Sustainable and cost-effective production process for the upcycling of olive, grape and nut by-products into 4 natural and healthy ingredients for nutraceutical and cosmetic applications

Project Information

UP4HEALTH

Grant agreement ID: 888003

DOI

10.3030/888003

Project closed

EC signature date 28 April 2020

Start date 1 June 2020

End date 31 December 2024

Funded under

• SOCIETAL CHALLENGES - Food security, sustainable agriculture and forestry, marine, maritime and inland water research, and the bioeconomy

Total cost

€ 5 542 448,75

EU contribution

€ 4 009 921,52

Coordinated by

ISANATUR SPAIN SL
Spain

Periodic Reporting for period 3 - UP4HEALTH (Sustainable and cost-effective production process for the upcycling of olive, grape and nut by-products into 4 natural and healthy ingredients for nutraceutical and cosmetic applications)

Reporting period: 2023-06-01 to 2024-12-31

Summary of the context and overall objectives of the project

The UP4HEALTH project addresses the challenge of demonstrating, at a pre-industrial scale, an integrated biorefinery capable of recovering valuable biomolecules from food processing by-products. These recovered compounds are converted into natural, healthy, and sustainable high-value ingredients targeting the nutraceutical and cosmetic sectors. The project responds to the increasing demand for functional, natural products by consumers and bio-based, sustainable formulations by industry, aligning with the growing market trend toward environmental responsibility and healthier options.
In the context of limited resources and the pressing issue of food waste, millions of tons of by-products are discarded annually by the food processing industry, leading to management costs amounting to €143 billion across the European Union. Among these, olive and grape by-products alone account for over 9.3 million tons of residual biomass, rich in bioactive compounds. These materials represent a largely untapped opportunity for valorisation, creating significant market potential for the UP4HEALTH project.
Despite the promise of existing technologies for recovering high-value ingredients from food by-products, market availability of such products remains limited due to several barriers. The primary challenge lies in validating a scalable and affordable business model to upgrade by-products with diverse compositions while addressing bottlenecks, including logistical constraints and investment costs.
UP4HEALTH has developed an upcycling process based on a zero-waste approach, focusing on three locally available Mediterranean feedstocks (olive pomace, grape pomace, and olive pits). This process enables the production of four sustainable and organic ingredients:
1. Natural fruit water rich in polyphenols
2. Dietary fibre with high polyphenol content
3. Natural fruit oily extracts
4. Prebiotic xylooligosaccharides (XOS)
These ingredients are designed to be integrated into functional foods, nutraceutical supplements, and cosmetic formulations, addressing the needs of diverse consumer groups, such as the elderly, health-conscious individuals, and athletes.
The project aims to deliver bio-based specialty ingredients with both biofunctional and technological properties for high-end markets. By valorising plant-based by-products from the food industry, UP4HEALTH supports the development of healthier and more sustainable products, contributing to a circular economy while adding value to underutilised food waste.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

A comprehensive strategy was developed to ensure the year-round supply of raw materials. This strategy included establishing agreements with ISA's usual supplier of organic olives and selecting those with the highest polyphenol content. Nuts were sourced from a major Spanish supplier. However, obtaining authorization and collaboration with a management body for grape by-products proved challenging due to specific regulatory requirements.
During the implementation of the UP4HEALTH project, ISA had access to over 100 tons per year of olive pomace, 100 tons per year of grape pomace, and 20 tons per year of nut by-products. These raw materials were used for process optimization and functional ingredient production to meet end-user needs. Nutritional and functional analyses revealed a high antioxidant potential, attributed to significant levels of tyrosol, hydroxytyrosol, and oleocanthal polyphenols. These evaluations played a crucial role in selecting optimal functional ingredients such as olive pulp powder, olive pulp extract, and XOS derived from olive crushed pits, which were encapsulated and incorporated into the final products.
To ensure safety, toxicological assessments of olive by-products used as raw materials were conducted by IPB-CIMO. The functional ingredients were successfully integrated into diverse food matrices, including meat, oil, yogurt, snack bars, biscuits, smooth foods, and drinkable gels. Properties such as solubility, emulsification, viscosity, flavor, and odor were evaluated to validate stability and organoleptic characteristics.
The UP4HEALTH project was presented to key stakeholders, including the Irish Government Education Committee and the Northern Ireland Department of Agriculture, Environment and Rural Development.
Additionally, a review article titled “New Approach Methodologies (NAMs) for safety testing of complex food matrices: A review of status, considerations, and regulatory adoption” was submitted and accepted, contributing to the dissemination of the project's scientific advancements.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The UP4HEALTH project represents a significant advancement in bridging gaps between multiple sectors, fostering new value chains across the Agrofood, Specialty Ingredient, Food Supplement, and Cosmetic industries. This collaboration enables the Agrofood sector to provide raw materials, which are then processed into high-value functional ingredients and products tailored for high-end markets, including functional foods (ISA, AMX, BZN, AIN, IK), dietary supplements (ZADE), and cosmetics (ZADE). As a result, UP4HEALTH facilitates the creation of four new cross-sector interconnections within the bio-based economy, driving innovation and sustainability.
The project establishes the foundation for twelve sustainable and locally rooted bio-based value chains, including seven in the olive by-product line and five in the grape by-product line. These value chains leverage the advanced purification levels achieved in downstream processing to deliver diverse functional ingredients for multiple applications. These include eight products for the nutraceutical sector (functional food such as meat, snack bars, smooth foods, drinkable gels, olive oil, natural beverages, yogurt, and dietary supplements) and one product for the cosmetics sector, all meeting current market demands.
By prioritizing a circular economy approach, UP4HEALTH transforms unavoidable residues from the olive oil and wine sectors, which account for 30% of total production losses, into valuable resources for bioactive compound production. This innovation supports the market introduction of healthier and more sustainable nutraceutical and cosmetic products while addressing global challenges such as waste reduction and resource efficiency.
From a socio-economic perspective, UP4HEALTH delivers measurable impacts:
• Wineries and olive mills will enhance their competitiveness through cost savings in logistics and waste treatment, as by-products are repurposed into valuable raw materials.
• The versatile and efficient processing technologies developed by UP4HEALTH enable upcycling companies to manage a wide variety of raw materials, adapting to local agricultural practices and seasonal availability.
• Local biorefineries will strengthen regional economies by utilizing locally sourced biomass, creating dynamic and competitive economic hubs across Europe. This regional approach ensures a durable supply of biomass, contributing to sustainable growth at all European levels.
In a broader societal context, UP4HEALTH supports the transition toward more productive, resource-efficient, resilient, and less wasteful food systems, while enhancing ecosystem services. By transforming waste into valuable resources and fostering regional development, the project promotes sustainable practices and advances the bioeconomy in alignment with European Green Deal objectives.