Valorization of food industry waste and by-products using 3D printing: A study on the development of value-added functional cookies

3D printing: trends and approaches toward achieving long-term sustainability in the food industry

Global food security has recently been under serious threat from the rapid rise in the world's population, the problems brought on by climate change, and the appearance of new pandemics. As a result, the need for novel and innovative solutions to solve the existing problems and improve food sustainability has become crucial. 3D printing is expected to play a significant role in providing tangible contributions to the food industry in achieving sustainable development goals. The 3D food printing holds the potential to produce highly customized food in terms of shape, texture, flavor, structure and nutritional value and enable us to create new unique formulations and edible alternatives. The problem of whether the cost of the printed meal and 3D printing itself can be sustainably produced is becoming more and more important due to global concerns. This review intends to provide a comprehensive overview of 3D printed foods with an overview of the current printing methodologies, illustrating the technology's influencing factors, and its applications in personalized nutrition, packaging, value addition, and valorization aspects to fully integrate sustainability concerns thus exploring the potential of 3D food printing.

Evaluating the 3D printability of pearl millet flour with banana pulp blends

BACKGROUND

Three-dimensional (3D) food printing is a promising method for developing nutritious snack foods with complex and customized structures. In this study, to develop a pearl millet-based snack formulation, the printability of pearl millet flour (PMF) was assessed, without and with the addition of banana pulp (BP), a natural taste and flavor enhancer, at five different levels (PMF:BP of 100:0, 80:20, 60:40, 40:60, 20:80 and 0:100).

RESULTS

The water activity significantly decreased with increases in the proportion of BP; higher water activity was exhibited at 100:0 (0.99). The BP proportion influences all the color values (redness: 2-11; yellowness: 17-31.87; total color difference: 2-17). All formulations exhibited shear-thinning behavior (n = 0.02-0.49) and higher hardness (0.2-0.4 N), but not all were printable. A significant decrease in adhesiveness (-0.2 to -0.03 N s) and higher storage modulus (2000-6000 Pa) occurred with an increased proportion of BP. Findings from detailed rheological behavior assessment (static, dynamic and three-interval thixotropy tests) better correlated with trends observed during 3D extrusion printing. The highest yield stress was attained (80 Pa) in the 100:0 formulation. From the thixotropy test, more deformation (>80%) and recovery (>100%) were attained by three of the formulations (100:0, 80:20, 60:40). Overall, the best constructs were obtained (based on the visual sensory characteristics) for the 60:40 formulation printed at 600 mm min-1 printing speed and 240 rpm extrusion motor speed through a 1.22 mm nozzle.

CONCLUSION

The findings of this work will provide valuable insights into the development of novel millet-based 3D printed foods. © 2024 Society of Chemical Industry.

Three-dimensional food printing: its readiness for a food and nutrition insecure world

Three-dimensional (3D) food printing is a rapidly emerging technology offering unprecedented potential for customised food design and personalised nutrition. Here, we evaluate the technological advances in extrusion-based 3D food printing and its possibilities to promote healthy and sustainable eating. We consider the challenges in implementing the technology in real-world applications. We propose viable applications for 3D food printing in health care, health promotion and food waste upcycling. Finally, we outline future work on 3D food printing in food safety, acceptability and economics, ethics and regulations.

Innovations in Food Packaging for a Sustainable and Circular Economy

Packaging is fundamental to maintaining the quality of food, but its contribution with a negative footprint to the environment must be completely changed worldwide to reduce pollution and climate change. Innovative and sustainable packaging and new strategies of reutilization are necessary to reduce plastic waste accumulation, maintain food quality and safety, and reduce food losses and waste. The purpose of this chapter is to present innovations in food packaging for a sustainable and circular economy. First, to present the eco-design packaging approach as well as new strategies for recycled or recyclable materials in food packaging. Second, to show current trends in new packaging materials developed from the use of agro-industrial wastes as well as new methods of production, including 3D/4D printing, electrostatic spinning, and the use of nanomaterials.

