GourmetPro, in collaboration with The Serial Upcyclers’ Club, was thrilled to host a thought-provoking webinar on upcycling in the food and beverage sector. Moderated by Christine Couvelier, renowned global culinary trendologist, advocate for sustainability, and GourmetPro expert, the session featured two inspiring panelists.

• Elizabeth Yorke, founder of Saving Grains, is a chef and food researcher passionate about creating nutritious, flavorful products from brewers’ spent grain. 

• Aditi Jhala, founder of The Misfits, is on a mission to transform surplus and imperfect produce into healthy, delicious snacks and spreads.

Together, they shared insights, solutions, and a vision for a sustainable future through upcycling.

Food waste is a global crisis

The statistics on food waste are staggering.

Around 13% of all food produced globally is lost before it reaches consumers, and nearly a fifth is wasted post-purchase. Shockingly, this amounts to 1 billion edible meals wasted daily across the world, even as 735 million people go hungry.

This waste has significant consequences, accounting for 8-10% of global greenhouse gas emissions, roughly 4.4 billion tons of CO2 emissions annually. The financial toll is immense, with US$1 trillion lost each year due to wasted inputs like land, water, and labor. Despite the urgent need for solutions, investment to combat food waste is minimal.

Upcycling offers a viable path forward. By repurposing food byproducts, this innovative approach can address waste while fostering sustainability, nutrition, and economic growth.

What exactly is upcycling in food?

Upcycling transforms byproducts or surplus food into valuable products. This concept goes beyond recycling, promoting tasteful innovation while reducing environmental impact. Unlike waste, upcycled ingredients are safe, nutritious, and full of potential, as emphasized by Elizabeth and Aditi.

Elizabeth, whose company works with brewers’ spent grain, prefers terms like "byproducts" or "ingredients" over "waste." She noted, “Waste carries a negative connotation, making it seem unsuitable for consumption." Similarly, Aditi clarified misconceptions about upcycled food: “Imperfect produce is often thought to be low-quality, but it’s just as nutritious as its perfect counterparts.”

The potential of upcycled foods

The upcycled food market is growing rapidly, projected to reach $93.2 billion by 2031, a 64% increase compared to 2023. 

While North America leads the way in food upcycling at the moment, regions like Asia are brimming with untapped opportunities. Some of the key drivers for this interest in upcycling include the need to combat food insecurity as well as the growing demand for sustainable practices, but the push from innovative entrepreneurs like Elizabeth and Aditi cannot be discounted.

Ingredients derived from upcycled byproducts, such as fibers, flavors, and colors, are also gaining traction. This growth is supported by certifications like Upcycled Certified, which guarantees transparency and trust. 

Saving Grains: Community-based circular economy

Elizabeth’s company, Saving Grains, embodies the essence of upcycling by transforming brewers’ spent grain (BSG) into nutritious and versatile products. BSG is a byproduct of beer production and is abundant yet underutilized in cities like Bengaluru, which boasts around 60 microbreweries. Each brewery produces approximately 200 kilograms of spent grain daily, which often ends up in landfills or is used as animal feed.

Saving Grains intercepts this byproduct and dries it to create flour. This nutrient-rich flour, packed with 22% protein and 46% dietary fiber, serves as the base for innovative products like granola, crackers, ladoos, and chapatis. Elizabeth explained how these products enrich diets while reducing waste: “Our chapatis are not just familiar daily bread; they’re packed with higher fiber and protein, enhancing nutrition while preserving tradition.”

Beyond food production, Saving Grains also fosters a community-based circular economy. By engaging microbreweries, chefs, and researchers, the company ensures the grain is processed responsibly and reintroduced into the food system sustainably. Elizabeth emphasized her commitment to collaboration: “We work with researchers and partners to explore additional uses, from fermentation to creating miso and soy sauce, aiming for a zero-waste process.”

The Misfits: Reviving imperfect produce

Aditi’s The Misfits is another stellar example of how upcycling can transform surplus and imperfect produce into high-quality, flavorful products. The Misfits procures vegetables and fruits that would otherwise be discarded due to cosmetic blemishes or surplus production. These ingredients, often rejected by markets and consumers, are perfectly edible and nutritious.

Misfits specializes in creating plant-based, clean-label products, including spreads, dips, and snacks. For example, their carrot top pesto, made from upcycled carrot greens, contains 13 grams of protein per 100 grams. Another standout product is their cocoa spread, which combines pumpkin and chickpeas to deliver 11 grams of protein and 8 grams of fiber per serving.

Since launching in May 2024, Misfits has already made a measurable impact. The company has:

• Rescued 90 kilograms of vegetables.

• Saved 12,000 liters of water that would have gone into growing new produce.

• Prevented the emission of 50 kilograms of greenhouse gases.

Aditi spoke about the philosophy driving The Misfits: “This is about valuing what we already have. Food is precious, and by rescuing and upcycling, we not only fight waste but also provide additional income to farmers and nutritious options to consumers.”

