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  • Project category
    Shaping a circular industrial ecosystem and supporting life-cycle thinking
  • Basic information
    A Matter of Fruit
    A Matter of Fruit – How juice consumption can help tackle our waste problem
    A Matter of Fruit develops natural materials from local industrial juice press residues (also known as pomace), mainly using apple waste. This juice by-product is transformed into flexible films which offer a non-toxic alternative to synthetic materials and fossil-fuel based plastics. The new material is fully compostable and recyclable. In this way the initial pomace cycle is being extended and enables the matter to circulate further, replacing harmful linear systems.
    Regional
    Germany
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    It addresses urban-rural linkages
    It refers to other types of transformations (soft investment)
    Yes
    ESF : European Social Fund
    Funded by the design-in-tech accelerator DesignFarmBerlin from March 2022 - February 2023
    No
    Yes
    2023-01-30
    As an individual
    Yes
    Previous participants
  • Description of the project
    The industrial processing of fruit and vegetables into juice produces huge amounts of another substance whose potential is hardly recognised: pomace. The residues that occur during pressing are found later, above all, in the biogas plant, for pectin production or as animal feed, but their actually possible qualities are not really used. Germany, as the world champion in drinking apple juice, produces a particularly large amount of apple juice press residues – up to 200,000 tons per year, thus offers a raw material that can be sourced regionally. A survey of juice producers in the German state Brandenburg has shown that producers are still looking for a better solution for their pomace, as to some extend, pomace still has to be disposed of at their expense.
    'A Matter of Fruit' is dedicated to the development of processes to convert pomace mainly into biodegradable films that can be used as alternatives to synthetic material. Depending on the thickness, it can be categorised between paper, plastic or leather and offers potential for different areas of application in interior spaces. A first use case has been developed for circular building concepts: here the films are applied as light diffusers and blinds to create a warm, natural atmosphere indoors and to provide an alternative to plastics such as soft PVC or Polyurethane.
    In addition to the films, a printing paste made from apple pomace was developed, which further expands the design options and areas of application for the material. Tests have shown that the material is ideal for laser cutting and engraving. Due to its fusibility, the material can be welded or pressed into shape and, for example, transformed into a plant pot at the end of the first cycle of use, which biologically decomposes after being potted in the ground. This expands the natural pomace cycle, whereby the material can be returned to the biological cycle at the end of its life.
    Circular Economy
    Material Design
    Plastic Alternative
    Utilize Food Waste
    Compostability
    The new apple pomace material is made of the by-products from the juice industry. This means neither additional land is needed to grow the resources, nor its usage is competing with the food industry. The usage of regional juice press residue sources from Germany or Europe, links to shorter transportation routes, thus lower CO2 footprint and, compared to conventional plastics, production does not depend on fossil fuel rich countries.
    The material can be repaired, recycled or composted which enriches a circular economy.
    By using the new natural material, it contributes to a healthier living: unlike many current plastic items, no harmful plasticisers are leaking into the home or nature.
    Preliminary tests have shown that the material degrades within three weeks, when embedded into soil. The material has been tested for tensile strength by the research institute Fraunhofer UMSICHT. The results have shown that its strength is comparable to conventional plastics which shows that the pomace films can to an extent be used as an alternative.
    When designing the material, it was important to use as few additives as possible – and to push boundaries: how can different properties be developed solely through different processing methods? For example, granulating pomace in different grain sizes can expand the scope for design and influences the haptic and translucency of the material: from smooth to abrasive, from transparent to opaque – a big variety of options are possible without loosing its monomaterialism. In addition to the material, an ink has been developed, also from the apple juice press residues, extending the design possibilities and application areas for the material even further. By producing the films with increased thickness, they become sturdier and less translucent and compare to a leather-like material. Due to its natural colour and especially in combination with light, the material can create a warm atmosphere in interior spaces. It aims to re-connect people to nature. It shows the possibility of creating products from nature that can be digested by nature after the end of its life.
    The focus of A Matter of Fruit is to create a better environment to everyone. By creating circular films for the human living and working space, a material has been developed that addresses the wasteful usage of our resources. Instead of concentrating on specific social issues, the project aims to create a better foundation for all (human) beings and find better solutions to balance our relationship with nature.
    A Matter of Fruit aims to make the new material accessible and affordable to all, by increasing the production capacity of the films, as long as nature’s biodiversity is not endangered.
