Pacific Nut Producer Magazine

Tag: food innovation

  • Turning Food Scraps into Opportunities

    For every juicy tomato or crunchy almond California grows, there’s a pile of pulp, hulls or scraps that often goes to waste. A new online tool, created by University of California, Davis researchers, tracks those agricultural byproducts aiming to find innovative ways to put them to use.

    The Byproduct Database, maintained by the AI Institute for Next Generation Food Systems, is an ongoing research project that includes a catalog of byproducts like fruit skins and nut shells, and potential ways to reuse them across different industries.

    Edward “Ned” Spang, principal investigator and associate professor with the Department of Food Science and Technology, said about one third of the food produced worldwide, doesn’t get eaten. The database consolidates information about food waste in one place, detailing what the various leftovers are made of and where they’re available in the state. Spang believes it could help guide decisions on reducing waste by potentially turning these materials into new products for food, cosmetics or pharmaceutical industries.

    “In the food production space, there’s a lot of edible material, or potentially valuable material, that’s been overlooked for a long time as waste,” Spang said. “So, the questions we are trying to understand include: ‘How much of this material is out there? What is it composed of? Where is it? When is it available?’”

    Tomatoes, almonds, pistachios and pomegranates

    The pilot phase of the database currently features four major crops: tomatoes, almonds, pistachios and pomegranates. As the research team continues to gather data, they will update the site to include other crops and byproducts, including wine grapes, stone fruits and citrus. In collaboration with Ilias Tagkopoulos with the Department of Computer Science, Spang is looking into developing and applying AI tools to expand the site faster and with less manual work.

    For pistachios, the website illustrates that the largest byproduct is the hull, which is often discarded, and that undersized pistachios could be a valuable resource if there was a market for it. The website helps outline the various byproducts for potential upcycling, where leftovers are transformed into new ingredients. Local companies are already developing new products using materials such as brewers’ spent grain (a byproduct of beer production), okara (a fibrous byproduct from soymilk production) and grape pomace (leftovers from winemaking).

    Researchers are looking at where food gets lost in the field and at the processing plant. With tomatoes, some get damaged on the vine, others get tossed out for not meeting quality standards. Spang said those leftovers, or side streams, are opportunities for upcycling.

    “It’s a material that’s already been cultivated, harvested and processed, so anything you do that’s economically productive means that all the resources embedded in that material, like fertilizer, water and energy, were not wasted in vain,” said Spang, who also directs the Robert Mondavi Institute of Wine and Food Science. “It is a real win-win opportunity.”

    Finding new uses

    The skin and pulp of a tomato contain lycopene, an antioxidant known for its health benefits. Users of the website can visualize where these leftover tomato parts, and its valuable lycopene, are found, helping to imagine new ways to make use of this healthy compound.

    “We expect our primary user to be entrepreneurs who are looking for new business models in upcycling, or who might have an advanced extraction technology to derive value from some of these overlooked materials,” Spang explained. “But producers and growers would also benefit as new revenue streams deliver value up and down the food supply chain.”

    The database will soon include cost estimates and economic variables to help users make more informed decisions. This will allow them to assess factors like how much lycopene is in a byproduct, its value per milligram and the costs associated with extracting it.

    New space for agricultural innovation on campus

    The research project is funded by a grant from the Resnick Agricultural Innovation Research Fund, created by a $50 million gift by Lynda and Stewart Resnick, co-owners of The Wonderful Company. Part of that donation also establishes the Resnick Center for Agricultural Innovation, currently under construction on campus, that will include a large space for biomass staging and extraction, a process to pull valuable compounds from fruits, vegetables and grain residues.

    Food waste happens, but this work is helping build a food system that wastes less and supports sustainability, which Spang hopes will excite everyone.

    “We have to be a little more creative with our food system,” he said. “We can make our current food system more productive by investigating novel upcycling ideas and processing systems that create more revenue for producers and hopefully deliver more value to consumers as well.” — By Tiffany Dobbyn, College of Agricultural and Environmental Sciences, UC Davis, tadobbyn@ucdavis.edu

  • Commercializing Almond Hulls as Food Ingredients

    Almond Board of California — Historically used for dairy cattle feed, almond hulls have had a consistent place in the animal nutrition space. However, a declining dairy herd, in combination with hulls being traded below their production cost, has propelled the industry and the Almond Board of California (ABC) to think about alternative revenue-generating opportunities.

    Helping lead this charge is ABC’s Biomass Working Group, formed in 2017 to explore new applications for almond co-products.

    “This biomass working group is where business meets science,” said Michael Kelley, chairman of the committee and president of Central California Almond Growers Association (CCAGA). “We have become exceedingly appreciative of the ideas and the potential for the commercialization of products using almond hulls.”

    Nutrition Potential

    One area almond hulls have shown strong potential for is human food products. Because of their high fiber content, natural sugars, phytochemicals, minerals, and processing versatility, they offer multiple benefits in the value-added ingredients food space.

    Being that they make up 50% of the almond fruit, they are also abundant in California, creating a reliable and readily available supply for large-scale product development.

