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

Brewer's spent grain: Unveiling innovative applications in the food and packaging industry

Brewer's spent grain, a byproduct of beer brewing, is often discarded as waste, leading to environmental concerns. However, the growing interest in sustainability and the circular bioeconomy has prompted research into its use in food and packaging industries. The objective of this review paper is to explore recent advancements in food applications, focusing on various aspects such as processing innovations, food properties, sensory acceptability, and safety considerations. The paper highlights the role of functional bioactive compounds of BSG in food and evaluates their pharmacological activities. Additionally, it investigates the development of sustainable food-packaging materials derived from BSG, discussing their applications, challenges, and potential for eco-friendly packaging solutions. The inclusion of BSG significantly impacts the food matrix during processing, which can negatively affect the physical, rheological, and textural properties and sensory acceptability. To enhance BSGs desirability as a food ingredient, various approaches have been employed, including drying, fermentation, extrusion, and modifications using enzyme treatments, dough enhancers, and texture modifiers. BSG-derived biodegradable films and coatings demonstrate a promising potential for food-packaging applications, offering desirable properties such as sustainability and effective performance. Key challenges for adopting BSG-based solutions in food and packaging industries include limited consumer awareness, commercialization strategies, and the need for life cycle assessment and life cycle costing for successful integration and widespread adoption.

Application of a multivariate approach to the study of chemometric and sensory profiles of cookies fortified with brewers' spent grain

This work was aimed to investigate the effects of three factors on cookie quality: brewers' spent grain (BSG) composition [65% malted barley and 35% of unmalted durum (DA) or soft (RI), or emmer (EM) wheats]; geographical origin of the cereals used in brewing (Daunia or Salento); and percentages of BSG in cookie formulation (30 or 40%). A control made of 100% Manitoba flour was produced. Statistical analyses were performed to evaluate the effects of those factors (Analysis of Variance), the possibility to distinguish the various types of cookies (Principal Component Analysis), and the relationships among variables (Pearson Correlation Analysis).The single and interactive effects of the three factors were significant for almost all variables. Cookies with 40% EM spent grains showed the highest ash, dietary fibre, and total phenolic contents but cookies with 30% DA or RI spent grains received the highest overall quality scores due to the higher intensity of their fresh baked flavour and their lower hardness and fibrousness. Based on the nutritional and sensory characteristics, cookies fortified with RI and DA were the best to consume. Although few physicochemical differences can be attributed to geographical origin, a slightly higher overall sensory score was assigned to those produced with Salento cereals. Principal Component Analysis showed a clear separation between the control made of 100% Manitoba flour and the group of fortified cookies. Among the latter, the cookies produced with RI and DA spent grains were indistinguishable from each other due to their similar quality characteristics.

Supplementary Information

The online version contains supplementary material available at 10.1007/s13197-024-06064-3.

Advances in the valorization of brewing by-products

Beer is the most consumed alcoholic beverage worldwide, and its production involves the generation of a huge volume of by-products (i.e., spent grain, spent hop, and spent yeast). This review aims to highlight the main properties of these by-products as a valuable source of biomolecules (i.e., proteins, cellulose, hemicellulose, lignin, phenolic compounds, and lipids) and the biorefining methods used in the last decade for their valorization. The pros and cons of the technologies employed will be shown, highlighting which of them could be more ready for the transition to an industrial scale, and which applications (e.g., food and feed, bioenergy, biochemicals, and biomaterials) are the most feasible.