Viability Study on the Use of Three Different Gels for 3D Food Printing

Three-dimensional food printing is one of the modern techniques for food customization. The difficulty of this technique lies in the formulation of new matrices. These new formulations must have good extrusion characteristics and, at the same time, maintain the structure once printed. These qualities are related to textural and rheological properties. Printability studies are those whose objective is to know the above properties. Some authors have correlated printability with rheological and physicochemical parameters. The aim of this study was to characterize three gels to test prediction models and to determine the most important rheological and textural parameters (G', G″, Tanδ, maxF, average) in printability. The formulations studied were bovine gelatin (4%) with kappa-carrageenan (0.5%) (Gb + K), porcine gelatin (5%) plus iota-carrageenan (2%) (Gp + I), and methylcellulose (4%) (MC). The samples were characterized by an oscillatory test for the rheological properties and an extrusion test for the textural properties. In addition, the density was obtained to apply the predictive models and correlate the rheological and textural parameters to determine their influence. Gp + I and Gb + K showed higher values of maximum force in the extrusion test than MC, but MC had less deviation in the mean force during the test. All the samples showed a predominantly elastic behavior and damping factor (Tanδ) between 0.14 (Gb + K) and 0.37 (MC). It was observed that the tangent of the phase angle (Tanδ) had a large positive influence on the maximum and average force studied in the extrusion tests. The sample results did not match 100% with the predictions made from the models. It was possible to print samples that were higher in height without obtaining deformations over time of more than 5%. Further work is needed to optimize models and parameters for more accurate prediction.

Fiber Enrichment of 3D Printed Apricot Gel Snacks with Orange By-Products

Concern about food waste has become a major global concern. The waste generated by the agri-food industry poses an environmental challenge. However, the development of 3D printing technology offers an opportunity to address this problem. By incorporating food waste into inks, it can create personalized food tailored to individual needs. The aim of this study is the valorization of orange by-products (OB_P) in 3D printed gels to obtain a final product in the form of a fiber-enriched snack. Gelatin gels were printed with different concentrations of apricot pulp (30, 50, and 70%) and OB_P was added. These gels were subjected to a freeze-drying process. The rheology of the gels before and after printing, the printing precision, and the post-treatment of the freeze-dried product, including color, shear force, and the presence of bioactive compounds, were evaluated. The addition of OB_P resulted in an increase in the elasticity (997-1242u) of the samples and improved the printability of them. However, an increase in the hardness (173-184u) was observed in the freeze-dried samples. The use of OB_P not only improves the printability of the gels but also enables obtaining fiber-enriched snacks, which could contribute to the reduction in food waste and the promotion of healthy and sustainable food.

Rheological and physicochemical properties of Spirulina platensis residues-based inks for extrusion 3D food printing

Novel food matrices (such as microalgae, plants, fungi, and microbial proteins) with high protein content and biological value, good amino acid profile, and functionality have been explored. Phycocyanin and active polysaccharides extracted from Spirulina platensis are used as food additives, treatment of colitis, as well as obesity prevention. However, most of the remaining Spirulina platensis residues are mainly used as fish feed at present. 3D food printing is one of the promising development techniques used in the food industry. The aim of this study was to develop a novel 3D printing material of Spirulina platensis residues with shear thinning characteristics, high viscosity and rapid recovery. The effects of moisture content and pretreatment method on the rheological properties of Spirulina platensis residues were clarified. Scanning electron microscopy was used to observe the microstructure and texture profile analysis was used to determine the texture characteristics of Spirulina platensis residues, rheology was used to determine the key 3D printing factors such as viscosity and modulus of Spirulina platensis residues. More importantly, the printing process could be realized under ambient conditions. The development of microalgae residue ink promoted the high-value and comprehensive utilization of microalgae, and also broadened the application of microalgae in the food field.

Screening of Chemical Composition, Antimicrobial and Antioxidant Activities in Pomegranate, Quince, and Persimmon Leaf, Peel, and Seed: Valorization of Autumn Fruits By-Products for a One Health Perspective

