Getting more value from surplus and waste

Bakery Sector
1st August 2017

Project delivered by:

 WRAP’s
vision is a
world in which
resources
are used
sustainably
Our mission is to accelerate the
move to a sustainable resource-
efficient economy through:
• Re-inventing how we design,
produce and sell products
• Re-thinking how we use and
consume products
• Re-defining what is possible
through re-use and recycling.

Find out more at

wrap.org.uk
Contents

1. Summary
2. Background
3. Methodology
4. Surplus/waste mapping results
5. Getting more value opportunities
6. Conclusions and next steps
Appendices
1. Summary
1. Summary – Surplus/waste mapping results
Around 117,000 tonnes of surplus dough and baked product is generated by the UK
wrapped bakery sector each year, of which 78,000 tonnes is by-product sent to animal
feed. The remaining waste goes to land spread, anaerobic digestion and a small
percentage to energy from waste. Despite ongoing long term improvements an
estimated 35,000 tonnes is unavoidable. There are a number of practical onsite aspects
that need to be considered when getting more value from waste:
• The need for weekly collections due to limited space onsite for storage
• Raw dough waste is particularly difficult to handle as it continues to expand
• Redistributing product for human consumption is priority
• Space for modifications to the waste then this will have to
be reviewed with each specific site before-hand
• A significant percentage of the surplus will be
packaged product (in plastic packaging)
• Most of the surplus is consistent across the entire year
1. Summary – Getting more value: Chemicals
and pharmaceuticals
• A number of high value chemicals (e.g. cosmetic actives, pharmaceuticals,
fragrances) are currently produced on an industrial scale through fermentation
• Product values can vary from £1 / kg (industrial solvent) to £5,000 / kg
(flavour/fragrance)
• There is growing interest from industry in the production of high-value chemicals
from food wastes, driven by the historically variable price of glucose syrup, and the
environmental impact through
using feedstocks originating from wheat
• The Biorenewables Development Centre (BDC)
is currently working with two multi-nationals to
assess the potential of producing
pharmaceuticals from bread processing and
sandwich manufacturing wastes
1. Summary - Getting more value:
Beer utilising surplus bread
• While the majority of beer production worldwide utilises malted barley as the grain
sugar source, there is a large market in ‘wheat beer’ where a large proportion of
the malted barley is replaced with malted wheat
• Established brewers in the UK have been manufacturing beer using bread waste
• One third of the malted grain requirement is replaced with bread,
and the brewing process proceeds as normal. Some brewers now
have a range of beers based specifically on bread waste
• The market for these speciality beers is small at present, but there
is a growing desire from consumers to source their food and drink
ethically
• Some brewers has been successful in promoting their products
as being made using bread for which there is:
‘no home for it to be eaten by those in need’’
1. Summary - Getting more value:
Pet Food
• The UK pet food sector currently sources most of its ingredients from outside the
UK and is actively exploring opportunities to bring that supply chain closer to home
• Drivers include security of supply and marketing/PR claims
• Wheat is a major component in many brands of pet food, and there is no evidence
to suggest this is likely to change
• A number of manufacturers have indicated that they would consider testing bread
surplus in future products
• It would need to be sourced and processed at a favourable price compared to the
equivalent wheat component (2017: £145-150 / tonne).
• Consideration would need to be given to the format of the bread surplus (i.e. de-
packaged, milled/crumbed, and dried to <10% moisture content)
• If this processing could be done by bread manufacturers the product would be of
higher value, incur lower transportation costs, and be more stable for storage
1. Summary – A bubble map ranking the
opportunities
The bubble diagram illustrates the
key opportunities according to
their scores. Opportunities are
plotted according to:
• Technology readiness (X-axis)
• Environmental impact
reduction (Y-axis)
• Commercial potential (size of
the circle).
Bubble plot key:
1. Production of high value
chemicals: pharmaceuticals
2. Beer production - utilising
surplus bread
3. Pet food
Bubble size is representative of
commercial evaluation score.
1. Summary - Conclusions and next
steps
• The assessment of value adding opportunities explored a number of potentially
high value options for using surplus streams
• Three options were evaluated as higher priority. Technology providers and
interested end-users and markets, such as pet food, have been identified for each
area
• For businesses looking to progress these opportunities, an internal review of all the
options presented is recommended to confirm the top priority areas of interest
• Feasibility studies may be required to further review stakeholders and specific
solutions in the prioritised areas, and to understand the fit with the company’s
strategy, investment scope, facilities and capabilities, as well as regulatory
requirements where needed
• Please contact WRAP for further details relating to the recommendations
2. Background
2. Background - Getting more from
waste through Courtauld 2025
Courtauld 2025 is an ambitious voluntary
agreement that brings together a broad range of
organisations to make food and drink production
and consumption more sustainable