    By drinking regional juice, civil society can be involved in the project, and also benefit from environmental impacts in the long run. The circular material that has been developed for the human living and working space, creates safer, natural indoor spaces and at the same time reduces the leakage of toxic material into the environment. All people are invited to participate in this circular product usage by repairing or returning the material after its end of life.
    Following stakeholders were engaged in the design and implementation of the project:
    - DesignFarmBerlin: providing valuable coaching and mentoring
    - Research Institutes such as Fraunhofer UMSICHT and IAP: testing and evaluating the material, pulsing device for natural coatings & processing techniques
    - Juice Producers from the German State Brandenburg: Providing valuable information about juice production and its residues, showing interest in future collaborations and better use for their by-product
    - Impact Hub Berlin: First Use Case of the material in their CRCLR house
    - LXSY Architekten: Joint development of a light diffuser using apple pomace material
    - Consumers of regional apple juice: responsible for creating regional available raw material that can be used for creating a natural alternative to fussil-fuel based plastics
    The project connected disciplines and knowledge fields from the area of material & surface design / circular design, science (chemistry, biotechnology, food technology) and production (food industry, agriculture). By exploring the possibilities how food waste can be used to design a new natural material, some additional areas such as food/bio chemistry and the juice industry have been examined and further research has been conducted. This way it was possible to work out that the components of pomace, such as pectin, are valuable parts. Applicable as a binder, pectin plays a major role in creating pomace films, avoiding the usage of further additives. Looking at the manufacturing process of apple juice, it revealed that the by-product of only one producer, which would have ended up in landfill, could be used to produce up to 39.300m of apple pomace film per year.
    By brigading the different disciplines the manufacturing processes, regional and circular concept of the project could be developed and expended further.
    The outcome and result of the project is, that a first use case for the material could be implemented. Together with the Impact Hub Berlin and LXSY Architekten, a light diffuser made of apple films for the CRCLR house has been developed and will be installed in March 2023. The natural diffuser is able to replace conventional plastic films that would have been used instead for that effect. The installation of the apple pomace film lamps fully fits the concept that the Impact Hub is aiming to achieve for their premises: a circular house, which is constructed according to circular economy principles; all building materials being either reused or reusable.
    Furthermore, a food by-product that would have ended up in landfill, is now elevated to a higher purpose while replacing environmentally harmful materials.
    In case the light diffuser is no longer used, the material can be returned to A Matter of Fruit for recycling purposes. Alternatively, the material can be composted.
    Like conventional plastic, the new material made of juice press residues is very versatile. Tests have shown, that the material is extremely suitable for lasercutting and engraving. Due to its fusibility, the material can be welded, moulded or pressed into shape. This means that zero waste products can be created and additional material such as thread or glue is not needed.
    The aim of A Matter of Fruit is to take over responsibility for its developed materials. Since the new pomace material is recyclable and compostable, it can also be processed further after use. For example, before it ends up prematurely in the compost, it can be transformed into a plant pot, thus replacing plastic pots in order to save even further resources. Tests have shown that when the plant is planted in the ground together with the 'pomace pot', the material degrades within three weeks.
    The juice press residues are currently mainly used as fodder and compost, to obtain pectin or to produce biogas and – in theory – undergo a circular process. However, its unique qualities could be put to much better use. The new 'pomace material‘ is compostable and recyclable and can be used as an alternative to fossil-fuel based plastics. This way the initial pomace cycle is extended, where the material can circulate further, replacing harmful linear systems.
    When designing the new material, it was important that in the end it remains recyclable by nature. The idea is, to only borrow elements from our nature for a limited amount of time and returning it back after it is no longer needed. Planning the return of ‘old material’ should become as important as sourcing ‘new’ natural material. This blurs the boundaries between new and old and an actual endless loop becomes possible.
    Apples for juice production are grown and pressed all over the world. Apple pomace should ideally be processed further where it is produced. A pomace film production can occur wherever juice is produced industrially. The films should also be used regionally. In this way, a local cycle can be established and additionally, long transport routes can be avoided.
    Next to apple waste, the process can also be applied to orange peels, which occur in huge amounts during orange juice production.
    The project addresses the global challenge of transforming linear systems into circular ones. The new pomace material is compostable and can return to the natural cycle after its use. A Matter of Fruit also provides local material alternatives to products made of fossil-fuel based raw materials. Especially in Germany, a lot of juice waste is yearly generated. By using this locally available raw material, a long way of transportation can be avoided, thus reducing CO2 emissions.
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