Antimicrobial resistance is increasing globally and is now one of the major public health problems. Therefore, there is a need to search for new antimicrobial agents. The food industry generates large amounts of by-products that are rich in bioactive compounds, such as phenolic compounds, which are known to have several health benefits, including antioxidant and antimicrobial properties. Thus, we aimed to characterize the phenolic compounds present in pomegranate, quince, and persimmon by-products, as well as their antioxidant and antimicrobial activities. Phenolic compounds were extracted from pomegranate, quince, and persimmon leaves, seeds, and peels using a mixture of ethanol/water (80/20). The polyphenol profile of the extracts was determined by high-performance liquid chromatography. The antioxidant activity of the extracts was determined by the 2,2-diphenyl-1-picrylhydrazyl (DPPH), ferric reducing antioxidant power (FRAP), and cupric reducing antioxidant capacity (CUPRAC) methods. Antimicrobial susceptibility was evaluated using the Kirby-Bauer disk diffusion method. In general, leaves showed higher concentrations of phenolics than the peel and seeds of fruits. In total, 23 phenolic compounds were identified and quantified, with sanguiin and apigenin-3-O-galactoside being present in the highest concentrations. Leaf extracts of pomegranate showed higher antioxidant activities than the other components in all methods used. In general, all extracts had a greater antimicrobial activity against Gram-positive bacteria. Persimmon leaf and seed extracts inhibited a greater number of bacteria, both Gram-positive and -negative. The lowest minimum inhibitory concentration (MIC) detected among Gram-positive and -negative bacteria was 10 mg/mL for pomegranate peel and leaf extracts against Staphylococcus aureus and S. pseudintermedius and for pomegranate leaf extract against Escherichia coli. Our results reinforce the need to value food industry by-products that could be used as food preservatives and antibiotic adjuvants against multiresistant bacteria.

Value Addition Employing Waste Bio-Materials in Environmental Remedies and Food Sector

Overall, combating food waste necessitates a multifaceted approach that includes education, infrastructure, and policy change. By working together to implement these strategies, we can help reduce the negative impacts of food waste and create a more sustainable and equitable food system. The sustained supply of nutrient-rich agrifood commodities is seriously threatened by inefficiencies caused by agricultural losses, which must be addressed. As per the statistical data given by the Food and Agriculture Organisation (FAO) of the United Nations, nearly 33.33% of the food that is produced for utilization is wasted and frittered away on a global level, which can be estimated as a loss of 1.3 billion metric tons per annum, which includes 30% cereals, 20% dairy products 35% seafood and fish, 45% fruits and vegetables, and 20% of meat. This review summarizes the various types of waste originating from various segments of the food industry, such as fruits and vegetables, dairy, marine, and brewery, also focusing on their potential for developing commercially available value-added products such as bioplastics, bio-fertilizers, food additives, antioxidants, antibiotics, biochar, organic acids, and enzymes. The paramount highlights include food waste valorization, which is a sustainable yet profitable alternative to waste management, and harnessing Machine Learning and Artificial Intelligence technology to minimize food waste. Detail of sustainability and feasibility of food waste-derived metabolic chemical compounds, along with the market outlook and recycling of food wastes, have been elucidated in this review.

Investigation into the Physicochemical and Textural Properties of an Iron-Rich 3D-Printed Hybrid Food

In the context of dietary transition, blending animal-source protein with plant-source protein offers a promising way to exploit their nutritional complementarity. This study investigates the feasibility of formulating an iron-rich hybrid food product blending plant-source and animal-source protein ingredients for iron-deficient populations. Using a commercial 3D-food printer, two different-shaped products composed mainly of pork and chicken liver and red lentils were designed. After baking at 180 °C with 70% steam, the 3D-printed products were packed under two different modified atmospheres (MAP): O₂-MAP (70% oxygen + 30% carbon dioxide) and N₂-MAP (70% nitrogen + 30% carbon dioxide) and stored at 4 °C. pH, water content, a_w, lipid oxidation, heme iron and non-heme iron contents and textural properties were measured after 0, 7, 14 and 21 days in storage. After 21 days in storage, the 3D-printed hybrid products had an iron content of around 13 mg/100 g, regardless of the product form and packaging method. However, O₂-MAP products showed significant (p < 0.05) time-course changes from day 0 to day 7, i.e., an increase in lipid oxidation, a decrease in heme iron content and an increase in product hardness, gumminess and chewiness. This work opens prospects for developing hybrid food products that upvalue animal by-products.

3D Printing Approach to Valorization of Agri-Food Processing Waste Streams

With increasing evidence of their relevance to resource recovery, waste utilization, zero waste, a circular economy, and sustainability, food-processing waste streams are being viewed as an aspect of both research and commercial interest. Accordingly, different approaches have evolved for their management and utilization. With excellent levels of customization, three-dimensional (3D) printing has found numerous applications in various sectors. The focus of this review article is to explain the state of the art, innovative interventions, and promising features of 3D printing technology for the valorization of agri-food processing waste streams. Based on recent works, this article covers two aspects: the conversion of processing waste streams into edible novel foods or inedible biodegradable materials for food packing and allied applications. However, this application domain cannot be limited to only what is already established, as there are ample prospects for several other application fields intertwining 3D food printing and waste processing. In addition, this article presents the key merits of the technology and emphasizes research needs and directions for future work on this disruptive technology, specific to food-printing applications.