This part of Courtauld 2025 finds innovative ways

to get more value out of wastes and surpluses via:
• value adding projects for dairy, bakery, fresh
produce and drinks sectors
• value adding support via academic networks
• internal evaluation of opportunities through
quantification, characterisation of compounds
from the by-products/wastes
• providing insights on value adding
opportunities
2. Background - Aim and objectives

The aim of this work was to consider current processes in the UK wrapped bakery sector that result in
process surplus with a view to transforming this into valuable commodities
The project objectives were, as far as reasonably possible within the resource constraints, to:
• Map and quantify the food surplus streams across the production lines of selected bakery sites
• Undertake a comprehensive review and evaluation of options available to enhance these bakery
sector wastes, including any technologies and approaches which have not previously been applied
to the UK industry
• Identify an array of suitable and innovative technologies which are capable of recovering valuable
chemicals and compounds from the surplus
• Appraise said technologies or innovations in terms of:
• practical, economic and technical feasibility
• technical readiness level and expected timeframes to market readiness
• barriers to commercialisation and expected costs to overcome these barriers
• market impact and commercial value of the technology
2. Background – Project scope

During 2016 and 2017, WRAP, in collaboration with Green Gain, Lucid Insight and the BDC,
conducted detailed mapping of the process surplus flows from the UK bakery industry.

Initial mapping was carried out across selected sites at major stakeholders in the wrapped bakery
product sector. The mapping work aimed to identify the process surplus being generated across
the following, wrapped bakery product categories:

• Bread

• Rolls and baps

• Sandwich alternatives (wraps and thins)

• Breakfast products (crumpets, pancakes and potato cakes)

3. Methodology
3. Methodology - Overall project process
Mapping
• Onsite audits of processes at selected sites across UK wrapped bakery sector stakeholders
• Investigated the following products: bread, rolls, wraps, thins, crumpets, potato-cakes, and
Mapping pancakes
• Established quantities of dough and baked product surplus at each process stage
• Related this site-specific data to national bakery sector production to provide UK-wide quantities

Options Identification
• Global secondary searches: scientific, patent, market, and industry sources
Value adding • Identification of adjacent sectors, industry and related areas
Phase 1 • Access to networks and targeted knowledge holders
• Ideas were identified and screened against a high-level assessment of the
technology readiness, and market attractiveness
Options Evaluation
Value • Targeted searches conducted to gather data on specific
solutions
adding • Interviews with experts and stakeholders provided further
insights
Phase 2 • Tests and trials conducted on materials
• Scoring and prioritisation of options
3. Methodology – identifying surplus
arisings
Sites were selected for auditing from across participating UK wrapped bakery sector
stakeholders
Product lines were identified, with a focus on: Bread; Rolls and Baps; Sandwich
Alternatives (wraps and thins); and Breakfast Products (crumpets, pancakes and
potato cakes).
A number of stages were involved in carrying out the surplus mapping:
1. Site tours
2. A manufacturing process overview
3. Analysis of production efficiency databases, sales data, and waste data
4. Quantification and composition of process surplus
5. Identification of surplus ‘Hot spots’
6. Quantifying the proportion of the surplus that could be avoided
7. Using generic industry research and data to extrapolate findings for the sector
3. Methodology – identifying opportunities
for getting more value
The UK wrapped bakery sector mapping data was then used to identify
opportunities for getting more value from surplus by using the following
approach: Task 1: • Volumes and composition
Review of surplus/waste data • Sources of arisings with geographic breakdown

Task 2: • Composition of difficult to avoid streams (protein,

fat, carbohydrate, calorific value, moisture content
Characterisation etc.)

