Apple processing waste gains new packaging potential

Researchers at Massey University in New Zealand are exploring how apple processing waste could be transformed into stronger fibre-based food packaging, creating additional value from a by-product that is currently used mainly as animal feed.

The project combines apple pomace — the skins, pulp and seeds remaining after juice and food processing — with conventional wood pulp to produce paper-based packaging materials with improved mechanical properties.

Twenty percent apple pomace improves material strength

Preliminary results indicate that replacing part of the conventional fibre with apple waste can do more than reduce reliance on virgin wood pulp. Researchers found that adding 20% apple pomace increased both tensile strength and tensile stiffness by approximately 50% compared with traditional wood-pulp paper.

The results suggest that food-processing residues could become functional raw materials rather than simply low-value fillers, potentially improving packaging performance while supporting more circular material systems.

Hawke’s Bay offers a consistent waste stream

The research is particularly relevant to New Zealand’s Hawke’s Bay region, where apples are processed for juice and other products throughout much of the year, generating a relatively consistent supply of pomace.

Using locally available agricultural residues could reduce waste while also creating a new domestic fibre source for packaging manufacturers.

Barrier performance remains the next challenge

Mechanical strength is only one requirement for food packaging. The research team is now focusing on improving resistance to water, oils and grease so that the material can be used across a broader range of foodservice applications.

Plant-based coatings are being evaluated as potential barrier technologies, with takeaway containers and other direct food-contact formats identified as future target applications.

Laboratory production supports standardised testing

A laboratory-scale paper handsheet-making system has been commissioned as part of the project, allowing researchers to manufacture test sheets under controlled conditions and evaluate them using international testing standards.

This equipment makes it possible to adjust fibre ratios, coatings and processing conditions systematically before considering larger-scale manufacturing trials.

Research supports a circular bioeconomy

The concept reflects growing interest in using agricultural and food-processing side streams as raw materials for packaging. Fruit residues contain cellulose and other plant-based components that can potentially supplement conventional fibre sources.

Rather than treating these materials as waste, the approach aims to retain more of their economic value within the production system while reducing dependence on additional raw materials.

Commercial feasibility still needs to be demonstrated

The project remains at proof-of-concept stage. Researchers will need to assess manufacturing costs, processing consistency, food-contact requirements and compatibility with existing paper and packaging production equipment before commercialisation becomes possible.

Scaling the technology will also require reliable preparation of apple pomace so that seasonal and biological variations do not create inconsistent packaging performance.

Fruit waste could open a broader material platform

Although apple pomace is the initial focus, the researchers see potential for other fruit-processing residues to be investigated as alternative fibre sources.

If commercially viable, the approach could provide packaging producers with a broader portfolio of locally sourced renewable materials while giving food processors new outlets for by-products that currently have limited economic value.

Food and packaging waste streams become interconnected

The Massey project demonstrates how packaging development can become integrated with the wider food production system. Waste generated during food processing could ultimately return to the same value chain as packaging for future food products.

With early testing showing substantial improvements in mechanical performance, the next stage will determine whether apple pomace can move from laboratory sheets to practical packaging formats capable of meeting the barrier, safety and production requirements of commercial food applications.