Functional ingredients from food wastes: the case-study of cocoa bean shells

The valorisation of food by-products is a promising strategy for sustainability within the circular economy. Cocoa bean shells (CBSs), a by-product of the cocoa production chain, are a waste rich in bioactive compounds, including polyphenols, dietary fibres and lipids. This thesis investigates innovative approaches to convert CBSs into functional ingredients for food and nutraceutical applications. Key findings include improving the fermentability of CBSs through enzymatic treatments, which enhances the production of short chain fatty acids (SCFAs) that support gut health and prebiotic functionality. This work has demonstrated the preservation of antioxidant compounds during fibre modification, optimising the properties of CBSs for potential nutritional benefits. Non-conventional extraction techniques, including ultrasound and microwave methods, were used to efficiently recover antioxidant polyphenols (e.g. clovamide), achieving higher yields and antioxidant activity compared to traditional methods. Application in model food systems demonstrated CBSs as versatile functional ingredients with favourable and potential health benefits. The research also investigated CBSs lipid fractions, highlighting their unique bioactive compositions. Taken together, these studies highlight the potential of CBSs as a sustainable resource for functional foods, contributing to waste reduction and innovation in line with the EU Green Deal targets. By advancing extraction, modification and application techniques, this work underlines the role of CBSs in promoting health and environmental sustainability, providing scalable solutions for the up-cycling of food by-products.