• Existing routes or uses

Task 3:
• Temporal availability (seasonal/storage/transport)
Current accessibility • Spatial availability - transport, storage

Task 4: • Likely market changes (price)

Future accessibility • Future quantities (anticipated sector growth)

• Identification of existing and close market

Task 5:
commercial value adding opportunities based on a
Options appraisal TRL evaluation and a basic cost benefit analysis
 3. Methodology - Scoring

A scoring system on a scale of 0 to 10 was developed for scoring and ranking these
opportunities for getting more value. The selected criteria are outlined in the following
slides. The highest priority options were scored on the following areas:
• Technology Evaluation: Technology readiness level, and Technical
feasibility/complexity to reach commercialisation
• Commercial Evaluation: Size and trajectory of market, value of product & potential
scale of production, benefit from specific product, and Capex and cost/complexity to
manufacture product
• Environment and Resource Evaluation: Residues remaining if specific value
adding option is applied, waste hierarchy and displacing of fossil derived products,
and resource input (energy, water, chemical) requirements

*It is recognised that other criteria could be addressed, but were outside the scope of this study
3. Methodology - Scoring criteria

Criteria Description of criteria

TRL Technology readiness level

Technology Feasibility, complexity and level of investment to reach
Evaluation Feasibility commercialisation

Market health Size and trajectory of market in Europe

Commercial Product value Value of product & potential scale of production from by-product
Evaluation Novelty, differentiation, disruption (cost), or specific benefit derived from
Product differentiation by-product utilisation

Cost & complexity Cost and complexity to manufacture product

Residues Residues volume and potential to valorise or challenge to dispose

Environment
Relative position on the waste hiererchy, or whether displacing fossil
and Resource
Waste hierarchy derived products
Efficiency
Resource input Resource input (energy, water, materials) for processing
4. Surplus/waste
mapping results
4. Surplus/waste mapping results
• Bakery process surplus and waste occurs for a variety of reasons and may differ
according to the on-site setup, age and efficiency of the process lines, maintenance
programmes and staff training. Issues discovered later in the process usually result in
higher surplus and waste levels.
• Typical issues include machine malfunctions, operator errors, defective material, mix
errors, oven damage, issues with process jams, slicer damage, packaging malfunctions,
quality control, new product development, dispatch errors, and clean-in-place residues
• For the UK wrapped bakery sector the majority of the
‘easy wins’ of waste reduction have already been
addressed
• Ongoing waste reduction efforts therefore require
long-term investment, technological innovation,
maintenance programmes, continued staff training, and
increased collaboration across the food supply chain
 4. Surplus/waste mapping results
Data extrapolated for the total UK wrapped bakery sector process surplus and waste across the four
product categories is estimated in tonnes below (split by dough and baked surplus in the final column):

Tonnes Typical Total Surplus split

Product produced per production surplus per Dough (D)
annum surplus annum & Baked (B)
Wrapped bread 2,738,700 3% 82,161 D – 32,864
B – 49,297
Rolls & baps 628,700 3% 18,861 D – 3,772
B – 15,089

Breakfast products 660,400 1% 6,604 D - 1,981

B – 4,623
Sandwich 367,500 2.5% 9,188 D – 919
alternatives B – 8,269
TOTAL 4,395,300 - 116,814 D – 39,536
B – 77,278
4. Surplus/waste mapping results –
Existing management methods
Based on the mapping work, the UK wrapped bakery sector typically manages its surplus
and waste through the following methods (tonnes per annum and percentage by category):
• Dough and baked waste primarily
go to animal feed, with some
localised AD arrangements also in
place
• Waste from the CIP (clean in
place) process captured in
settlement tanks is managed via
land spreading
• Energy from waste is used to
manage any contaminated food
waste
• Redistribution is being rolled out
4. Surplus/ waste mapping results –
Existing management methods
The typical values and costs for these surplus/waste management methods across the
UK wrapped bakery sector are as follows:

Method Surplus/waste description % of total Cost(-)/ income(+)

