25 Oct 2023 --- Rescuing ingredients that would otherwise go to waste is the hallmark of the upcycling trend that is ever more present across several F&B categories. From upcycled oils to upcycled functional citrus fibers, companies are learning how to create side streams for previously unwanted ingredients to innovative products with higher sustainability credentials that claim they are better for the planet, less of a drain on natural resources and help mitigate consumer concerns over climate change.

The need for sustainable practices is abundantly clear. Brands also need consumers to recognize the action they’ve taken to create food and beverages with a conscience - and they want to tell the story behind their upcycled offerings. 

Meanwhile, upcycled certification bodies are cropping up to give the stamp of approval to upcycled products.

Upcycle to protect the planet
Pierre-Albert Thomas, global director, Rousselot Functional Ingredients, says that as the global population continues to grow, more people are recognizing the finite nature of Earth’s resources. Therefore, the significance of adopting sustainable practices in food consumption and production becomes more apparent.

“Governments are taking active steps to encourage people not to waste resources, and the media is playing a crucial role in spreading this message. Consumers know, for example, that a significant portion of food produced for human consumption is lost or discarded, even as food shortages persist in many parts of the world,” he tells Food Ingredients First. 

“All these messages are motivating people to reevaluate their consumption patterns. They are embracing new habits that involve reusing, repairing objects or clothing, and reducing energy and water consumption. Additionally, accepting “ugly” vegetables, for example, and incorporating upcycling practices into their lives is part of this broader shift toward responsible consumption.”

Thomas also cites “a return to traditional values” as another dynamic influencing the upcycling trend. 

“There is a resurgence of interest in age-old principles that underscore the importance of valuing every resource and minimizing waste. This approach encourages individuals to extract the maximum value from all products and resources.” 

Rousselot has a long history of producing gelatin and collagen, extracting these ingredients from animal raw materials. The processing of animal bones and skins into gelatin/collagen is a crucial step, notes Thomas. “Without this process, gelatin and collagen, which are exceptionally versatile resources, would be lost for many food, pharma or nutritional applications.”

“But more than this, we’re always finding new ways to use gelatin and collagen to unlock their full potential. For example, collagen peptides are well known for making your skin look better, helping with mobility, and aiding sports nutrition. New studies are regularly done, highlighting new benefits. For example, a recent study found collagen peptides can help athletes sleep better and recover faster, and another one showed they are also good for gut health.”

The company produces many grades with different specificities in terms of gel strength or viscosity, each grade fitting a specific food or pharmaceutical application. Thomas flags one of the company’s latest innovations, Simogel, a new gelatin solution that enables the production of  functional gummies without the traditional starch molding process. 

“Today, functional gummies are gaining traction in the market as they deliver tangible benefits to consumers. With products like Simogel, this is wher the concept of upcycling truly comes to life,” he notes. 

Repurposing previously unloved products
Kelly Gilroy, vice president, Sustainable and Natural Products, Univar Solutions, agrees there is a significant market ask and need for sustainability, driven by a growing eco-conscious consumer base.

“The upcycling of ingredients helps with repurposing food by-products that would otherwise go to waste. Additionally, circular economy initiatives and corporate social responsibility commitments are prompting businesses to adopt ingredient upcycling as a means of reducing their environmental footprint. These converging market and consumer trends are pushing the upcycling movement, making it a prominent and necessary practice in today’s economy,” she tells us. 

Univar Solutions sources oils from growers, producers, and co-operatives from all around the world, reaching the native regions wher these botanicals grow best. Many oils the company offers are upcycled because they are derived from the waste produced by another industry — most typically the food industry. 

“EarthOil is wher we innovate to help brands and manufacturers achieve their sustainability goals by incorporating natural feedstocks and reducing waste. EarthOil is a brand we acquired in 2018 that offers more than 300 essential and vegetable oils to customers,” Gilroy continues. 

“We have several upcycled products in our portfolio. First, is rose hip, an organic, canina species. Rose hips are harvested in huge quantities in Lesotho, a landlocked country surrounded by South Africa. The hips are then sold into the food industry for jam and tea production. The waste from this process is small and contains hard-shelled seeds. These seeds produce a deep yellow and rose-tinted oil, which is widely used in beauty and personal care skin and hair care applications.” 

