Bridging lab and industry: The impact of a bio‐conversion unit on black soldier fly larvae production and microbiome dynamics

Abstract Background This study evaluates the viability of a novel bio‐conversion unit ( BCU ) for extensive black soldier fly larvae ( BSFL ) production as a sustainable feed additive for livestock. The BCU 's effectiveness in converting organic byproducts into valuable biomass via the production of BSFL was assessed to reduce reliance on environmentally taxing feed sources like soy and fishmeal. Additionally, the BCU was tested for its ability to replicate small‐scale BSFL experiments in a realistic industrial environment while facilitating simultaneous testing of multiple feeding substrates for BSFL. BSFLs were reared in the BCU on various low‐bioburden commercial byproducts, and their yield, macronutrient and micronutrient profiles were compared to those of larvae raised on a nutritionally balanced diet. High‐throughput amplicon sequencing was used to investigate the impact of different diets on the BSFL gut microbiome, replicating laboratory findings on an industrial scale. Results Larvae reared on low‐bioburden substrate in the BCU demonstrated comparable or improved protein and fat content compared to those reared on animal feed, with consistently high yields across all byproduct substrates. Micronutrient analysis revealed elevated calcium levels (compared to the literature), among other essential elements, in the byproduct‐fed larvae, further supporting their potential as a nutritious livestock feed additive. Microbiome analysis confirmed a stable core microbiome across all conditions, with some genera emerging as dominant at the industrial scale, highlighting the importance of larger‐scale replication for accurate microbiome research. Conclusion In this pilot study, the BCU proves to be a reliable and efficient system for broad BSFL production, converting organic byproducts into high‐quality biomass suitable for animal feed. Its controlled environment and scalability make it a valuable tool for conducting industrial‐scale scientific research on BSFL , bridging the gap between laboratory studies and real‐world applications.