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A research team from The Chinese University of Hong Kong (CUHK), has developed an innovative technology that could enable the use of natural enzymes for large-scale manufacturing, offering a cleaner, more efficient alternative to traditional chemical processes, which could reduce costs by more than 80% compared with current commercial methods. The research team led by Professor Michael Kenneth Chan from CUHK’s School of Life Sciences was recently awarded a merit prize in the National Disruptive Technology Innovation Competition 2025, highlighting its potential to drive the transition towards green manufacturing.

Retaining enzyme cofactors to slash costs

Enzymes are biological macromolecules that act as catalysts, accelerating chemical reactions without being consumed in the process. They can perform complex reactions quickly and cleanly within living cells, often using only water under mild conditions. While they offer a promising alternative to traditional manufacturing – which frequently relies on toxic substances, high temperatures and waste-heavy processes – enzymes have historically been difficult and expensive to prepare, stabilise and reuse in industrial settings.

Led by Professor Michael Kenneth Chan from CUHK’s School of Life Sciences, the team has overcome these long-standing barriers by engineering enzymes to self-assemble into tiny, solid particles directly inside bacteria. Unlike conventional methods that require complicated and costly purification steps, these enzyme particles can be collected simply by breaking open the cells. The result is a robust, ready-to-use material that is stable, reusable and highly adaptable for industrial applications.

The critical advantage of the new technology is its ability to retain expensive “helper molecules”, known as cofactors, which are essential for enzyme function. In standard industrial processes, cofactors must be constantly replenished, significantly driving up operational costs. The new system traps these cofactors inside the enzyme particles, allowing them to be recycled over long periods. This innovation dramatically reduces waste and expense. The production costs could be reduced by more than 80% compared with current commercial methods.

Enabling sustainable production of high-value medicines and eco-friendly nylon

The team has proven the technology’s viability by operating the enzyme particles continuously in flow reactors for months. They have successfully produced chemical components for high-value pharmaceutical building blocks and environmentally friendly nylon-like materials under mild conditions.

Professor Chan said: “Our goal is to make green chemistry practical for multiple chemical transformations. By creating enzyme systems that are easy to produce, long-lasting and recyclable, this platform opens the door to cleaner industrial manufacturing. With continued development and industrial collaboration, this technology could help replace polluting chemical processes and support a more sustainable future.”

The CUHK team has established a start-up company, RoboZyme, to further develop this technology and transition it from the laboratory to the commercial sector.