Upcycled foods: A nudge toward nutrition

One of the aims of the United Nations Sustainable Development Goals (SDG) is to end hunger and ensure access by all people to safe, nutritious, and sufficient food all year round. An obvious synergy exists between the second SDG “Zero Hunger” and SDG target 12.3 which focuses on halving food waste and reducing food losses. In addition to helping improve global food security, reducing food waste provides financial and environmental benefits. Upcycling food is a technical solution for food waste reduction that retains the nutritional and financial value of food by-products. However, many of the upcycled foods produced are discretionary foods such as biscuits, crackers, and other snack food that are not part of a healthy dietary pattern, and should only be eaten sometimes in small amounts. Given the importance of ensuring a sustainable healthy diet, this paper discusses opportunities for upcycled food manufacturers to produce more nutritious products.

Acceptability Analysis of 3D-Printed Food in the Area of the Czech Republic Based on Survey

The aim of the research was to observe consumer perceptions of 3D food printing and to highlight possible applications of this production. The questionnaire survey took place in the Czech Republic and was attended by 1156 respondents. The questionnaire was divided into six sections: (1) Socio-Demographic Data; (2) 3D Common Printing Awareness; (3) 3D Food Printing Awareness; (4) 3D Food Printing, Worries and Understanding; (5) Application; (6) Investments. Although awareness of 3D food printing is increasing, a very small fraction of respondents had encountered printed food in person (1.5%; n = 17). Respondents expressed concerns about the health benefits and the reduced prices of novel foods, and they perceived printed foods as ultra-processed foods (56.0%; n = 647). Concerns have also been raised about job losses due to the introduction of new technology. On the contrary, they perceived that quality raw materials would be used to prepare printed foods (52.4%; n = 606). Most respondents believed that printed foods would be visually appealing and would find application in several food industry sectors. Most respondents believed that 3D food printing is the future of the food sector (83.8%; n = 969). The gained results can be helpful for 3D food printer producers, as well as for future experiments dealing with 3D food printing issues.

Consumer acceptance of new food trends resulting from the fourth industrial revolution technologies: A narrative review of literature and future perspectives

The growing consumer awareness of climate change and the resulting food sustainability issues have led to an increasing adoption of several emerging food trends. Some of these trends have been strengthened by the emergence of the fourth industrial revolution (or Industry 4.0), and its innovations and technologies that have fundamentally reshaped and transformed current strategies and prospects for food production and consumption patterns. In this review a general overview of the industrial revolutions through a food perspective will be provided. Then, the current knowledge base regarding consumer acceptance of eight traditional animal-proteins alternatives (e.g., plant-based foods and insects) and more recent trends (e.g., cell-cultured meat and 3D-printed foods) will be updated. A special focus will be given to the impact of digital technologies and other food Industry 4.0 innovations on the shift toward greener, healthier, and more sustainable diets. Emerging food trends have promising potential to promote nutritious and sustainable alternatives to animal-based products. This literature narrative review showed that plant-based foods are the largest portion of alternative proteins but intensive research is being done with other sources (notably the insects and cell-cultured animal products). Recent technological advances are likely to have significant roles in enhancing sensory and nutritional properties, improving consumer perception of these emerging foods. Thus, consumer acceptance and consumption of new foods are predicted to continue growing, although more effort should be made to make these food products more convenient, nutritious, and affordable, and to market them to consumers positively emphasizing their safety and benefits.

The fourth industrial revolution in the food industry-part II: Emerging food trends

The food industry has recently been under unprecedented pressure due to major global challenges, such as climate change, exponential increase in world population and urbanization, and the worldwide spread of new diseases and pandemics, such as the COVID-19. The fourth industrial revolution (Industry 4.0) has been gaining momentum since 2015 and has revolutionized the way in which food is produced, transported, stored, perceived, and consumed worldwide, leading to the emergence of new food trends. After reviewing Industry 4.0 technologies (e.g. artificial intelligence, smart sensors, robotics, blockchain, and the Internet of Things) in Part I of this work (Hassoun, Aït-Kaddour, et al. 2022. The fourth industrial revolution in the food industry-Part I: Industry 4.0 technologies. Critical Reviews in Food Science and Nutrition, 1-17.), this complimentary review will focus on emerging food trends (such as fortified and functional foods, additive manufacturing technologies, cultured meat, precision fermentation, and personalized food) and their connection with Industry 4.0 innovations. Implementation of new food trends has been associated with recent advances in Industry 4.0 technologies, enabling a range of new possibilities. The results show several positive food trends that reflect increased awareness of food chain actors of the food-related health and environmental impacts of food systems. Emergence of other food trends and higher consumer interest and engagement in the transition toward sustainable food development and innovative green strategies are expected in the future.

