A circular economy redefines sustainability by turning waste into valuable resources and optimising every ingredient. In the food and beverage sector, it is all about reducing, reusing, recycling and recovering to build a more efficient and eco-friendly supply chain.
FoodBev Media’s editorial director, Siân Yates, explores the latest innovations driving this green revolution, and discovers how this approach is truly bringing sustainability full circle.
In a world facing challenges like climate change, inflation and resource depletion, the circular economy offers a promising solution. This forward-thinking model not only reimagines waste but transforms it into valuable resources, paving the way for a sustainable future for both manufacturers and consumers.
Unlike the traditional linear economy, which follows a ‘take, make, dispose’ path, the circular economy seeks to minimise waste by creating closed-loop systems where products, materials and resources are continuously reused, repaired, remanufactured and recycled.
Waste not, want not
At the heart of the circular economy is the idea of upcycling – taking what was once considered waste and turning it into something valuable.
“Upcycling presents a unique solution globally,” Amanda Oenbring, chief executive officer of the Upcycled Food Association, commented. “Globally we know that 30-40% of total food production is lost before it reaches the market, with the impacts on certain products being high percentages. The future we are creating now is one where these numbers are drastically diminished.”
Companies like Crush Dynamics are leading the charge here. The company is transforming grape pomace, a byproduct of winemaking, into natural, multifunctional food ingredients. In Crush’s world, the remnants of winemaking are not relegated to compost heaps but are
instead transformed into nutritious food ingredients. CEO Kirk Moir explained that the company’s patented fermentation process not only reduces food waste, but also enhances the nutritional profile of food products.
“We view grape derivatives not as byproducts but as untapped resources rich in polyphenols,” he said. “Through our patented fermentation process, we unlock the full potential of our ‘crush’ input removing both the inherent bitterness and astringent taste of the tannins, creating high-value multi-functional ingredients that not only enhance the nutritional profile of food products but also support sustainability goals at global scale.”
He continued: “This approach allows large food manufacturers to integrate more sustainable practices into their supply chains, reducing their reliance on synthetic, highly processed additives, sugars and sodium, contributing to a more resilient food system”.
Crush’s approach addresses the issues of food waste and carbon emissions – 15 million tonnes of grape crush are discarded annually, contributing significantly to greenhouse gases. It creates a dual benefit: reducing reliance on synthetic additives while delivering superior taste and texture to plant-based foods. What is more, it effectively removes unwanted off-notes while enriching food products with essential nutrients.
Similarly, Fiberstar is turning citrus peel waste – a byproduct of the citrus juicing sector – into Citri-Fi, a high-functioning citrus fibre that enhances food quality and nutrition. Brock Lundberg, chief science officer, noted the environmental benefits of the process: reducing agricultural waste while creating a natural, high-value ingredient for food manufacturers.
“Our patented process minimises water usage and wastewater, turning what was once discarded into a product that improves the food industry,” he told The Plant Base. The versatility of Citri-Fi allows it to be incorporated into various applications, proving that sustainability and quality can go hand in hand.
“Because Citri-Fi provides multiple functionalities, such as water holding and emulsion stabilisation, this upcycled fibre can aid in reducing the reliance on food ingredients that have large carbon footprints, such as meat and dairy products,” Lundberg added.
Yeast: The unsung hero of sustainability
Another exciting development in the plant-based sector comes from Yeap, a start-up that harnesses leftover yeasts from industrial processes. CEO Jonathan Goshen highlights the environmental impact of Yeap’s approach: “By using byproducts, we reduce overall waste, save water, minimise carbon emissions and produce a more affordable protein”.
The resulting upcycled concentrated protein is versatile, making it ideal for a range of applications, from dairy alternatives to protein bars. Yeap’s innovative process involves using existing technology and machinery to produce its protein, employing methods such as filtration and separation. This not only streamlines production but also minimises resource consumption, reinforcing the principles of the circular economy.
The company’s focus on yeast as an upcycled protein ingredient opens new avenues for plant-based manufacturers, allowing them to create products that are not only nutritious but also environmentally friendly.
With applications ranging from hard cheeses to protein snacks, Yeap’s ingredient offers a compelling solution for manufacturers looking to enhance their product offerings. For instance, in dairy alternatives, Yeap’s protein can achieve a creamy texture that rivals traditional dairy, thus appealing to consumers seeking plant-based options without sacrificing taste.
Innovations in packaging
The circular economy extends beyond food production to packaging, where companies like
Mondi and Traceless are pioneering new solutions. Their collaboration focuses on developing a bio-circular coating made from agricultural byproducts, aimed at effectively replacing traditional plastic coatings.