Assessing the Potential of Brewer's Spent Grain to Enhance Cookie Physicochemical and Nutritional Profiles

Brewers' spent grain (BSG), the major by-product of the brewery industry, has high nutritional value, making it suitable for upcycling into products such as healthy, and sustainable cookies. Nonetheless, the incorporation of BSG in cookies can impact their quality, given the increased fiber and protein content. This work explored the effect of replacing wheat flour with BSG at 50% and 75% in cookie formulations, focusing on physical, chemical, and sensory properties. The dietary fiber, lipid, and protein content of cookies improved considerably with the highest incorporation of BSG, increasing from 6.37% to 15.54%, 9.95% to 13.06%, and 9.59% to 12.29%, respectively. Conversely, moisture and water activity decreased from 11.03% to 3.37% and 0.742 to 0.506, respectively, forecasting a lower risk of microbial contamination and increased shelf-life. The incorporation of BSG in cookies resulted in decreased brightness and increased hardness, from 40 N to 97 N. Moreover, colorimetric shifts among the control cookies and the two BSG-rich formulations could be easily identified by an untrained observer. Sensory evaluation showed that cookies with 50% BSG retained acceptable sensory characteristics, suggesting potential for further development. Overall, BSG enhances the nutritional profile of cookies with no excessive detrimental impact on sensory features.

Non-Conventional Brewers' Spent Grains, an Alternative Raw Material in Bread-Making

The main objective of this experiment was to investigate the technological potential of upcycling unsparged non-conventional brewers' spent grains (BSGs) in bread-making and assess the comparative quality of bread enriched with non-fermented and lactic acid-fermented BSGs obtained from mashes brewed with starch adjuncts of buckwheat and oats. After the runoff of the first wort, unsparged non-conventional BSGs with approximately 75% moisture, acidic pH, and yield in the soluble extract above 56.6% (w/w d.m.) were used in substituting wheat flour with 5 and 15% (w/w d.m.) in bread-making recipes. The highest loaf volume value (318.68 cm3/100 g) was observed for 5% fermented buckwheat-BSG addition. Except for the samples with 5% fermented BSGs, specific volumes decreased. Crumb moisture was reduced by up to 22% for all samples, with this parameter related to bread weight. Bread porosity, elasticity, acidity, and overall sensory acceptability were better for fermented than non-fermented BSGs. The results proved that non-conventional BSGs with buckwheat and oats addition have the potential to be valorized in new bread assortments, and lactic acid fermentation applied to the BSGs is beneficial, even for overall sensory acceptability and quality of baked end-products. Technological, buckwheat-BSG was more convenient than oats-BSG. Further research continues to optimize and upscale Technology Readiness Levels.

Effect of Physical Separation with Ultrasound Application on Brewers' Spent Grain to Obtain Powders for Potential Application in Foodstuffs

Brewers' spent grain (BSG) is the primary by-product of beer production, and its potential use in food products is largely dependent on its processing, given its moisture content of up to 80%. This study aimed to evaluate the effects of physical separation with ultrasound application on the color, total phenolic content (TPC), antioxidant activity, proximate composition, total dietary fibers, and particle size distribution of BSG powders. Wet BSG (W) was subjected to two processes: one without ultrasound (A) and one with ultrasound (B). Both processes included pressing, convective air-drying, sieving, fraction separation (A1 and B1 as coarse with particles ≥ 2.36 mm; A2 and B2 as fine with particles < 2.36 mm), and milling. The total color difference compared to W increased through both processes, ranging from 1.1 (B1 vs. A1) to 5.7 (B1 vs. A2). There was no significant difference in TPC, but process B powders, particularly B2, showed lower antioxidant activity against ABTS•+, likely due to the release of antioxidant compounds into the liquid fraction during pressing after ultrasound treatment. Nonetheless, process B powders exhibited a higher content of soluble dietary fibers. In conclusion, ultrasound application shows potential for further extraction of soluble fibers. However, process A might be more practical for industrial and craft brewers. Further studies on the use of the resulting BSG powders as food ingredients are recommended.

