In February 2026, Emirates Flight Catering (EKFC), one of the world’s largest airline catering operations, reached a significant milestone in its sustainability strategy. At its central facility in Dubai, the company commissioned one of the world’s largest commercial bioreactors, designed to treat food waste on-site and radically reduce its environmental footprint. Through this large-scale technological investment, EKFC will mitigate its carbon emissions by 2,000 tons annually while converting waste into valuable secondary raw materials.
In the global aviation sector, food waste is one of the most critical yet often overlooked sustainability challenges. EKFC’s new development intervenes at the source, preventing organic waste from reaching landfills where it would generate harmful methane gas.
High-Tech in the Kitchen: How the Power Knot Bioreactor Works
Installed at the Dubai Central Commissary Unit, the Power Knot LFC-3000 bioreactor is a fusion of biological innovation and industrial efficiency. The equipment utilizes the principle of natural aerobic digestion: using oxygen, heat, and specialized microorganism cultures to break down kitchen scraps and leftover food.
A unique feature of this bioreactor is that—unlike mechanical systems that depreciate over time—its efficiency continually increases. As the internal microbial culture matures and adapts to the diverse composition of food ingredients, the decomposition process becomes faster and more stable. This “learning” biological system ensures that the machine operates at maximum performance over the long term.
6-Ton Daily Capacity and Measurable Environmental Benefits
The scale of the project is supported by the latest operational data. Since the pilot run in December 2025, the volume of processed waste has been steadily rising:
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Current Performance: Processing an average of 3.5 tons of food waste daily.
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Planned Capacity: Once biological maturation is complete, the plant will be capable of handling 6 tons of waste per day.
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Carbon Balance: Based on UN and UK DEFRA methodologies, EKFC calculates that every ton of food waste diverted from landfills prevents approximately 0.7 tons of $CO_2$ equivalent emissions.
At full capacity, the bioreactor prevents more than 2,000 tons of $CO_2e$ from entering the atmosphere annually, contributing significantly to the climate goals of Dubai and the UAE.
Circular Economy: Greywater and Nutrient Recovery
The bioreactor does not merely destroy waste; it generates valuable outputs. The “greywater” produced at the end of the decomposition process is rich in nutrients, making it ideal for irrigation. The company repurposes this water for landscaping and horticultural work around the site, reducing freshwater consumption.
Furthermore, the remaining solids are utilized as soil enhancers and organic nutrients. This approach aligns perfectly with the philosophy of EKFC’s “Bustanica” vertical farm, which provides 28,000 servings of chemical-free greens daily for Emirates flights, establishing a sustainable local food chain.
AI-Driven Control and Strategic Vision
The installation of the bioreactor is just one element of Emirates Flight Catering’s complex technological arsenal. The company employs Artificial Intelligence (AI) and smart camera systems on production lines to monitor food loss in real-time and optimize inventory usage. This data-driven approach has already helped reduce waste by 30-40%.
Shahreyar Nawabi, CEO of EKFC, emphasized that the investment is an integral part of the UAE’s “Net Zero 2050” strategy. Alongside the bioreactor, the company’s solar projects (generating 4,000 MWh annually) and the electrification of its ground fleet—including the first electric high-loader vehicles arriving in 2026—ensure that Emirates’ catering operations remain among the greenest in the world.
Official Sources and References:
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Original Press Release (Emirates Media Centre): Emirates Flight Catering (EKFC) commissions large-scale bioreactor
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National Framework: UAE Net Zero by 2050 Strategic Initiative
