Food waste is a growing concern in the baking industry, particularly for large-scale industrial bakeries that produce high volumes of bread. In response to this challenge, innovative solutions are emerging to repurpose surplus bread, turning potential waste into valuable raw materials. One such initiative is Fazer’s "Brewed with Fazer Rescued Bread" concept, which demonstrates how surplus rye bread can be upcycled for beer production.

The Scale of Food Waste in Industrial Baking

Industrial bakeries often face unavoidable food loss due to factors such as underweight loaves, imperfect shapes, and overproduction. According to industry estimates, bakery waste constitutes a significant proportion of food loss in Europe. Reducing this waste is not only an environmental priority but also an economic opportunity.

Fazer, a leading Finnish bakery, has set a target to cut food loss by 50% by 2030. By the end of 2024, the company had already reduced food loss by 13% from its 2020 baseline. The "Brewed with Fazer Rescued Bread" initiative is a key step towards this goal, demonstrating that surplus bread can be transformed into an ingredient for beer brewing.

Turning Waste into a Marketable Ingredient

The collaboration between Fazer Bakery and Teerenpeli Brewery & Distillery offers a blueprint for other industrial bakers. Rye bread that is unsuitable for retail is repurposed as a brewing ingredient, partially replacing malt in the beer production process. The result is a high-quality product that aligns with the growing demand for sustainable alternatives in the food and beverage industry.

Katariina Rommi, Senior Manager at Fazer Lab, highlights the potential of this approach:

"Our dedicated cross-functional venture team explored various production technologies and commercialisation approaches to make surplus bread a viable ingredient for breweries. The result is an ingredient that can be used exactly like malt in brewing."

Why Industrial Bakers Should Consider Upcycling Surplus Bread

For industrial bakeries looking to reduce waste, upcycling surplus bread offers several advantages:

• Cost Savings – Instead of treating unsellable bread as waste, bakeries can monetise it by selling it to breweries or other industries.

  
  

• Sustainability Gains – Reducing food loss supports corporate sustainability goals and aligns with regulatory expectations.

  
  

• New Business Partnerships – Collaborations with breweries and other food producers can open new revenue streams and create innovative product lines.

  
  

• Brand Value – Consumers are increasingly drawn to brands that prioritise sustainability and responsible food production.

  
  

Expanding the Concept Beyond Brewing

While beer brewing is one promising application, surplus bread can be repurposed in various ways. Some bakeries have already explored using dried bread crumbs in new bakery products, while others have investigated fermentation processes to create new food ingredients. The key is to approach surplus bread as a resource rather than waste.

Looking Ahead: Opportunities for Industrial Bakeries

The success of Fazer’s initiative signals a broader shift in the industrial baking sector. As sustainability becomes a key driver of innovation, bakeries that adopt circular economy principles will not only reduce waste but also improve profitability. With increasing consumer awareness and tightening food waste regulations, now is the time for industrial bakers to explore how surplus bread can be transformed into a valuable asset.

By turning food waste into opportunity, industrial bakeries can lead the way in sustainable food production—while enhancing their bottom line.