    While some may question their safety for human consumption, there are positive indicators that prove almond hulls can meet food-grade quality standards. ABC Associate Director of Food Research and Technology, Guangwei Huang, noted that almond hulls have long been used safely in livestock feed, with no negative effects on animal health or performance. Studies have also shown that pesticide residue and toxicity exposure are not a concern.

    To explore these possibilities further, ABC partnered with Mattson, a product innovation firm, to develop samples of what could be done with hulls.

    These included a high-fiber bar made with 15% almond hulls, delivering five grams of fiber per serving, and a coffee beverage crafted from coarse-ground, roasted hulls. When added to coffee, almond hull powder helped reduce bitterness and enhanced sweetness. In baked goods like bread, it boosted both fiber and phytochemical content.

    Opportunity in “Upcycled” Markets

    Another advantage almond hulls offer is that by adding just 10% or more of almond hull powder to a product, it can qualify for a new third-party “upcycled” certification. While “upcycling” is a relatively new term, it’s become increasingly important to consumers concerned about food waste, noted Daniel Kurzrock, founder and CEO of Upcycled Foods.

    After working with upcycled ingredients across various commodities, Kurzrock said he’s seen firsthand the wide-ranging benefits. These include improved sustainability and circularity, the creation of new revenue streams, reduced disposal costs and stronger alignment with shifting consumer values.

    “The almond industry is not alone in seeing this potential,” he said. “There’s profit potential for every aspect of the stakeholder chain if we’re able to create uses that are solving problems for companies that buy ingredients.”

    Because the end-market for almond hulls is still being widely explored, he also suggested that at this stage in development, it’s important to initiate customer conversations before deciding what to invest in.

    “An approach that we find to be working with other materials is doing a pilot to produce some quantity of viable hulls that can go to a miller or a secondary processor to start those customer conversations,” he said.

    Steps for Commercialization

    While it’s not realistic to expect the hulls to be process-ready when leaving the huller/sheller, Huang said efforts to clean and improve their quality can still make a significant impact.

    “When the time comes, the industry needs to set minimal specifications or quality requirements for almond hulls for food uses,” Huang said. “We are trying to minimize foreign material, and most importantly, we need the involvement and attention of stakeholders. We’re not expecting the huller/seller to get hulls to the ready-to-process stage, but they can minimize those foreign materials down to less than 5%.”

    The industry must also complete a GRAS (Generally Recognized As Safe) assessment for human consumption, a requirement mandated by the Food and Drug Administration since hulls haven’t previously been used as a food ingredient. This assessment  is expected to be completed by late 2025, Huang said.

    Innovations in Processing

    Several companies in the almond industry are already investing in hull-cleaning systems to ensure they are ready for when almond hulls receive food-safe approval. One of those pioneer companies is Cortez Growers Association.

    Recognizing almond hulls as a potential revenue stream, Cortez implemented a cleaning system to remove unwanted materials – sticks, shells, and almond meats – that typically end up in the hull pile. By separating these components, they could sell the almond meats as hash, a “refreshing benefit” to add value to what was once considered waste, said general manager, Dave Thiel.

    Other processors are also refining their methods. Corbin Sturdivan of Wilkey Industries explained that current hull cleaning systems include an aspirator to remove the shell from the hull and a detwigger deck to remove sticks from the hulls.

    “While this has worked for many years to reduce the fiber content for dairy feed, there is more refinement that we can do with this system by introducing additional screening and additional aspiration,” Sturdivan said.

    Through their trials with ABC, Sturdivan and his team discovered that by adding a screen to sift through the hulls, they could be better classified and ranked.

    “We would de-twig the product; it would be screened, and the screen would sift out all of the fines from the hulls,” he said. “What is left over is what we would call scalped hulls, and this is your larger, good material created from the early stages of hulling.”

    From their observation, Wilkey Industries also found that 1 to 1.3% of total hull weight can actually be recoverable kernel.

    “That translates to roughly 3% of your kernel production that is actually sitting in the hull pile,” he said. “So, by integrating a screen and some additional aspiration, not only can we clean the hulls, but we can also reclaim those kernels and hash that have much higher value to be sold instead of letting them go to dairy feed uses.”

    Additional Sorting Techniques

    As cleaning technologies continue to advance, innovations in color sorting are emerging as a key tool for preparing almond hulls for food-grade applications. The team at Chandler Automation has spent time working on this, and the initial models have been successful at “creating pure hull piles in one pass,” said CEO, Sean Chandler.

    More research is needed to determine where this best fits in the manufacturing process – be it at the huller, processor, or a separate site and how it will be financially feasible.

    “We have to do more research on our side to see the best way to mechanically clean hulls, mechanically feed it, and mechanically pass it through our systems because the technology is there to create that pure, premium hull,” he said.

    Looking Ahead

    As ABC continues to refine its strategy for marketing almond hulls as a food ingredient, the industry is taking proactive measures to position itself for success, and that starts with collaboration among all players involved.

    “We are about to begin a new journey to generate more revenue from almond hulls,” Huang concluded. “It will take a while and more effort to develop the market and demand, but if you are interested in creating more value out of almond hulls, many of us can work together to shorten the process.”