Sustainable valorisation pathways mitigating environmental pollution from brewers' spent grains

Integral multi-valorization of agro-industrial wastes: A review

Agriculture and industries related to the agriculture sector generate a large amount of waste each year. These wastes are usually burned or dumped, causing damage to the environment, the economy and society. Due to their composition, they have great potential for obtaining high value-added products in biorefineries. This fact, added to the growing demand for energy and chemicals from fossil resources, is driving the interest of the scientific community in them. Biorefinery processes are hardly profitable when applied individually, so a better alternative is to develop integrated multi-feedstock and multi-product biorefinery schemes using all biomass fractions in a zero-waste approach. However, for industrial scale application, extensive research, scale-up studies, and techno-economic and environmental feasibility analyses are needed. This review compiles information on integrated multi-biorefinery processes from agro-industrial wastes to shed light on the path towards sustainable development and circular bioeconomy.

Subcritical water treatment to modify insoluble dietary fibers from brewer's spent grain for improved functionality and gut fermentability

Lactic acid (LA)-assisted subcritical water treatment (SWT) was applied to modify the insoluble dietary fiber (IDF) from brewer's spent grain (BSG) for enhancing its functionality and gut fermentability. Modified IDFs were thoroughly characterized for their chemical and structural properties. The results revealed that increasing the treatment temperature and LA concentration reduced hemicellulose content in IDFs from 38.4 % to 0.7 %, alongside a decreased yield (84.8 %-51.4 %), reduced particle size (519.8-288.6 μm), and more porous structure of IDFs. These modifications were linked to improved functionalities, evidenced by the highest water and oil holding capacity increasing by 36 % and 67 %, respectively. Remarkably, the highest glucose adsorption capacity increased by 6.5 folds. Notably, modified IDFs exhibited slower in-vitro fermentation, elevated short-chain fatty acids (SCFAs) production, and a higher proportion of butyrate in SCFAs. These findings highlight the potential of LA-assisted SWT in transforming BSG-derived IDF into a valuable functional food ingredient.

Sustainable Particleboards Based on Brewer's Spent Grains

Brewer's spent grain (BSG) is the main solid waste generated in beer production and primarily consists of barley malt husks. Based on the active promotion of circular economy practices aimed at recycling food industry by-products, this study assessed for the first time the production of particleboards based on BSG as the sole source of lignocellulosic material and natural adhesive without the use of additives or other substrates. In order to achieve particleboards from entirely sustainable sources, BSG particles have to self-bind by thermo-compression with water. In this context, the aim of this study is to assess the effects of pressing temperatures and particle size on properties such as modulus of elasticity, modulus of rupture, internal bond, thickness swelling, and water absorption. The performance of binderless boards was compared with that of a control panel (control) using BSG combined with phenolic resin. Processing conditions were selected to produce boards with a target density of 1000 kg/m³ and a thickness of 5 mm. To confirm the efficiency of the self-adhesion process, scanning electron microscopy was used to examine the boards. The processes of self-adhesion and particle-to-particle contact were facilitated at a pressing temperature of 170 °C and a particle size range of 200-2380 µm (ground BSG), resulting in improved flexural properties and enhanced water resistance. The properties of BSG-based binderless boards were comparable to those reported for other biomass residues, suggesting that they might be used in non-structural applications, such as interior decoration.

Sequential Extraction and Attenuated Total Reflection-Fourier Transform Infrared Spectroscopy Monitoring in the Biorefining of Brewer's Spent Grain

The brewing industry plays a significant role in producing a substantial annual volume of by-products, which contributes to the global accumulation of food waste. The primary by-product generated is brewer's spent grain (BSG), a lignocellulosic biomass rich in proteins, fiber, and moisture content. Leveraging biorefining and valorization techniques for BSG represents a promising strategy to enhance sustainability, resilience, and circularity within the brewing chain. To date, most studies have focused on extracting proteins from BSG. Yet, it is crucial to note that the fiber part of BSG also holds considerable potential for biorefining processes. This study introduces a novel sequential extraction method designed to integrally recover the major components of BSG. Notably, it introduces a reactive extraction approach that enables the simultaneous extraction and tuneable functionalization of the hemicellulose component. Additionally, the study assesses the utility of the attenuated total reflection-Fourier transform infrared (ATR-FTIR) spectroscopy as a user-friendly tool to monitor and evaluate the effectiveness of the fractionation process. This spectroscopic technique can provide valuable insights into the changes and composition of BSG throughout the extraction process.

