USE OF THE SUBPRODUCTS FOR THEIR INCORPORATION INTO THE PRODUCTION PROCESS

Company and project background

La Vendita is a company specialising in the organic cultivation and processing of Aloe vera, located in a rural environment and committed to sustainable agricultural practices. Our main products include Aloe vera gel and juice, as well as natural cosmetic formulations. In line with our vision of integral use of resources, we decided to tackle one of the main challenges of our activity: the generation of vegetable by-products that, until now, were discarded as waste.
In this context, we developed the USEALOE project within the European Up2Circ call for proposals, with the aim of recovering Aloe vera by-products -inflorescences, plantlets and leaf peels- and incorporating them back into the production process. This allows us to reuse the waste generated by developing new product lines such as infusions with Aloe vera flowers, cosmetic gels from young shoots and functional powder obtained from the peels.

What motivated you to make your business more circular?

The main motivation for moving towards a more circular model at La Vendita was the need to reduce the environmental impact associated with the generation of plant by-products, especially Aloe vera inflorescences, shoots and peels. The external treatment of this waste not only entailed a high logistical and economic cost, but also a significant impact on CO₂ emissions, as it had to be transported to a composting plant 30 km away. This represented a clear inefficiency in the use of our own natural resources.

Implementation Process

What were the objectives of your project?

The USEALOE project was conceived with the main objective of reducing the volume of by-products generated in the cultivation and processing of Aloe vera, reincorporating them into the production process by recovering them as new raw materials. This was translated into a quantifiable goal: to reuse at least 90% of the by-products generated annually (equivalent to more than 386,000 kg/year), avoiding their disposal as waste and transforming them into value-added products.

What activities did you carry out as part of your project?

The USEALOE project was developed through a series of activities. We started with the management and coordination of the project, establishing multidisciplinary teams and performance indicators. Subsequently, physicochemical and functional analyses of the by-products -inflorescences, hyacinths and peels- were carried out in collaboration with CICYTEX, which allowed us to determine their content in bioactive compounds and define their potential applications in food, cosmetics and nutraceuticals.

This was followed by the development and prototyping of the products, integrating the by-products. During this phase, laboratory tests were carried out to assess the stability, safety and functionality of each product, as well as organoleptic studies to ensure market acceptance. Specialised equipment, such as drying ovens, was also purchased to guarantee the quality and stability of the new raw materials.

What feedback did you receive from stakeholders (customers, suppliers etc.)?

We received positive and constructive feedback from various stakeholders.  In particular, customers and end consumers favourably valued the introduction of more sustainable products, especially the Aloe vera infusions with flowers, for their innovative character and their alignment with ecological and proximity consumption trends. Transparency in the traceability of ingredients and the narrative associated with the integral use of the plant were highlighted.

Impact & Outcomes

What are the main results and outcomes of the project for your company?

The USEALOE project has allowed La Vendita to reduce 90% of the by-products generated during the cultivation and processing of Aloe vera, increasing by 50% the efficiency in the use of raw materials. This resulted in lower logistical costs by avoiding the transport of waste, and in the creation of new product lines such as infusions, gels and functional powders, which has improved our position in the organic products market.

Did you detect a positive impact of circular transition for your company and for the environment?

Yes, the circular transition driven by the USEALOE project has had a positive impact on both La Vendita and the environment. At the corporate level, we have improved production efficiency by 50% thanks to the reuse of by-products that were previously discarded, optimizing the use of raw materials and reducing logistics costs. In environmental terms, we have avoided the emission of approximately CO₂ by eliminating the transportation of waste.  In addition, 90% of the total volume of by-products generated can now be reused.

Which changes have you already implemented?

As a result of the USEALOE project, at La Vendita we have incorporated the harvesting and processing of Aloe vera inflorescences, shoots and peels as a regular part of the process. These by-products are already used in the manufacture of infusions and gels, which are part of the active commercial catalog. In addition, specific drying and processing equipment has been purchased and installed to stabilize these ingredients.

Lessons learned

What key lessons did you learn regarding circular innovation?

One of the main lessons learned in the USEALOE project is that circular innovation requires a systemic vision and cross-departmental coordination. A good technical idea is not enough; it is essential to integrate all areas. We have also found that, to ensure feasibility, it is essential to conduct a thorough characterization of the by-products and anticipate potential regulatory and technical challenges.

Did you encounter any challenges?

During the implementation of the USEALOE project we faced several challenges, mainly of a technical and operational nature. One of the most relevant was the detection of high levels of aloin, which represented a risk to the safety of the final product. To solve this, we incorporated an active carbon filtration system. This process involved an investment of time and resources not initially foreseen.

If you could do your project again, what would you do differently?

If we had the opportunity to repeat the USEALOE project, we would start earlier with the technical-functional characterization of the by-products, as this phase was more complex and lengthy than expected.
We would also dedicate more initial time to assess the real needs for equipment and personnel, in order to avoid budget deviations.

Future plans & recommendations

What are your next steps towards circular transition? (Which partners would you like to team up with/collaborate)?

We are working on expanding our energy infrastructure by installing new solar panels, with the aim of further reducing the carbon footprint of our processes and moving towards a model of sustainable energy self-consumption.
In parallel, and in collaboration with technological centers, we want to open a new line of research focused on the valorization of aloin, a compound present in Aloe vera peels that we eliminate for safety reasons in our formulations, but which has a high pharmaceutical potential. This initiative will allow us to transform a critical waste into a new opportunity to generate value in the biopharmaceutical sector.

Is there any advice you would give to other SMEs looking to implement a circular project?

For other SMEs wishing to implement a circular economy project, we would advise them to start with an internal audit of waste or by-products to identify which raw material streams are not being used and what potential they have.
We recommend starting with small-scale validation of processes and products before making larger investments. The circular economy offers great opportunities, but requires a systemic vision, rigorous planning and flexibility to adapt to technical and market challenges.

How can policymakers or financial institutions better support businesses in adopting circular practices?

From our experience with the USEALOE project, access to specific grants for innovation in circular economy has been key, but it would be very useful to expand the funds available for later stages of industrial scale-up, where the highest costs are usually concentrated.