Plant to fork: from sustainably sourced bio-based feedstock to 3D printed delicacies
Authors: Marti Patrizia , Cai Giampiero , Parri Sara , Di Noi Agata , Mastrodonato Sebastiano , Gullì Antonino 
Published: January 2025

The research presented in this article reflects on the theme of vegetables byproducts as a material to encourage the consumption of plant-based food in a sustainable perspective. We present a case study of cultivation of tomatoes optimized for the synthesis of bioactives such as polyphenols, which usually concentrate in the peel and are normally discarded during industrial and domestic processing. It is estimated that the European tomato industry produces more than 200,000 tonnes of waste - peels and seeds - annually, which constitute an environmental problem and an economic cost. Currently, industrial tomato waste is used in the production of animal feed and biogas, with low efficiency.In our project, the feedstock produced in hydroponic and aeroponic cultivations, is transformed into food enriched with bioactive components and transformed through additive manufacturing, to offer an innovative, engaging and sustainable consumption experience. Our objective is to transform enriched tomato peels into nutritious 3D printed pasta.The development of food ingredients from sustainably sourced bio-based feedstock leverages hydroponic and aeroponic systems to grow plants under controlled conditions. Hydroponics, a soilless cultivation method, utilises nutrient-rich water solutions to precisely control the growing environment, leading to accelerated plant growth and increased yields. Similarly, aeroponics is a soilless technology that optimises efficiency by using minimal nutrient solutions and water. This method allows for even more precise nutrient delivery to plants, resulting in reduced environmental impact and energy savings. Both hydroponic and aeroponic systems enable meticulous control over various plant growth parameters, which can be adjusted to enhance the synthesis of bioactive compounds. This approach aims to boost polyphenol content by exposing plants to specific abiotic stressors, such as increased UV light, extreme temperatures, controlled drought, and moderate salt levels. These stressors stimulate polyphenol synthesis enhancing the nutritional and health benefits of the plants. Polyphenols are naturally occurring compounds present in a variety of plant-based foods. Renowned for their antioxidant and anti-inflammatory properties, polyphenols are instrumental in lowering the risk of chronic diseases such as cancer, heart disease, and diabetes. Our plant to fork process develops in different phases:1)Tomato plants are grown in hydroponic and aeroponic systems to increase polyphenol production in response to stress conditions like drought, UV exposure, and pathogen attacks, particularly in exposed plant parts like leaves and fruit peels, enhancing flavor, shelf life, and resistance. 2)Tomatoes obtained with this type of cultivation are harvested and peeled, and the peels are analyzed to measure the polyphenol content.3)The tomato peels are then dried at 45° centigrade, in total dehydration at 0° humidity for 6 hours, with a fan power of 2 on a scale of 1 to 7.4)The dry peels are then pulverized into a very fine powder and mixed with water and flour until a soft, elastic dough is obtained. The dough is obtained mixing 40 gr of tomato peels, 50 gr of semolina flour, 50 gr of durum wheat flour, 60 ml of water, 2 gr of salt, extra virgin olive oil to taste.5)The resulting dough is processed with the Foodini 3D food printer to obtain various shapes of tomato pasta that can be consumed as fresh or dry pasta. The dry pasta is obtained throgh a new drying process in two next steps using the following parameters: a) 8 hours, 12% humidity, 40°/50° temperature; b) 6 hours, total dehydration at 0° humidity, 50°/60° temperature.6)The pasta is analysed again to measure the amount of polyphenols after transformation.The project is a concrete example of a sustainable process from plant to fork to valorise food byproducts such as tomato peels enriched with bio-active components and transformed with 3D printing technologies to allow for an aesthetically attractive rendering of food with beneficial properties for health and environment.