Effective Degradation of Brewer Spent Grains by a Novel Thermostable GH10 Xylanase

Brewer spent grains (BSGs) are one of the most abundant by-products in brewing industry. Due to microbiological instability and high perishability, the efficient degradation of BSGs is of environmental and economic importance. Streptomyces sp. F-3 could grow in the medium with BSGs as the only carbon and nitrogen source. Proteome mass spectrometry revealed that a GH10 xylanase SsXyn10A could be secreted in large quantities. SsXyn10A showed optimum activity at pH 7.0 and 60 °C. SsXyn10A exhibited excellent thermostability which retained approximately 100% and 58% after incubation for 5 h at 50 and 60 °C. SsXyn10A displayed high activity to beechwood xylan (BX) and wheat arabinoxylan (WAX). SsXyn10A is active against xylotetracose (X4), xylopentose (X5), and xylohexose (X6) to produce main products xylobiose (X2) and xylotriose (X3). Ssxyn10A showed synergistic effects with commercial cellulase on BSGs hydrolyzing into soluble sugar. In addition, the steam explosion pretreatment of BSGs as the substrate produced twice as much reducing sugar as the degradation of the original substrate. This study will contribute to efficient utilization of BSGs and provide a thermostable GH10 xylanase which has potential application in biomass hydrolysis.

Versatile Applications of Brewer's Spent Grain: Solid-State Fermentation and Nutritional Added Value

Brewer's spent grain (BSG) is a major by-product in the beer-brewing process which contributes to 85% of the entire generated by-product in the brewing process. BSG is rich in proteins, and most of the malt proteins (74-78%) remain insoluble in BSG after the mashing process. Solid-state fermentation (SSF) is a promising bioprocess that enables microorganisms to survive in environments with minimal water and has shown to enhance the nutritional composition of BSG. In this review, the potential application of protein, amino acids (proline, threonine, and serine), phenolic contents, and soluble sugars (glucose, fructose, xylose, arabinose, and cellobiose) extracted from BSG by various microorganisms using SSF is explored. Incorporation of BSG into animal feed, human diets, and as a substrate for microorganisms are the prospects that could be implemented in the industrial scale. This review also discussed various advances to improve the fermentation yield such as symbiotic fermentation, the addition of nitrogen supplements, and an optimal mixture of the agro-industrial waste substrate. Future perspectives on SSF are also addressed to provide important ideas for immediate and future studies. However, challenges include optimizing SSF conditions and design of bioreactors, and operational costs must be addressed in the future to overcome current obstacles. Overall, this mini review highlights the potential benefits of BSG utilization and SSF in a sustainable way.

Potential of Nanocellulose as a Dietary Fiber Isolated from Brewer's Spent Grain

Steady growth in beer production is increasing the number of by-products named brewers' spent grain. Such by-products are a source of several components, where cellulose is usually present in high amounts. The aim of this study was to develop a protocol to obtain a mix of cellulose microfibers with an average diameter of 8-12 µm and cellulose nanoplatelets with an average thickness of 100 nm, which has several applications in the food industry. The process comprised one alkaline treatment followed by acid hydrolysis, giving a new mix of micro and nanocellulose. This mix was characterized by Fourier transform infrared spectroscopy, scanning electron microscopy, and laser scanning microscopy corroborating the presence and measurements of the cellulose nanostructure, showing an aspect ratio of up to 500. Finally, we demonstrated that the administration of this new type of nanocellulose allowed us to control the weight of mice (feed intake), showing a significant percentage of weight reduction (4.96%) after 15 days compared with their initial weight, indicating the possibility of using this material as a dietary fiber.