Green Methods to Recover Bioactive Compounds from Food Industry Waste: A Sustainable Practice from the Perspective of the Circular Economy

The worrying and constant increase in the quantities of food and beverage industry by-products and wastes is one of the main factors contributing to global environmental pollution. Since this is a direct consequence of continuous population growth, it is imperative to reduce waste production and keep it under control. Re-purposing agro-industrial wastes, giving them new life and new directions of use, is a good first step in this direction, and, in global food production, vegetables and fruits account for a significant percentage. In this paper, brewery waste, cocoa bean shells, banana and citrus peels and pineapple wastes are examined. These are sources of bioactive molecules such as polyphenols, whose regular intake in the human diet is related to the prevention of various diseases linked to oxidative stress. In order to recover such bioactive compounds using more sustainable methods than conventional extraction, innovative solutions have been evaluated in the past decades. Of particular interest is the use of deep eutectic solvents (DESs) and compressed solvents, associated with green techniques such as microwave-assisted extraction (MAE), ultrasonic-assisted extraction (UAE), pressurized liquid extraction (PLE) and pulsed-electric-field-assisted extraction (PEF). These novel techniques are gaining importance because, in most cases, they allow for optimizing the extraction yield, quality, costs and time.

Study on the Effect of Microwaved Brewer's Spent Grains on the Quality and Flavor Characteristics of Bread

To enable a wider utilization of co-products from beer processing and minimize the negative effect of added grain on bread quality, flavor, and other attributes, brewer's spent grains (BSG) are processed through microwave pretreatment, and then the microwave-treated BSG (MW-BSG) is added to bread. So far, there has been no investigation on the effect of microwave-pretreated BSG on bread quality and flavor. In this study, we examined the effects of diverse microwave treatment variables on the physicochemical structure of BSG and explored the consequences of MW-BSG on the quality and flavor of bread. The results showed that soluble dietary fiber and water-soluble protein levels in MW-BSG increased significantly (144.88% and 23.35%) at a 540 W microwave power, 3 min processing time, and 1:5 material-liquid ratio of BSG to water. The proper addition of MW-BSG positively affected the bread texture properties and color, but excessive amounts led to an irregular size and distribution of the bread crumbs. The result of electronic nose and HS-SPME-GC-MS analyses showed that the addition of MW-BSG modified the odor profile of the bread. A sensory evaluation showed mean scores ranging from 6.81 to 4.41 for bread containing 0-10% MW-BSG. Consumers found a maximum level of 6% MW-BSG acceptable. This study endeavors to decrease environmental contamination caused by brewing waste by broadening the methods by which beer co-products can be utilized through an innovative approach.

Nutritional Components of Wheat Based Food: Composition, Properties, and Uses

Wheats (bread and durum wheats) and their main end-use products (particularly bread and pasta) have an important role in the Mediterranean diet as they substantially contribute to nutrient intake [...].

The Rheology and Textural Properties of Bakery Products Upcycling Brewers' Spent Grain

This study aimed to evaluate the rheological properties of doughs with 50% brewers' spent grain (BSG) derived from a rye-based (RBSG) and barley-based (BBSG) beer added, and the textural profile of the related baked products. Simple model systems using BSG flour mixed with water were studied. Two bakery products, focaccia and cookies, were made as food systems using BSG in a 1:1 ratio with wheat flour (WF). Their rheological properties and texture after baking were characterized. BSG-added dough exhibited viscoelastic properties with a solid gel-like behavior. The addition of BSG increased G' > G″ and decreased the dough flexibility. BSG addition in baked RBSG focaccia increased the hardness, gumminess, and chewiness by 10%, 9%, and 12%, respectively. BBSG cookies had a 20% increase in fracturability. A positive correlation was found between the rheological metrics of the dough and the textural parameters of BBSG-added cookies. PCA analysis revealed that complex viscosity, G', G″, and cohesiveness separated BBSG focaccia from RBSG focaccia and the control. Therefore, the rheological properties of BSG dough will have industrial relevance for 3D-printed customized food products with fiber. Adding RBSG and BBSG to selected foods will increase the up-cycling potential by combining techno-functional properties.

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.