At Senson, we have set a bold target: by 2027, 10% of our sales will come from circular economy products. This ambition has been the driving force behind the creation of Rye Revived, an experiment of how collaboration can turn industrial side streams into value.
From surplus bread to sustainable extract
Traditionally, crust edges and leftover bread have been reprocessed as animal feed or otherwise recycled. Now, through Senson’s expertise in natural extraction, this side stream is transformed into a high-quality, food-grade extract designed especially for brewing and baking. It gives surplus bread a new life in human consumption.
– We explored a similar project back in the 1980s, but with the technology available at that time it wasn’t possible to make it work as intended, says Arttu Ruusunen, Product Development Engineer at Senson.
Where it All Began
The development of Rye Revived began with a thorough assessment of the surplus rye bread streams. This included analyzing volumes, rheology, moisture levels, and nutritional content, as well as potential food safety risks during storage.
Special attention was needed for storage conditions, since surplus bread has a higher moisture content than grains or malts, making it more susceptible to spoilage.
– This project has been carried out in close collaboration with local bakeries. The entire supply chain had to be carefully considered to ensure that the side streams would not spoil along the way, says Pontus Forth, Managing Director of Senson
Food Safety at the Core
Ensuring food safety and hygiene has been a central focus throughout the development of Rye Revived.
– Once surplus bread leaves the oven, it is packaged in clean conditions, providing a safe starting point, explains Arttu Ruusunen.
After grinding, the increased surface area of the bread cubes makes the material more prone to spoilage, so Senson’s team prioritized rapid processing and selected side streams with the lowest moisture content.
Storage stability was verified through systematic shelf-life tests and confirmed by an external laboratory.
– During extraction, high temperatures eliminate potential microbes, and evaporation ensures a stable final product.
Extensive analyses further confirmed the safety and quality of the extract.
– Since the bread is originally baked from carefully controlled flour with no pesticide or mycotoxin risks, the raw material itself provided a reliable foundation.
The result is a food-grade extract that meets high standards of safety and hygiene.
A Distinctive Flavor Profile
Compared to extracts made from virgin raw materials, Rye Revived offers a distinct taste. While visually similar to standard extracts, its flavor is saltier, more complex, and rye-forward, with deep and dark notes that bring new character to brewing and baking.
– We have already tested the extract in a kvass-type drink, which is traditionally made from bread at home, explains Arttu Ruusunen.
The Product Development Engineer at Senson also sees potential for Rye Revived well beyond brewing. The extract could be applied in breakfast cereals or snack bars, such as muesli bars.
– As important as adding taste is that the product enables manufacturers to reduce food waste and take concrete steps toward circular economy production, says Pontus Forth
Shaping the Future of Circular Food Solutions
Looking ahead, we see products like Rye Revived as an important pillar in building the future of the food industry. While surplus materials always require careful development to ensure food safety, the direction is clear: circular economy solutions will play an increasing role in sustainable food production.
– With our strategic goal of reaching 10% of sales from circular economy products by 2027, we are positioning ourselves at the forefront of innovation. Rye Revived is not the final destination but part of a longer process where we continue learning, testing, and developing new solutions together with our partners, says Pontus Forth
Want to know more about Rye Revived ? Meet Us at Drinktec 2025
Rye Revived is not yet a commercial product but part of our ongoing R&D efforts. The next steps will focus on scaling, testing, and co-developing with partners to explore its full potential.
We are excited to showcase this concept at Drinktec 2025 in Munich, where we invite the industry to discuss and shape the future of circular food solutions with us.