Dough and baked surplus (sometimes Dough +£13 to +37/t

Animal feed 67%
packaged)
Baked +£45 to +50/t
Dough and baked waste (sometimes £0
AD 5%
packaged) (subject to local arrangement)

Interceptor sludge from CIP and loss to

Land-spreading 23% -£55 to -£60/t
drains

Redistribution Edible product still within sell-by-date 3% £0/t

Energy from waste Contaminated waste unsuitable for feed 2% -£50 to -£75/t
4. Surplus/waste mapping results – Difficult
to avoid waste
Surplus and waste that might be difficult to avoid in the long term for the UK wrapped bakery sector
has been estimated across the four products. This difficult to avoid estimate is the minimum waste
theoretically available for adding
Surplus and Total Difficult to
Source surplus and value to in the long term.
waste type waste (tpa) avoid (tpa)
In theory, only around 5% of
Dough (40%) 32,864 9,859 waste is difficult to avoid. To
Wrapped bread
Product (60%) 49,297 14,789 achieve this would require a level
of investment that currently
Dough (20%) 3,772 1,132 exceeds economic return.
Rolls
Product (80%) 15,089 4,527
The minimum difficult to avoid
Breakfast Dough (30%) 1,981 594 surplus and waste has been
products Baked (70%) 4,623 1,387 estimated at a more realistic 30%
Sandwich Dough (10%) 919 276 of the current UK waste total.
alternatives Baked (90%) 8,269 2,481 The UK opportunity for getting
DOUGH 39,536 11,861 more value from surplus and
TOTAL BAKED 77,278 23,184 waste in the long term will be
OVERALL 116,814 35,045 between 35,000 and 116,800
tonnes per annum
4. Surplus/waste mapping results - summary
Around 117,000 tonnes of surplus dough and baked product is generated by the UK
wrapped bakery sector each year, of which 78,000 tonnes is by-product sent to animal
feed. The remaining waste goes to land spread, anaerobic digestion and a small
percentage to energy from waste. Despite ongoing long term improvements an
estimated 35,000 tonnes is unavoidable. There are a number of practical onsite aspects
that need to be considered when getting more value from waste:
• The need for weekly collections due to limited space onsite for storage
• Raw dough waste is particularly difficult to handle as it continues to expand
• Redistributing product for human consumption is priority
• Space for modifications to the waste then this will have to
be reviewed with each specific site before-hand
• A significant percentage of the surplus will be
packaged product (in plastic packaging)
• Most of the surplus is consistent across the entire year
5. Opportunities
for getting more
value
5. Getting more value – Opportunity
mapping
The first phase of identifying opportunities for getting more value involved a
mapping process
Research of the available literature and research papers on extracting value
from bakery waste was undertaken
Based on this research a broad range of opportunities for getting more value
from waste were mapped
The mapping includes all types of opportunities, ranging from options which
have commercial potential to opportunities that are still being researched in the
lab
The list is intended to show the range of potential possibilities, but does not
consider the economic or technical feasibility of using the waste materials
5. Getting more value – Mapping biofuel
opportunities
5. Getting more value – Mapping food, drink
and health opportunities
5. Getting more value – Mapping industrial
chemical opportunities
5. Getting more value – Mapping animal feed
and fertilizer opportunities
5. Getting more value – Ranking table

Following the opportunities mapping exercise, research was undertaken to explore the
opportunities for getting more value that currently have commercial potential
These opportunities were assessed following engagement with organisations and
supply chains already involved in progressing these value adding activities
Work was undertaken to gather information in relation to:

• Industry application • Technology required

• Application (format, logistics etc.) • Application (end use)
• Practical considerations • Contacts and reference points

This information is summarised in the following tables with the opportunities ranked
to their technical, environmental and commercial potential
 5. Getting more value – Ranking table