Spent Grain: A Functional Ingredient for Food Applications

Spent grain is the solid fraction remaining after wort removal. It is nutritionally rich, composed of fibers—mainly hemicellulose, cellulose, and lignin—proteins, lipids, vitamins, and minerals, and must be managed properly. Spent grain is a by-product with high moisture, high protein and high fiber content and is susceptible to microbial contamination; thus, a suitable, cost-effective, and environmentally friendly valorization method of processing it is required. This by-product is used as a raw material in the production of many other food products—bakery products, pasta, cookies, muffins, wafers, snacks, yogurt or plant-based yogurt alternatives, Frankfurter sausages or fruit beverages—due to its nutritional values. The circular economy is built on waste reduction and the reuse of by-products, which find opportunities in the regeneration and recycling of waste materials and energy that become inputs in other processes and food products. Waste disposal in the food industry has become a major issue in recent years when attempting to maintain hygiene standards and avoid soil, air and water contamination. Fortifying food products with spent grain follows the precepts of the circular bio-economy and industrial symbiosis of strengthening sustainable development. The purpose of this review is to update information on the addition of spent grain to various foods and the influence of spent grain on these foods.

Functional Bread Produced in a Circular Economy Perspective: The Use of Brewers' Spent Grain

Brewers' spent grain (BSG) is the main by-product of the brewing industry, corresponding to ~85% of its solid residues. The attention of food technologists towards BSG is due to its content in nutraceutical compounds and its suitability to be dried, ground, and used for bakery products. This work was aimed to investigate the use of BSG as a functional ingredient in bread-making. BSGs were characterised for formulation (three mixtures of malted barley and unmalted durum (Da), soft (Ri), or emmer (Em) wheats) and origin (two cereal cultivation places). The breads enriched with two different percentages of each BSG flour and gluten were analysed to evaluate the effects of replacements on their overall quality and functional characteristics. Principal Component Analysis homogeneously grouped BSGs by type and origin and breads into three sets: the control bread, with high values of crumb development, a specific volume, a minimum and maximum height, and cohesiveness; Em breads, with high values of IDF, TPC, crispiness, porosity, fibrousness, and wheat smell; and the group of Ri and Da breads, which have high values of overall smell intensity, toasty smell, pore size, crust thickness, overall quality, a darker crumb colour, and intermediate TPC. Based on these results, Em breads had the highest concentrations of nutraceuticals but the lowest overall quality. Ri and Da breads were the best choice (intermediate phenolic and fibre contents and overall quality comparable to that of control bread). Practical applications: the transformation of breweries into biorefineries capable of turning BSG into high-value, low-perishable ingredients; the extensive use of BSGs to increase the production of food commodities; and the study of food formulations marketable with health claims.

Biorefinery of Brewery Spent Grain by Solid-State Fermentation and Ionic Liquids

Novel environmentally friendly pretreatments have been developed in recent years to improve biomass fractionation. Solid-state fermentation (SSF) and treatment with ionic liquids show low environmental impact and can be used in biorefinery of biomass. In this work, these processes were assessed with brewery spent grain (BSG). First, BSG was used as a substrate to produce cellulases and xylanases by SSF with the fungi Aspergillus brasiliensis CECT 2700 and Trichoderma reesei CECT 2414. Then, BSG was pretreated with the ionic liquid [N₁₁₁₂OH][Gly] and hydrolyzed with the crude enzymatic extracts. Results showed that SSF of BSG with A. brasiliensis achieved the highest enzyme production; meanwhile, the pretreatment with ionic liquids allowed glucan and xylan fractions to increase and reduce the lignin content. In addition, a mixture of the extracts from both fungi in a ratio of 2.5:0.5 Aspergillus/Trichoderma (v/v) efficiently hydrolyzed the BSG previously treated with the ionic liquid [N₁₁₁₂OH][Gly], reaching saccharification percentages of 80.68%, 54.29%, and 19.58% for glucan, xylan, and arabinan, respectively. In conclusion, the results demonstrated that the BSG biorefinery process developed in this work is an effective way to obtain fermentable sugar-containing solutions, which can be used to produce value-added products.

