Meeting the Challenges of Upcycling Ingredients

The food system alone is responsible for a third of global greenhouse gas emissions (Crippa et al. 2021). In addition to environmental advantages and economic benefits, appropriate food waste management also can contribute to the food security of the growing global population. This has led to an increased interest in upcycling food ingredients, which involves converting food waste into edible products.

The Upcycled Food Association defines upcycled foods as those that "use ingredients that otherwise would not have been consumed by humans, are procured and produced using verifiable supply chains, and have a positive environmental impact." Upcycling offers an opportunity to reduce food waste, create new sources of revenue, and develop sustainable food products. In addition, upcycling food ingredients can have a positive impact on the environment by reducing greenhouse gas emissions and conserving resources (Aschemann-Witzel et al. 2023). Very recently, researchers have reported some roadblocks to its widespread adoption, such as consumer safety concerns, neophobia, and disgust (Bhatt et al. 2020, Hellali and Koraï 2023). This article will discuss the challenges of product development using upcycled food products and the factors affecting consumer acceptance of upcycled food products.

Product Development Challenges

Product development using upcycled food ingredients presents unique challenges that differ from those encountered with traditional ingredients. The main challenges of using upcycled food ingredients are the following:

1. Sourcing and processing of the ingredients. The quality and consistency of the ingredients can vary, depending on the source of the waste. The processing of the waste also can affect the quality of the ingredients. For example, processing methods such as heating and drying can affect the nutritional value and sensory properties of the ingredients.
2. Formulation and processing of final product. Formulating and processing the final product using upcycled food ingredients also presents challenges. The properties of the ingredients, such as flavor, texture, and functionality, can differ from those of traditional ingredients. The formulation and processing of the final product need to be optimized to ensure that the final product meets the desired quality and functionality.
3. Sensory attributes. Taste strongly influences dietary preferences. Studies have been conducted to evaluate upcycled food’s organoleptic properties such as fungi burgers from surplus bread or biscuits from defatted flour. These researchers found that upcycled food sensory features rely on product composition and upcycled ingredient proportion used in the formulation. Upcycled foods may taste and feel differently from conventional food products, making them less appealing. Product developers need to ensure that upcycled food products provide a taste experience that consumers enjoy. This can be challenging since upcycled ingredients may have unique flavor profiles that differ from traditional ingredients.

There are several strategies product developers can use to address these challenges. Utilizing technology to effectively sort, process, and distribute high-quality products is necessary for upcycling food waste into new products. Food waste collection and sorting are crucial steps in the upcycling process. It might be tough to identify and separate the valuable materials from the waste without suitable sorting and collection procedures. It is essential to make investments in effective collecting and sorting systems that can handle enormous volumes of waste. Some businesses are using sophisticated robots and artificial intelligence technologies to do this. These systems can be trained to identify various food waste types and classify it accordingly.

In addition, a variety of cutting-edge processing methods are required for upcycling food waste into new products. Depending on the kind of food waste being processed and the desired end product, different methods may be used. For instance, some food product developers might use enzymatic or microbial fermentation processes to transform organic trash into useful nutrients, while others might use mechanical processing methods to make new products from waste. Companies must make investments in specialist processing machinery, such as high-speed grinders and shredders, or specialized fermenters, to do this. These technologies can aid in efficient and economical conversion of food waste into usable products.

The sensory properties of upcycled food products also can be improved by optimizing the formulation and processing of the product. For example, the particle size of the upcycled ingredients can be controlled to improve the texture of the product. The addition of flavoring agents and masking agents can also help to improve the taste and aroma of the product. However, by using flavor masking techniques or incorporating upcycled ingredients into products with complementary flavors, product developers can create upcycled food products that are delicious and satisfying. The texture is another important factor to consider when developing upcycled food products. Depending on the type of upcycled ingredient used, the texture of the final product may be affected. For example, using upcycled flour made from cereal byproducts may result in a denser texture in baked goods.

Product development scientists need to carefully consider the impact of upcycled ingredients on the texture of the final product and adjust as needed to create a product that meets consumer expectations. Product developers can address this by using techniques such as color masking or by incorporating upcycled ingredients into products that naturally have a more rustic appearance.

Strategies for Success

In the process of upcycling, quality monitoring is crucial. For the products to be marketed and consumed, they must meet a set of quality requirements. Systems for quality control can aid in ensuring the safety, reliability, traceability, and nutritional value of upcycled goods. To evaluate the nutritional value and safety of upcycled items, food product developers must invest in cutting-edge laboratory testing tools. Gas chromatography and mass spectrometry can be used to examine the nutritional content of upcycled products, while microbiological testing can help to assure the safety of those items.

Additionally, dedicated software applications can be used to monitor the consistency and quality of a product throughout time, identifying and resolving any problems that may occur. Food product developers must comply with regulatory requirements related to the production and sale of upcycled foods. They must also be aware of the regulatory framework for upcycled foods in different markets and ensure that their products comply with the relevant regulations.