Bioprocessing of Wheat and Amaranth Bran for the Reduction of Fructan Levels and Application in 3D-Printed Snacks

Bran can enrich snacks with dietary fibre but contains fructans that trigger symptoms in people with irritable bowel syndrome (IBS). This study aimed to investigate the bioprocessing of wheat and amaranth bran for degrading fructans and its application (at 20% flour-based) in 3D-printed snacks. Bran was bioprocessed with Saccharomyces cerevisiae alone or combined with inulinase, Kluyveromyces marxianus, Limosilactobacillus fermentum, or commercial starter LV1 for 24 h. Fructans, fructose, glucose, and mannitol in the bran were analysed enzymatically. Dough rheology, snack printing precision, shrinkage in baking, texture, colour, and sensory attributes were determined. The fructan content of wheat bran was 2.64% dry weight, and in amaranth bran, it was 0.96% dry weight. Bioprocessing reduced fructan content (up to 93%) depending on the bran type and bioprocessing agent, while fructose and mannitol remained below the cut-off value for IBS patients. Bran bioprocessing increased the complex viscosity and yield stress of dough (by up to 43 and 183%, respectively) in addition to printing precision (by up to 13%), while it lessened shrinkage in baking (by 20–69%) and the hardness of the snacks (by 20%). The intensity of snack sensory attributes depended on the bran type and bioprocessing agent, but the liking (“neither like nor dislike”) was similar between samples. In conclusion, snacks can be enriched with fibre while remaining low in fructans by applying bioprocessed wheat or amaranth bran and 3D printing.

Application of 3D Printing in the Design of Functional Gluten-Free Dough

The design of functional foods through 3D printing is proposed here as one of the most appropriate technologies to provide closer food personalization for the population. However, it is essential to study the properties of the biomaterials intended to be printed. This work will evaluate the incorporation of rosehip as a functional ingredient in a gluten-free dough. Three types of dough (control, rosehip, and encapsulated rosehip) were printed in a rectangular figure of dimensions 7 cm long, 2 cm wide, and 1, 2, and 3 cm high. Changes in printed figures before and after baking were evaluated by image analysis. Physicochemical properties, total phenols (TP), antioxidant capacity (AC), and total carotenoids (TC) were determined both in the pre-printed doughs and in the printed and baked samples. The bread enriched with rosehips presented more orange colors in dough and crumbs. They were also more acidic than control, probably due to the ascorbic acid content of rosehip. The addition of rosehip generally makes the product more resistant to breakage, which could be due to the fiber content of the rosehip. It was observed that the incorporation of rosehip notably improved the functional properties of the bread.

Effect of Labelling and Information on Consumer Perception of Foods Presented as 3D Printed

Labelling and information have been shown to increase acceptance of novel food technologies. The novel technology of 3 Dimensional Printing (3DP) of foods is not well known among consumers. The study aim was to investigate the effect of the 3DP label and benefits information on consumer acceptance and perception of plausible 3DP foods. Commercially available foods, such as milk chocolate swirls, gummy candy carrots, and baked potato Smiles^®, represented 3DP benefits, and each was evaluated in a sensory panel. Participants rated acceptance and perceived quality after each of three product presentations; first labeled “conventional”, then labeled “3D printed”, and again labeled 3D printed after information presentation. Participants indicated product preference after the third presentation. Food Technology Neophobia (FTN), attitude, and previous 3DP knowledge were queried. Quality rating of chocolate swirls and gummy candy carrots increased when labeled as 3DP versus conventional; information did not further increase quality ratings. Participants preferred 3DP chocolate swirls and gummy candy carrots to conventional in the final evaluation. Label and information did not change flavor, texture, or overall acceptance ratings for any product. Attitude towards 3DP of foods increased with lower FTN. Future studies could tailor information to consumer interests and knowledge gaps that highlight relevant benefits of 3DP.