Agri-Food Wastes for Bioplastics: European Prospective on Possible Applications in Their Second Life for a Circular Economy

Agri-food wastes (such as brewer's spent grain, olive pomace, residual pulp from fruit juice production, etc.) are produced annually in very high quantities posing a serious problem, both environmentally and economically. These wastes can be used as secondary starting materials to produce value-added goods within the principles of the circular economy. In this context, this review focuses on the use of agri-food wastes either to produce building blocks for bioplastics manufacturing or biofillers to be mixed with other bioplastics. The pros and cons of the literature analysis have been highlighted, together with the main aspects related to the production of bioplastics, their use and recycling. The high number of European Union (EU)-funded projects for the valorisation of agri-food waste with the best European practices for this industrial sector confirm a growing interest in safeguarding our planet from environmental pollution. However, problems such as the correct labelling and separation of bioplastics from fossil ones remain open and to be optimised, with the possibility of reuse before final composting and selective recovery of biomass.

The Potential of Brewer’s Spent Grain in the Circular Bioeconomy: State of the Art and Future Perspectives

Brewer’s spent grain (BSG) accounts for approximately 85% of the total mass of solid by-products in the brewing industry and represents an important secondary raw material of future biorefineries. Currently, the main application of BSG is limited to the feed and food industry. There is a strong need to develop sustainable pretreatment and fractionation processes to obtain BSG hydrolysates that enable efficient biotransformation into biofuels, biomaterials, or biochemicals. This paper aims to provide a comprehensive insight into the availability of BSG, chemical properties, and current and potential applications juxtaposed with the existing and emerging markets of the pyramid of bio-based products in the context of sustainable and circular bioeconomy. An economic evaluation of BSG for the production of highly valuable products is presented in the context of sustainable and circular bioeconomy targeting the market of Central and Eastern European countries (BIOEAST region).

Bioethanol and biogas production: an alternative valorisation pathway for green waste

Biofuels are a research field of great interest given the environmental benefits they offer over conventional fossil fuels. Nowadays, it is urgent to find ways of utilizing waste in the direction of biofuels production. The aim of this paper was the utilization of green waste (branches, leaves and ligno-cellulosic residues from tree prunings, hedge cuttings and grass clippings) towards biofuels production and specifically towards bioethanol and biogas. The experimental plan that was followed included biogas production through anaerobic digestion and bioethanol production through alcoholic fermentation after the necessary chemical pretreatment (acid or alkaline hydrolysis) prior to enzymatic hydrolysis and fermentation. Based on the results obtained, three valorisation scenarios of green waste were designed and compared in terms of product mass intensity, product yield and energy content of biofuels produced. The optimal results for bioethanol production were 5.22 g/L ethanol, 70.61% saccharification yield and 33.67% ethanol yield with acid pretreatment using H₂SO₄ 3% w/v, 475 μL/g cellulose CellicCtec2 and 10% solids loading. Regarding biogas, the highest biogas production observed was 267.1 mL biogas/g dry substrate resulting from anaerobic digestion of the alkaline stillage. Thus, the production of biofuels from green waste is technically feasible, although it provides moderate efficiencies. However, for a sustainable valorisation of green waste, other techno-economic factors such as the cost of enzymes, chemicals, energy, etc. must be taken into account.

Conversion of brewers' spent grain into proteinaceous animal feed using solid state fermentation

Brewers' spent grain (BSG) represents the 85% of the total residue produced during the beer brewing process, with a global annual production volume exceeding 30 Mtons. The current study concerns the application of solid state fermentation (SSF) as a bioprocess where the nutritional value of BSG is improved for further use as animal feed with increased value. The investigated SSF procedure was initiated by the edible fungi Pleurotus ostreatus, which constitutes a natural source of proteins, β-glucans, and various metabolites (vitamins, nutrients, etc.). Herein, the SSF of BSG resulted in a significant increase of protein content by 49.49%, a 10-fold increase of 1,3-1,6 β-glucans, and a respective reduction of cellulose by 11.42%. The application of this method is expected to provide some useful information on the utilization of BSG as substrate for fungi-initiated SSF, a bioprocess allowing the significant reduction of the environmental impact caused by the beer brewing industry and simultaneously producing animal feed with higher protein content and improved nutritional characteristics. Such studies contribute to confront the unavailability of proteinaceous animal feed observed in the last decade.