Challenges linked to upcycling

Upcycling in the food industry comes with its fair share of hurdles, as highlighted by both Elizabeth and Aditi during the webinar. These challenges span consumer education, logistics, and operational complexities.

Consumer perception

One of the biggest challenges is overcoming the negative perceptions surrounding upcycled food. Aditi noted that many consumers equate upcycled ingredients with “garbage”, assuming imperfect or surplus produce lacks nutrition or quality. Elizabeth emphasized the need to avoid the term "waste", as it implies something unfit for consumption. Instead, terms like "byproducts" or "ingredients" can help change the narrative.

Supply chain inconsistencies

The unpredictable availability of raw materials poses another significant challenge. Aditi explained how climate change and shifting weather patterns can disrupt the supply of produce like onions and carrots, making it hard to maintain steady production. Inconsistent supply chains are a big issue, and delays in crop availability can drive up costs and limit production capacity.

Manual processing and lack of machinery

Both entrepreneurs highlighted issues with the labor-intensive nature of processing upcycled ingredients. Aditi shared how sorting and peeling imperfect produce is challenging due to a lack of specialized machinery. For example, her team often manually processes 20-50 kilograms of onions per day, significantly increasing labor costs.

Elizabeth, meanwhile, pointed to the lack of small-scale processing equipment for BSG. Traditional systems are designed for large-scale breweries, leaving microbreweries without affordable options for drying or preserving grain. “We’ve had to rely on DIY solutions and look into alternative methods like fermentation,” she said.

Food safety concerns

Food safety is another concern, especially with highly perishable ingredients like BSG. Elizabeth explained how working with breweries to ensure timely collection and proper handling has been a learning curve. “There’s a need for innovation in preservation to ensure the safety and quality of upcycled products,” she noted.

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Opportunities in upcycling

Despite these challenges, the speakers underscored the immense opportunities within the upcycling industry. With innovation, collaboration, and consumer awareness, upcycling has the potential to transform food systems.

Consumer education and awareness

Elizabeth and Aditi both see education as a powerful tool for changing perceptions about upcycled foods. By offering products that are both nutritious and flavorful, they can shift mindsets. Aditi explained, “When consumers taste our carrot top pesto or cocoa spread, they realize how delicious upcycled food can be.”

Elizabeth highlighted the role of storytelling in creating a connection with consumers. She emphasized that people needed to understand the journey of the ingredients – from byproduct to a delicious, nutritious product.

Innovation in processes and products

Innovation is at the heart of upcycling. Elizabeth is exploring fermentation techniques and low-energy preservation methods for spent grain, aiming to make the process more sustainable. Aditi is experimenting with adding superfoods like moringa and ashwagandha to her spreads and dips to boost nutrition.

Both companies also see potential in expanding their product lines. Aditi aspires to rescue 2 tons of produce daily in the next five years, while Elizabeth aims to work with at least half of Bengaluru’s microbreweries to scale her operations.

Environmental and economic impact

Upcycling offers significant environmental and economic benefits. By repurposing ingredients that would otherwise go to waste, companies like Saving Grains and The Misfits can help reduce greenhouse gas emissions, conserve water, and prevent deforestation.

Aditi shared how Misfits has already seen savings in terms of reduced water use and GHG emissions since launching in May 2024. Similarly, Elizabeth sees brewers’ spent grain as a local, sustainable ingredient that eliminates the need for additional agricultural inputs.

Expanding market potential

The upcycled food market is expected to grow significantly, creating opportunities for businesses to cater to conscious consumers. Elizabeth noted that partnerships with breweries could introduce new revenue streams by helping them repurpose their byproducts. Meanwhile, certifications like Upcycled Certified help build trust and awareness, encouraging more companies to enter the space.

A collaborative vision for the future

Both speakers were emphatic about the importance of collaboration in scaling upcycling operations.

Saving Grains works with microbreweries, researchers, and chefs to repurpose BSG into new products. The company also engages local communities through workshops and partnerships with NGOs. 

Aditi echoed this sentiment, noting that collaboration among upcycling brands could amplify impact. “As more companies enter the space, we’ll create a stronger network to promote upcycled food and reduce waste collectively,” she said. The Misfits aims to rescue 2 tons of produce daily within five years while expanding the product line to reduce food insecurity.

Perhaps Christine summed it up best: “The future of food requires breaking traditional paradigms, innovating sustainably, and building a global community committed to reducing waste.”

This engaging webinar was a reminder that waste is simply imagination that hasn’t been utilized. The opportunities in upcycling are vast, spanning sustainability, nutrition, and economic benefits. As Elizabeth, Aditi, and Christine demonstrated, it’s time to rethink food systems and invest in a future where food waste is a thing of the past.

Let’s celebrate and support these innovations to ensure a healthier planet and plate for generations to come.

For all this and more, listen to the speakers firsthand:

Q&A 

There were also a few questions we were unable to get to. Here are the answers, with many thanks to Aditi and Elizabeth!

How would you make upcycling more scalable and make the cost of production reasonable finally? Specially the logistics costs and inventory costs ramp up the product cost, which comes with niche technologies?