Valorisation Fresh produce Industry Technology required Application notes Considerations References
# option utilised application
1 High value Bread waste Pharmaceutical Pre-treatment, enzymatic Production of pharmaceuticals No current examples at Government press release - use of food by-
chemicals - production hydrolysis and downstream through fermentation: commercial scale from bread. products in pharmaceuticals production:
Pharmaceutical processing to produce a glucose www.gov.uk/government/news/the-value-in-
products syrup for fermentation The BDC, GSK (GlaxoSmithKline, Sufficient supply and logistics of waste
Pharmaceutical company) and transportation need to be
Veolia (waste, water and energy considered. Biorenewables Development Centre
management service provider) news article - joint GSK/Veolia project:
are currently developing a If raw dough waste is to be used www.biorenewables.org/government-
process to convert bread waste it would require cooking off first advisers-look-york-experts-insight-bio-
into pharmaceuticals. This work to halt yeast activity and provide waste/
is currently at pilot scale (TRL4-5) a the material in a viable format
for processing
2 Beer Cooked bread Beer production Fermentation A number of brewers are utilising Need sufficient and regular Toast Ale:
waste surplus bread as a feedstock for supply - volume of bread www.toastale.com/
fermentation to produce beer required are not likely to be high
Northern Monk Brew Company - Wasted
Plain bread is preferred and Pear Farmhouse Ale, utilising leftover
material with inclusions such as croissants and pears:
seeds, fruit etc. are not currently www.northernmonkbrewco.com/beer/wast
utilised ed-pear-farmhouse-ale

A number of considerations Crumbs Brewing - Crumbs Amber Lager

around format of material need brewed using unsold bloomer loaves:
to be explored www.crumbsbrewing.co.uk/
 5. Getting more value – Ranking table

Valorisation Fresh produce Industry Technology required Application notes Considerations References
# option utilised application
3 Pet food Cooked Bread Pet food Processing: milling, crumbing, Pet food manufacturers include For bread waste to be Inspired Pet Nutrition -
ingredient waste ingredient drying various dried ingredients in their appropriate for pet food it would www.waggfoods.com/
products including bread. need to be classed as
microbiologically clean and fully MJ Petfoods -
Bread is more often included in traceable. Typically bread would www.mjpetfoods-proteins.co.uk/
'wet' food (i.e. tinned, pouched be included in low cost
products) rather than dried pet formulation rather than premium Custom Laboratory Products -
food products. products technology provider of low cost drying
equipment.
Flowability of material is crucial www.customlab.co.uk/products/pilot-
for the manufacturing process. kilning-vessel/
Consideration needs to be given
to format of bread waste (i.e. Urschel - technology providers for food
dried, crumbed etc.) processing equipment including bread
crumbing/milling:
Raw dough would not be www.urschel.com/
acceptable for pet food
formulations
 5. Getting more value – Ranking table

Valorisation Fresh Industry Technology required Application notes Considerations References Contacts
# option produce application
utilised
4 Biofuels Bread Biofuel Pre-treatment, enzymatic The production of bioethanol through Only one commercial example from St1 - Finnish energy company St1:
waste production hydrolysis and downstream fermentation: bread producing bioethanol from bakery www.st1.eu/contact-us
processing to produce a - St1 have a plant in Sweden that waste:
glucose syrup for fermentation uses bakery waste to produce Need sufficient and regular supply www.waste-management- Vivergo:
bioethanol world.com/a/bakery-waste-to-carbo- www.vivergofuels.com/contact/
Need to consider transport and load-bioethanol-production-in-sweden
A number of biethanol plants currently logistics costs
use wheat grain as a feedstock www.st1.eu/news/st1-built-a-waste-
including Vivergo in the UK (largest based-etanolix-ethanol-production-
bioethanol plant in Europe) plant-in-gothenburg

5 Anaerobic Bakery Energy Anaerobic digester Bakery waste is a suitable feedstock
digestion wastes: for anaerobic digestion and can
cooked produce high quantities of biogas.
bread, raw AD plants could process both cooked
dough final product and waste raw dough.
There are a number of food waste
plants in the UK which could take
bakery waste; More information can be
found on the WRAP website which
hosts a database of operational AD
plants across the UK.
Logistics of transporting waste to off-
site AD facilities.
Capital expenditure required to install
AD facilities on-site.
National Non-Food Crops Centre NNFCC:
(NNFCC) - Bioeconomy consultants: enquiries@nnfcc.co.uk
01904 435182
Biorenewables Development
WRAP
Centre:
Anaerobic Digestion & info@biorenewables.org
Bioresources Association
WRAP AD Database
http://www.wrap.org.uk/content/opera
tional-ad-sites

