Food Industry Embraces Fermentation to Turn Waste into Value

The food industry is increasingly turning to fermentation, an ancient technique, to transform processing byproducts into valuable and palatable ingredients. This approach not only addresses the environmental challenge of food waste but also unlocks new economic opportunities.

UK-based Fermtech, for instance, is employing fermentation to convert cocoa shells, typically discarded after cocoa bean processing, into a substitute for cocoa powder. Andy Clayton, Fermtech's CEO, noted the inherent "intense chocolatey nature" of cocoa shells and expressed that it's a "shame" for these byproducts to be composted or incinerated rather than processed to retain their flavors. He describes companies like his as "flavour miners," using microorganisms to break down tough plant materials into forms that humans can consume while preserving desirable tastes.

This strategy of utilizing a wider range of raw materials through fermentation offers benefits such as cost savings, environmental protection, and flavor diversification. For example, the pea protein industry generates significant amounts of leftover starch and fiber, which constitute about three-quarters of the pea after protein extraction. Bosco Emparanza, CEO of Spain's MOA Foodtech, highlighted that these remaining components are "a perfect substrate for fermentation."

MOA Foodtech leverages AI to optimize this process. The company collects data on environmental conditions and available substrates, then sequences the genomes of relevant microorganisms. This data informs an AI trained to identify optimal combinations of substrates and microorganisms for achieving the best yields in fermentation. Emparanza emphasized the accelerated pace of AI-driven bioprocess development, stating that what once took weeks can now be achieved in under an hour.

Through this technology, MOA Foodtech has identified specific microorganisms capable of effectively utilizing the residual starch and fiber from pea protein production. These byproducts, which might otherwise be sold cheaply for animal feed or discarded, are being repurposed for the human food chain. MOA Foodtech is actively working to reintegrate these processed byproducts into human consumption.

This innovative application of fermentation is not limited to cocoa and peas. The broader principle of using microorganisms to transform waste streams into useful ingredients is gaining traction across the food sector. By finding value in what was previously considered waste, companies are contributing to a more sustainable food system while developing novel products and enhancing flavor profiles.