Sustainable Solar Drying of Brewer’s Spent Grains: A Comparison with Conventional Electric Convective Drying

Spent grains from microbreweries are mostly formed by malting barley (or malt) and are suitable for a further valorization process. Transforming spent grains from waste to raw materials, for instance, in the production of nontraditional flour, requires a previous drying process. A natural convection solar dryer (NCSD) was evaluated as an alternative to a conventional electric convective dryer (CECD) for the dehydration process of local microbrewers’ spent grains. Two types of brewer’s spent grains (BSG; Golden ale and Red ale) were dried with both systems, and sustainability indices, specific energy consumption (eC), and CO2 emissions were calculated and used to assess the environmental advantages and disadvantages of the NCSD. Then, suitable models (empirical, neural networks, and computational fluid dynamics) were used to simulate both types of drying processes under different conditions. The drying times were 30–85 min (depending on the drying temperature, 363.15 K and 333.15 K) and 345–430 min (depending on the starting daytime hour at which the drying process began) for the CECD and the NCSD, respectively. However, eC and CO2 emissions for the CECD were 1.68–1.88 · 10−3 (kW h)/kg and 294.80–410.73 kg/(kW h) for the different drying temperatures. Using the NCSD, both indicators were null, considering this aspect as an environmental benefit.

Valorization of Brewers’ Spent Grains: Pretreatments and Fermentation, a Review

Brewers’ spent grains constitute a valuable byproduct of the beer industry. They are characterized by a rich nutritional composition consisting of around 70% lignocellulosic fibrous material, 20% proteins, 10% lipids, in addition to vitamins, minerals, amino acids, and phenolic compounds. These spent grains are produced in large amounts all through the year, are cheap, and lack economically feasible applications. Nowadays, 70% of these spent grains are used as animal feed, 10% are used for biogas production, and the remaining 20% are disposed in landfills. Due to the aforementioned facts, alternative uses of the brewers’ spent grains are highly sought-after. In fact, this nutrient-rich industrial by-product makes it a very good candidate for valorization through biotechnological processing, particularly microbial fermentation. After applying the needed pretreatments, using brewers’ spent grains as a substrate in submerged and solid-state fermentation of different microorganisms leads to the production of various value-added compounds such as organic acids, amino acids, volatile fatty acids, enzymes, vitamins, second-generation biofuels and other products.

A New Method to Overcome Carboxyamide Formation During AFEX Pretreatment of Lignocellulosic Biomass

Lignin-carbohydrate complexes (LCCs) in the plant cell wall are responsible for providing resistance against biomass-degrading enzymes produced by microorganisms. Four major types of lignin-carbohydrate bonds are reported in the literature, namely, benzyl ethers, benzyl esters, phenyl glycosides, and acetyl ester linkages. Ester’s linkages in the plant cell wall are labile to alkaline pretreatments, such as ammonia fiber expansion (AFEX), which uses liquid or gaseous ammonia to cleave those linkages in the plant cell wall and reduce biomass recalcitrance. Two competing reactions, notably hydrolysis and ammonolysis, take place during AFEX pretreatment process, producing different aliphatic and aromatic acids, as well as their amide counterparts. AFEX pretreated grasses and agricultural residues are known to increase conversion of biomass to sugars by four- to five-fold when subjected to commercial enzyme hydrolysis, yielding a sustainable feedstock for producing biofuels, biomaterials, and animal feed. Animal feed trials on dairy cows have demonstrated a 27% increase in milk production when compared to a control feedstock. However, the presence of carboxamides in feedstocks could promote neurotoxicity in animals if consumed beyond a certain concentration. Thus, there is the need to overcome regulatory hurdles associated with commercializing AFEX pretreated biomass as animal feed in the United States. This manuscript demonstrates a modified pretreatment for increasing the digestibility of industrial byproducts such as Brewer’s spent grains (BSG) and high-fiber meal (HFM) produced from BSG and dry distillers grains with soluble (DDGS), while avoiding the production of carboxamides. The three industrial byproducts were first treated with calculated amounts of alkali such as NaOH, Ca(OH)2, or KOH followed by AFEX pretreatment. We found that 4% alkali was able to de-esterify BSG and DDGS more efficiently than using 2% alkali at both 10 and 20% solids loading. AFEX pretreatment of de-esterified BSG, HFM, and DDGS produced twofold higher glucan conversion than respective untreated biomass. This new discovery can help overcome potential regulatory issues associated with the presence of carboxamides in ammonia-pretreated animal feeds and is expected to benefit several farmers around the world.