Mauri Products runs an AD plant Anaerobic Digestion &

based on bakery waste Bioresources Association
http://adbioresources.org/
5. Getting more value – The rationale for the
selection of key opportunities
The highest priority options have be scored on the following areas:
Technology Evaluation: Technology readiness level, and Technical
feasibility/complexity to reach commercialisation
Commercial Evaluation: Size and trajectory of market, value of product & potential
scale of production, benefit from specific product, and Capex and cost/complexity to
manufacture product
Environment and Resource Evaluation: Residues remaining if specific value adding
option is applied, waste hierarchy and displacing of fossil derived products, and
resource
 5. Getting more value – Chemicals and
pharmaceuticals
Cat egory Crit eria 0 1 2 3 4 5 6 7 8 9 10 Value % Cat egory
Technology TRL TRL 1 Commercial 6
65%
Evaluat ion Feasibilit y Complex Simple 7
Market healt h Small/ saturate Large/ rapid 9
Com m ercial Product value/ volum e Low High 9
66%
Evaluat ion Product different iat ion No benefits Strong benefits 8
CapEx & OpEx High Low 7
Residues Challenging None/ of value 9
Environm ent and
Wast e hierarchy Low High 8 77%
Resource Efficiency
Resource input High Low 6
MAX: 69%
Crit eria Rat ionale for score
TRL TRL level 4-5. Efficient glucose syrup production from bread waste has been proven to work at pilot scale with GSK. Currently developing business case for commercialisation
Feasibilit y Utilises well established existing technologies currently used commercially in the biofuels sector e.g. processing of wheat grain as a 1st generation biofuel feedstock
Market healt h Fast growing product segment with predicted growth of over 10% profits over the next three years
Value/ volum e High to very high value antibiotics
Different iat ion Product differentiation in the sustainability of supply and lower environmental impact - use of a waste displaces crop growth specifically for glucose production.
CapEx & OpEx CapEx/ OpEx to bread supplier will be low - end user will need to invest in a dedicated integrated plant to process material
Residues Protein fraction (containing residual fibre) is expected to be sold into the animal feed or pet food sectors, as is currently done with biofuel production residues
Hierarchy Use of food waste instead of food grade glucose produced from wheat grain. Residues could be directed towards animal feed / pet food sectors
Resource input Relatively high energy input requirements; heating, enzymes for hydrolysis, water usage.
5. Getting more value – Chemicals and
pharmaceuticals
• A number of high value chemicals (e.g. cosmetic actives, pharmaceuticals,
fragrances) are currently produced on an industrial scale through fermentation
• Product values can vary from £1 / kg (industrial solvent) to £5,000 / kg
(flavour/fragrance)
• There is growing interest from industry in the production of high-value chemicals
from food waste, driven by the historically variable price of glucose syrup, and the
environmental impact through using
feedstocks originating from wheat
• The Biorenewables Development Centre (BDC)
is currently working with two multi-nationals to
assess the potential of producing
pharmaceuticals from bread processing and
sandwich manufacturing process wastes
5. Getting more value – Chemicals and
pharmaceuticals
• The BDC has successfully demonstrated that a concentrated glucose syrup can be
produced from virgin bread waste and converted into an existing pharmaceutical
product at pilot scale (TRL 4-5)
• The consortium (BDC and other companies) is working to establish a dedicated
demonstration scale facility to produce a sustainable glucose syrup from starch rich
food manufacturing wastes including bread

