across consumer and industrial fields, it develops enzyme and bio-based solutions that support sustainability and bio-based production.

Kao head office in Japan

Kao chemical research facility

Industry Recognition

Awards and recognitions from global organizations reflecting our commitment to responsible and sustainable business practices.

  • Kao's CDP 2024 Triple A rating for climate, forests, and water security

  • Kao's Ethisphere World's Most Ethical Companies award recognition

  • Kao's CDP Supplier Engagement Leader 2024 award recognition

  • Kao's Prime Corporate ESG Performance award recognition

  • Kao's European Responsible Care Awards recognition

News & Annoucements

Ready to Improve Saccharification Performance for Your Specific Feedstock?

Kao offers on-site enzyme models for biomass processing and bioethanol production.
Get in touch to explore the most suitable approach for your operations.

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