Teeside University  

Ready-cooked meal

BrewsGate

A nutrient dense instant noodle product incorporating Brewers Spent Grain.

BrewsGate: A Circular Economy Revolution in Modern Nutrition BrewsGate is a technically optimised, eco-innovative instant noodle brand designed to disrupt the European convenience food sector. Developed for the Ecotrophelia competition, this product addresses the critical "sustainability gap" by transforming industrial side-streams into a high-protein, high-fibre, and affordable meal solution. By leveraging the principles of circular economy and industrial symbiosis, BrewsGate proves that high-quality nutrition and environmental stewardship do not have to come at a premium price. 1. The Core Innovation: Upcycling Brewer’s Spent Grain (BSG) The technical foundation of BrewsGate lies in the valorisation of Brewer’s Spent Grain (BSG), the primary solid byproduct of the brewing industry. Waste Reduction: BSG accounts for approximately 85% of total brewery waste. Globally, millions of tonnes are generated annually, much of which ends up in landfills, where it contributes to methane emissions. Environmental Impact: Diverting just 1 kg of BSG from a landfill prevents the generation of approximately 3.01 kg of CO2 Nutritional Goldmine: While traditionally treated as a low-value animal feed, BSG is exceptionally rich in dietary fibre, protein, and bioactive compounds. Raw Material Strategy: BrewsGate utilises milled, dried BSG. This format is selected over wet grain to ensure microbial stability, longer shelf life, and a uniform particle size (below 100 µm) that integrates seamlessly into a noodle dough matrix without disrupting the gluten network. 2. Technical Formulation and Product Engineering The development of the BrewsGate noodle followed a rigorous four-stage iterative process (F1- F4) to ensure the product met industrial standards for texture, taste, and rehydration. The "Gold Standard" Formula (F4) The final formulation achieves a precise balance of nutrition and structural integrity: 13.6% Upcycled BSG Flour: Provides the primary fibre boost and contributes to the product's sustainable credentials. 13.6% Chickpea Flour: Acts as a plant-based protein enhancer, creating a more diverse amino acid profile than wheat alone. 27.2% Very Strong Wheat Flour: This is a critical technical inclusion. The high protein content in "Very Strong" flour compensates for the "gluten dilution" effect caused by adding fibre-rich BSG and non-glutenous chickpea flour, ensuring the noodles maintain an al dente bite. 1.9% Vegetable Oil: Serves as a lubricant during the sheeting process and creates the internal porosity required for 3-minute rapid rehydration. 35.4% Water: Carefully calibrated for optimal dough hydration. Sensory and Flavour Optimisation