The success of upcycled food products depends on consumer acceptance, which is affected by various factors such as taste, texture, appearance, and perceived health benefits. To increase consumer acceptance, product developers need to address these factors and have the marketing team communicate the benefits of the product effectively to consumers. Appearance is important in consumer acceptance of upcycled food products. Consumers are used to certain visual cues in food products that signal freshness and quality, such as bright colors and uniform shapes. Upcycled ingredients may not always meet these visual cues, and as a result, the final product may have a different appearance than what consumers are used to. Perceived health benefits also are key factors in increasing consumer acceptance of upcycled food products (Thorsen et al. 2022). Consumers are increasingly concerned about the health impact of their food choices and are looking for products that are healthier. Product developers can communicate health benefits to consumers through product labeling, advertising, and public relations campaigns.

Global Status of Upcycled Foods

The majority of upcycling companies are united in their mission to reduce waste and protect the environment by finding novel uses for surplus food supplies. To combat the widespread issue of food waste, numerous companies have created cutting-edge processing methods for edible waste. Evidence of early commercial interest in upcycled foods includes the launch of organizations including Regrained, Ugly Co., Spudsy, and Planetarians in the United States; Kaffe Bueno in Denmark; Remashed in the United Kingdom; and Citizen Collective, Perfect Deli Fresh, and déjà in New Zealand. These companies have overcome the challenges of product development and have successfully positioned their products as sustainable and high-quality products.

Among some notable examples is ReGrained, a company that specializes in upcycling spent grain from the brewing process into snack bars. Spent grain is a byproduct of the brewing process that is typically discarded. ReGrained has developed a process to convert the spent grain into flour that can be used as an ingredient in snack bars. The flour is high in fiber and protein and has a nutty flavor that complements the other ingredients in the snack bars. ReGrained has successfully marketed its snack bars as sustainable and healthy products. The company has positioned its product as a high-quality snack that provides a unique taste experience.

ChicP is another success story. The company specializes in upcycling vegetable waste into hummus. Vegetable waste is a byproduct of the food industry that is typically discarded. ChicP has developed a process to convert vegetable waste into hummus that is high in fiber and protein and has a unique flavor profile. ChicP has successfully marketed its hummus as a sustainable and healthy alternative to traditional hummus. Similarly, using patented technology, The Coffee Cherry Company transforms the 46 billion pounds of coffee cherry pulp generated annually from the processing of green coffee beans into flour. The flour can be used to make a wide variety of baked goods, as well as noodles, pasta, and other similar products. The annual waste of millions of tons of this fruit in coffee-growing countries contributes to the contamination of groundwater and the release of greenhouse gases.

Billions of pounds of edible vegetables never make it to the U.S. market due to off-spec conditions such as sizing variance and cosmetic defects. Similarly, a lot of fresh-cut vegetables also do not make it to the American market. Matriark Foods works with farmers and food companies to salvage some of this wasted food. They add herbs and spices to these vegetables to make low-sodium, nutritional, shelf-stable broths and bases for schools, hospitals, and food banks, as well as a new retail presence. Each pallet of vegetable broth concentrate saves 1,500 lbs of veggies and makes 80,000 servings. Treasure8 has collaborated with the U.S. Department of Agriculture to create cutting-edge dehydration technology that can convert food scraps such as kale, peppers, and beets into healthy chips and powders.

Future Perspectives

Consumer perceptions of upcycled food are the biggest obstacle to overcome, even more so than defining it and evaluating how it fits in the food waste management hierarchy. Acceptance of upcycled food may be affected by food neophobia and technophobia due to the presence of substances that would not normally be utilized in human food. It's common for people to reject and even be afraid of new foods, especially those made either with unconventional methods or products.

Nonetheless, it is encouraging to note that consumer acceptance is affected by food labels, certification, ingredient lists, and place of origin. Carbon Trust and similar carbon footprint labels increase the acceptability of these products, especially among eco-conscious consumers. Since a well-designed logo can serve as a food quality indicator, the recent accreditation of upcycled foods by the Upcycled Food Association may help increase their popularity.

Price is another extrinsic indicator that plays a dual function in consumer decisions. A high price may decrease the likelihood of purchase, but conversely, a high price indicates high quality, which has a positive effect on perceived utility and demand. The high cost of environmentally friendly foods makes them unaffordable to the general public, particularly to those with limited incomes. Consumers’ propensity to pay for upcycled foods is contingent on their perception and marketing communication. People will be willing to pay a premium price, for instance, if they perceive the upcycled food to have the same quality as a conventional product. Similarly, consumers are prepared to pay a premium for upcycled foods with nutritional and environmental benefits.

However, when the marketing message emphasizes the source of the ingredients (e.g., food waste and suboptimal ingredients), consumers anticipate a price reduction. Therefore, transparency in upcycled food communication does not inherently persuade consumers to purchase or pay more; it may even influence their decisions negatively. In addition, the sensory properties and taste of the final product can also affect the consumer acceptance of the product. Consumer acceptance of upcycled food products is a critical factor in the success of these products.

Overall, upcycled food products present an opportunity to reduce food waste, create new sources of revenue, and develop sustainable food products. The challenges of product development using upcycled food ingredients can be addressed by careful sourcing and processing of the ingredients, formulation and processing of the final product, and effective communication of the benefits of the product to consumers. By addressing these challenges, product developers can create upcycled food products that meet consumer expectations and contribute to a more sustainable food system.