Recommendations:
• The consortium have expressed an interest in engaging with bakeries to explore
opportunities to convert some of their side streams into a glucose syrup that could
be used as a feedstock to produce pharmaceuticals.
• It is possible to follow-up with WRAP to discuss the opportunity to supply bread
waste materials for the production of pharmaceuticals.
 5. Getting more value – Beer utilising surplus
bread
Cat egory Crit eria 0 1 2 3 4 5 6 7 8 9 10 Value % Cat egory
Technology TRL TRL 1 Commercial 8
80%
Evaluat ion Feasibilit y Complex Simple 8
Market healt h Small/ saturate Large/ rapid 4
Com m ercial Product value/ volum e Low High 3
44%
Evaluat ion Product different iat ion No benefits Strong benefits 8
CapEx & OpEx High Low 7
Residues Challenging None/ of value 7
Environm ent and
Wast e hierarchy Low High 7 70%
Resource Efficiency
Resource input High Low 7
MAX: 65%
Crit eria Rat ionale for score
TRL A number of small brewers currently use bread for brewing. Issues with yeast growth conditions and final product flavour limit how much/ what type of bread can be used.
Feasibilit y Not complex to use bread as feedstock but consideration need to be given to format, tractability and type of bread to be used.
Market healt h Brewing is a crowded market with many players. Brewers currently using bread waste are small in terms of production volume. Bespoke, niche product
Value/ volum e Not a high value product and volume required is low at present
Different iat ion Appealing to growing segment of customers who desire greener products and are willing to pay a premium
CapEx & OpEx CapEx/ OpEx to bread supplier will be low - logistics of transportation and time limits on when bread must be used by may be challenging i.e. limited shelf life
Residues Waste generated will be directed towards the feed sector as is currently done with brewers waste stream, but this is generally be of little value (often not raising any income)
Hierarchy Beer is a luxury item, but using bread displaces the use of wheat which could be used in the animal feed/ human food sectors
Resource input Fairly low resource input required for processing - water used will end up in final product
5. Getting more value – Beer utilising surplus
bread
• While the majority of beer production worldwide utilises malted barley as the grain
sugar source, there is a large market in ‘wheat beer’ where a large proportion of
the malted barley is replaced with malted wheat
• Established brewers in the UK have been manufacturing beer using bread waste
• One third of the malted grain requirement is replaced with bread,
and the brewing process proceeds as normal. Some brewers now
have a range of beers based specifically on bread waste
• The market for these speciality beers is small at present, but there
is a growing desire from consumers to source their food and drink
ethically
• Some brewers have been successful in promoting their products
as being made using bread for which there is:
‘no home for it to be eaten by those in need’’
5. Getting more value – Beer utilising surplus
bread
Recommendations:
• Brewers already using bread are open to direct approaches to discuss supplying
bread surplus for use in their products (including products such as crumpets,
muffins etc.)
• Open discussions about bread types that you could supply, volumes and prices
• Such brewers have a number of requirements regarding the bread they use for
their beer:
 Truly surplus: ‘…we would rather bread was eaten…but if that not's possible then let's
drink it before we give to livestock’
 Of a certain type: Plain bread is best, no inclusions e.g. seeds, nuts, fruit etc. This is
likely to affect flavour & the head of the beer
 Sliced and still within life: Bread must be free from mould
 Full traceability: Brewers donate their spent grain to livestock and so documentation
is required to ensure that bread has been segregated from meat and dairy
 5. Getting more value – Pet Food

Cat egory Crit eria 0 1 2 3 4 5 6 7 8 9 10 Value % Cat egory

Technology TRL TRL 1 Commercial 7
70%
Evaluat ion Feasibilit y Complex Simple 7
Market healt h Small/ saturate Large/ rapid 7
Com m ercial Product value/ volum e Low High 5
46%
Evaluat ion Product different iat ion No benefits Strong benefits 4
CapEx & OpEx High Low 7
Residues Challenging None/ of value 9
Environm ent and
Wast e hierarchy Low High 7 77%
Resource Efficiency
Resource input High Low 7
MAX: 64%
Crit eria Rat ionale for score
TRL Bread has previously been used in pet food formulations. Bread would need to be depackaged, crumbed/ milled and dried.
Feasibilit y Dependent on whether suppliers would prepare the bread waste. Depackaging can be labour intensive.
Market healt h UK pet food manufacturers are expecting significant growth through export to USA and Asia. They don't typically include virgin bread waste in their products.
Value/ volum e Low value-high volume commodity. To be economically viable bread waste would need to be available at a lower price than equivalent volume of wheat grain.
Different iat ion No strong benefit in replacing wheat grain with bread, except for the ethical/ environmental claims of utilising surplus bread which might otherwise be wasted
CapEx & OpEx Dependent on intake format. Depackaging, crumbing/ milling and drying prior to inclusion in formations may required.
Residues The only residue would be water removed as part of the drying process - this could be utilised further.
Hierarchy Not back into the food chain but may displace other ingredients currently used that could go to animal feed etc.
Resource input Potential need for depackaging could raise resources required. Low cost drying method would be required to keep use of bread in pet food economically viable
5. Getting more value – Pet Food