Sayantan Paul

ELIZABETH: Upcycling food can become more scalable and cost-effective by applying the same principles used in traditional food manufacturing. 

• Centralized processing hubs near raw material sources, like breweries or food processing units, can reduce logistics costs significantly. 

• Collaborating with other upcyclers or food businesses to share infrastructure and facilities can help lower overheads. 

• Introducing automation and technology to improve production efficiency and yield can further reduce labor and material costs. 

• Bulk procurement of ingredients and packaging, along with strategic partnerships, can minimize input expenses. 

As consumer awareness and demand for upcycled products grow, scaling production will naturally distribute fixed costs over larger volumes, reducing per-unit costs. By embedding upcycled practices into existing food systems and integrating them into mainstream manufacturing and distribution channels, we can make upcycling both scalable and financially viable.

ADITI: I agree with Elizabeth’s answer and just want to add that raw material sources can also include farms from where produce is procured.

Can we reflect on how national policies enable the growth of upcycled food markets globally? In India, we are still researching this.

Harini Santhanam

ELIZABETH: National policies play a pivotal role in enabling the growth of upcycled food markets globally. In countries where governments have prioritized food waste reduction and circular economy practices, frameworks such as tax incentives, waste management regulations, and food safety guidelines for upcycled products have significantly accelerated the market's growth. For instance, clear labeling policies and certifications for upcycled foods in the US and Europe have boosted consumer confidence and created new opportunities for businesses.

In India, however, the upcycled food sector is still in its nascent stages, with research and advocacy playing a critical role in shaping the future. Policies focusing on food waste management, support for innovative startups, and awareness campaigns about upcycled foods could catalyze the sector’s growth.

How do you measure the CO2 reduction and water saving based on the amount of food waste diverted?

Saravana 

ELIZABETH: At Saving Grains, we adopt the methodology established by the Food & Agriculture Organization (FAO) in 2013 to estimate greenhouse gas emissions linked to food waste. According to the FAO, 1 kg of food waste generates approximately 2.5 kg of CO2 equivalent emissions. Inspired by tools like Too Good To Go, which quantify emissions saved per meal, we use this framework to measure our impact.

For every kilogram of brewers' spent grain upcycled through our products, we help divert potential food waste and reduce CO2 emissions by 2.5 kg. This calculation reinforces the environmental significance of our upcycling efforts while aligning with global sustainability metrics.

ADITI: The Misfits follows REFED Impact calculator, which is a useful tool for understanding the environmental and social benefits of food waste reduction strategies. It helps quantify the potential impact of food surplus management actions, such as greenhouse gas emissions reduction, water savings, and the recovery of meals for donation. 

The calculator covers various food waste destinations, including donation, composting, anaerobic digestion, and landfill diversion, and provides metrics tailored to different food types and sectors.

***

I would like to know how I can upcycle within my household, so as to reduce the waste from my home.

Uma 

ELIZABETH: Fermentation can be such an amazing tool to preserve anything and everything at home. One of my favorite people to look to for guidance is Kōbo Fermentary. They do an AMA every Saturday via their Instagram and answer all your fermentation questions.

ADITI: Upcycling food at home is a great way to reduce waste, save money, and get creative in the kitchen. 

• Use scraps for broths and stocks

  • Collect vegetable peels, herb stems, and bones (if not vegetarian) to make flavorful broths.

  • Freeze scraps in a bag until you have enough to boil them for stock.

• Transform overripe produce

  • Bananas: Make banana bread, pancakes, or freeze for smoothies.

  • Tomatoes: Turn into sauces or soups.

  • Berries: Blend into jams or mix into baked goods.

• Ferment foods

  • Use cabbage for sauerkraut or kimchi.

  • Ferment fruits or vegetables into condiments.

• Use citrus peels

  • Zest for flavoring dishes or desserts.

  • Dry peels to create natural cleaners or potpourri.

Every month, we publish 1 recipe to use leftovers, ensure zero-waste, or upcycle food at home. Please visit www.mymisfits.in or follow @bethemisfits for these recipes.

How have you approached packaging innovation and waste management in your work? I’ve heard about new materials being made from food waste – any thoughts on that?

Clara Mendoza

ELIZABETH: While we upcycle brewers' spent grain into high-protein, fiber-rich food products, we’re also exploring ways to extend its utility beyond consumption. One of our exciting initiatives is researching packaging solutions made from spent grain. Not all by-products need to become food products, there is tremendous space to explore packaging innovation. 

ADITI: Currently at The Misfits, we utilize the imperfect or surplus produce to make delicious, healthy, and nutritious dips, spreads, and snacks. Materials like corn husks, fruit peels, or sugarcane bagasse can be converted into bioplastics. However, it is too soon for us to explore these options. Having said that, our packaging is sustainable and we have a minimalistic approach towards it. We are proud to be Plastic Neutral, removing plastic from the environment every month. This reflects our commitment to sustainability and reducing our ecological footprint.

Interested in learning how you can incorporate upcycling in your food business?

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