“The waste from the rose hip seed oil pressing is what is known as a seed cake. In this case, the seed cake is processed a few kilometers down the road and sold as cattle feed. Another upcycled oil is grape seed oil, coming from South Africa, a large wine-making country. The seed waste from the juice and wine-making creates a valuable oil used in finished products. The solid waste from this process can be turned into a fine, natural scrub particle. The seed cake can also be put toward eco logs as an alternative source of fuel. In these examples, there is no waste and every part of the biomass is used.”

Creating value side streams
Thomas continues on why upcycling is an important concept for the business, a key driver for F&B manufacturers due to its multifaceted benefits of minimizing food waste, which aligns with sustainability goals but also reduces disposal costs. 

“Upcycling also allows manufacturers to create new products or ingredients from by-products, increasing resource efficiency and potentially expanding product lines.”

“It resonates with environmentally conscious consumers, strengthening brand reputation and attracting a growing market segment. Upcycling also can result in cost savings, as manufacturers find value in otherwise discarded materials. Overall, upcycling is a sustainable, cost-effective, and market-driven approach. It is a key driver for manufacturers seeking to thrive in a more eco-friendly and responsible industry,” she adds.

Meanwhile, Daniel Haley, global platform leader, Clean & Simple Ingredients at Ingredion, says the company was one of the first to begin leveraging upcycled material, exemplified by its potato and waxy rice ingredients, which utilizes side stream from potato processing and broken waxy rice grains. 

More recently, Ingredion has partnered with orange and lemon processors to develop its range of upcycled Fibertex multi-functional citrus fibers. 

“We’ve applied our technologies to transform materials that would have otherwise been discarded into functional ingredients that solve formulation challenges, boost nutrition, deliver unique texture and support a broader sustainability story, all while offering an ingredient that has high consumer appeal.”

Thomas stresses that the gelatin industry plays an essential role in reducing food waste and loss, as it is built on the use of by-products from the meat industry. “Without the gelatin industry, the volume of food wasted would be even greater, which underlines the importance of its existence,” he says.

“The biomass value pyramid is a model that ranks the conversion of agricultural crop residues and other biomass materials into various streams, according to their economic value. When investigating opportunities to prevent food waste by adding value to potential waste streams, this model can help determine which applications offer the greatest benefits and highest value.”

“In food applications, gelatin offers functional advantages to improve the texture, taste and stability of finished products.” 

Upcycling on the label
Manufacturers can use packaging claims like “made with upcycled ingredients” and “made with sustainable ingredients,” depending on local regulations. Manufacturers are also sharing more information about ingredient origin and manufacturing process via QR codes on packaging, and an increasing number are leveraging social platforms such as linkedIn and YouTube to communicate their sustainability programs, notes Haley.

“We see the emergence of organizations like The Upcycled Certified Program, which is the world’s first third-party certification program for upcycled food ingredients and products. These efforts are a way to signal transparency and quality to consumers, which in turn builds trust and brand loyalty.”  

Gilroy says that many brands will incorporate the upcycled ingredient story into their overall brand message, which demonstrates the brand’s commitment to transparency and builds brand loyalty.

“Food labels can make various upcycling claims that aid consumers in understanding the product’s sustainability story. These claims include “Upcycled Ingredients,” indicating the use of rescued or repurposed food components. “Reducing Food Waste” emphasizes the brand’s commitment to waste reduction and “Circular Economy,” communicating a broader sustainability approach. 

“Such labels help consumers make informed choices, highlighting the brand’s dedication to reducing environmental impact. They also raise awareness about food waste reduction and sustainability, encouraging consumers to support products and companies aligned with these values, contributing to a more sustainable and responsible food industry.” 

What’s next?
Sustainable practices, including upcycling and reducing food waste initiatives, will remain at the forefront of innovation, highlights Gilroy, who says Univar Solutions expects to see greater investment in alternative proteins, such as plant-based and cultured meats, as consumers seek healthier and more environmentally friendly options. 

“Personalization through artificial intelligence (AI) and data-driven insights will play a significant role in product development and marketing. Lastly, advanced food technology, like 3D printing and smart packaging, will enable customized and efficient food production and delivery. Overall, food manufacturers are embracing these trends to cater to evolving consumer preferences and address global challenges, making the industry more sustainable, innovative, and adaptable, “ she concludes.

Haley flags that Ingredion is continually looking to push the boundaries of innovation, delivering novel textures that consumers prefer. “This includes looking at side and waste streams of our current manufacturing processes, Ingredion has multiple products in development across fibers, starches, flours and proteins that would be upcycled from current processes.”