• The UK pet food sector currently sources most of its ingredients from outside the
UK and is actively exploring opportunities to bring that supply chain closer to home
• Drivers include security of supply and marketing/PR claims
• Wheat is a major component in many brands of pet food, and there is no evidence
to suggest this is likely to change
• A number of manufacturers have indicated that they would consider testing Bread
waste in future products
• It would need to be sourced and processed at a favourable price compared to the
equivalent wheat component (2017: £145-150 / tonne).
• Consideration would need to be given to the format of the bread waste (i.e. de-
packaged, milled/crumbed, and dried to <10% moisture content)
• If this processing could be done by bread manufacturers the product would be of
higher value, incur lower transportation costs, and be more stable for storage
5. Getting more value – Pet Food

Recommendations:
• Leading stakeholders in the pet food supply chain are open to contact from parties
interested in exploring the use of bread waste as a pet food component. This
includes suppliers of ingredients and raw materials to the UK and European Pet
Food Manufacturing Industry
• Manufacturers and suppliers to the industry have indicated that bread waste might
work for low cost formulations – subject to price
• Ensuring that the material is in the correct format is
essential and stakeholders are available that will
perform drying trials with bakery waste,
which would allow the pet food
sector to then carry out product testing.
5. Getting more value – A bubble map
ranking the opportunities
The bubble diagram illustrates the
key opportunities according to
their scores. Opportunities are
plotted according to:
• Technology readiness (X-axis)
• Environmental impact
reduction (Y-axis)
• Commercial potential (size of
the circle).
Bubble plot key:
1. Production of high value
chemicals: pharmaceuticals
2. Beer production - utilising
surplus bread
3. Pet food
Bubble size is representative of
commercial evaluation score.
6. Conclusions
and next steps
6. Conclusions and next steps

• Bakery surplus/waste occurs for a variety of reasons, many of which can be

addressed through ongoing reduction measures
• The process surplus/waste (dough and baked) primarily goes to animal feed and to
a lesser extent, anaerobic digestion.
• Around 117,000 tonnes of surplus dough and baked product is generated by the UK
wrapped bakery sector each year, of which 78,000 tonnes is by-product sent to
animal feed. The remaining waste goes to land spread, anaerobic digestion and a
small percentage to energy from waste. Despite ongoing long term improvements
an estimated 35,000 tonnes is unavoidable.
• Access to this material is subject to practical, onsite collection considerations
including: the need for weekly collections, the handling of raw dough, space onsite
and the fact that much of the waste will be packaged
6. Conclusions and next steps

• Research was undertaken to explore the opportunities for getting more value from
waste that currently have commercial potential.
• Work was undertaken to gather information in relation to:
• Industry application • Application (format, logistics etc.)
• Practical considerations • Technology required
• Application (end use) • Contacts and reference points
• Based on this process three opportunities were identified as high priorities
• The key opportunities are:
1. Production of high value chemicals & pharmaceuticals; 2. Beer; and 3. Pet food.
 6. Conclusions and next steps

• Follow up of specific opportunities of interest would be required to move these areas

forwards
• An internal review of all options presented is recommended to confirm the top priority
areas
• Feasibility studies may be required to further review players and specific solutions in the
prioritised areas
• The key technology owners, end-market players and relevant key stakeholders of interest,
can be contacted to assess their suitability for, and interest in, collaboration or supply
• Where further R&D is required for less developed solutions, funding is available from
organisations such as InnovateUK and the FoodWasteNet,
• In addition, there may be some areas that would benefit from broader industry
collaboration, for example, centralised drying facilities
• WRAP is keen to see bakery waste utilisation taken forwards. Please contact WRAP for
further details relating to the recommendations
Appendices
Appendix A – Technology readiness level
scoring
Technology readiness level scoring