This innovative solution not only responds to the growing demand for sustainable packaging but also boasts a 76% reduction in greenhouse gas emissions throughout its life cycle if used to replace virgin PET. As Marko Schuster, COO of Mondi, pointed out: “This is a fantastic example of how we can combine our R&D forces to be one step ahead in the sustainable packaging game”.
Mondi and Traceless are addressing a critical issue in the food and beverage sector: the reliance on plastic packaging. By developing a coating solution derived from renewable materials, they are not only reducing the environmental impact of packaging but also meeting consumer preferences for sustainable options.
The coating granulates are produced at Traceless’ pilot plant and applied to Mondi’s kraft paper at their R&D centre for further testing in the company’s laboratories. Full-scale industrial production later takes place at a designated plant in Hamburg. The coated kraft paper solution is designed to meet diverse packaging needs, making it suitable for a range of industries, from ecommerce to frozen foods.
This work demonstrates the feasibility of using agricultural byproducts in packaging and highlights the potential for reducing waste and emissions throughout the packaging life cycle.
Greener meat and dairy
In another exciting initiative, Swedish company The Green Dairy is showcasing the potential of food waste in a circular economy. Through substantial investments in research and development, it has pioneered a ‘world-first’ pilot system for drying residual mass, enabling the conversion of byproducts into food.
Its latest breakthrough is ReOat – a plant-based burger made from oat drink residues. “The industry has tried to find ways to make use of its residues to create a more circular food production for a long time,” said CEO Johan Girdo.
He added: “Residues that go to animal feed or are burned as biogas serve a purpose, but do not solve the issue of a circular food system that needs to feed more people in the long run...By utilising residues we can feed more people, reduce environmental impact and boost profitability.”
The Green Dairy’s approach is a testament to the power of collaboration and creativity in addressing food waste. By investing in R&D, it has pioneered a process that allows for the creation of high-quality food products using what was once considered waste.
The initiative has garnered attention not only for its environmental impact, but also for its potential to influence consumer behavior. By showcasing the possibilities of upcycled ingredients, The Green Dairy is helping to shift perceptions around food waste and sustainability.
A bright future for circular practices
The potential for circular economy approaches in the plant-based food and beverage sector is vast. Industry leaders predict that as consumer awareness grows, demand for upcycled products will increase, driving innovation and collaboration across the sector.
“If we are to have a shortage in food in the future to come, circular economy will shine – trying to re-use as much existing/used materials as possible,” enthused Yeap’s Goshen. “I believe that at the same time, consumer awareness is growing, and they will choose to purchase those upcycled products as well – increasing the demand and awareness around the globe.”
The transition to a circular economy is not just about reducing waste; it’s about reimagining
the entire food system. By embracing circular practices, plant-based food and beverage manufacturers can enhance their product offerings while contributing to a more sustainable future. This shift not only benefits the environment but also positions companies as leaders in the growing market for sustainable food options.
Five circular economy innovations in the plant-based space
1. Revyve (The Netherlands)
Initiative: Egg alternatives made from upcycled yeast
Revyve develops texturizing ingredients that are designed to provide a clean label and sustainable alternative to eggs in various applications. Upcycling is central to the company’s approach – its flagship product line is made using yeast from brewing industry sidestreams.
2. Too Good To Go (Global)
Initiative: Food waste reduction platform
Too Good To Go connects consumers with
food businesses (restaurants, supermarkets, cafés, etc.) to purchase surplus food at reduced prices before it becomes waste. The app-based platform combats food waste by helping redistribute edible food that would otherwise be thrown away.
3. Rubies in the Rubble (UK)
Initiative: Condiments made from surplus produce
Rubies in the Rubble creates high-quality chutneys, relishes and ketchups using surplus fruits and vegetables that would otherwise go to waste due to cosmetic imperfections. Their mission is to reduce food waste while offering delicious, sustainable products.
4. Renewal Mill (US)
Initiative: Upcycled ingredients from food byproducts
Renewal Mill specialises in transforming byproducts from food manufacturing into high-quality ingredients. Its flagship product, okara flour, is made from the pulp leftover from soya milk production. By using this waste stream, it helps create value from what would otherwise be discarded.
5. Inno-Pak (US)
Initiative: Sustainable packaging from agricultural waste
Inno-Pak has pioneered packaging solutions made from agricultural waste materials such as corn husks and wheat straw. This reduces reliance on virgin plastics and creates a fully compostable packaging solution, closing the loop between production and disposal.
