A new approach to upcycling food processing biomass by creating rice snacks with a rice bran emulsifier

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Transforming Food Waste into Nutritious Snacks Food waste is a growing global issue, with approximately 1.3 billion tons of food wasted each year. This problem is especially severe in developed nations such as South Korea, Japan, and the United States, where more than 56% of food waste is generated.

In South Korea alone, agricultural and food waste has increased by 15.8% in just five years, costing the economy around 20 trillion KRW (approximately $15 billion USD). As the demand for sustainable food production rises, researchers are exploring innovative ways to reduce waste while improving nutrition.

A recent study published in Food Science and Biotechnology (2025) presents a promising solution by upcycling rice bran a highly nutritious but underutilized byproduct of rice milling—into a natural emulsifier for rice crackers.

The Rice Bran Paradox: Nutrient-Rich but Underutilized

Rice bran is a byproduct of the rice milling process, making up 10–20% of the total husk weight. Despite being packed with essential nutrients, it is often discarded or used for animal feed due to its rapid spoilage.

This wasted ingredient is rich in protein (12–18%), making it an excellent gluten-free option for people with dietary sensitivities.

Additionally, it contains 15–20% healthy fats, particularly unsaturated fatty acids like oleic acid, which promote heart health. Beyond its macronutrient content, rice bran is loaded with powerful antioxidants such as gamma-oryzanol and vitamin E, which help combat free radicals and support overall well-being.

It is also an excellent source of dietary fiber (up to 12%), which aids digestion and promotes gut health.Despite these impressive benefits, rice bran is rarely used in food products due to its high perishability. Enzymes such as lipase and lipoxygenase break down fats in the bran, leading to rancidity and discoloration within hours of milling.

Globally, the rice industry produces around 60 million tons of rice bran annually, yet most of it remains underutilized. Finding ways to stabilize and repurpose rice bran could significantly reduce waste while adding valuable nutrients to processed foods.

From Spoilage to Stability: Crafting a Natural Emulsifier

To transform rice bran into a useful emulsifier, the researchers developed a three-step process to stabilize and refine it into a fine powder, branded as Migang. The first step involved an alkaline extraction process, where raw rice bran was soaked in alkaline water (pH 6–10) at a temperature between 25–40°C.

This treatment effectively neutralized the spoilage enzymes, preventing rancidity and preserving the nutritional components of the bran. After soaking, the mixture was filtered through a 60-mesh screen to remove husk fragments and other impurities.Once filtered, the liquid extract underwent concentration and drying.

The researchers used a spray drying technique, which transformed the liquid into a fine powder while maintaining its emulsifying properties. This powder was then sieved through a 40–60 mesh screen to ensure consistency and uniformity.

The final step involved incorporating Migang into rice cracker formulations. The researchers compared its performance against traditional emulsifiers, including glycerin fatty acid esters, soy lecithin, and sucrose fatty acid esters.

They prepared the rice cracker dough using a combination of 55–75% rice flour, 8–15% potato starch, and 15–25% rice bran oil, with varying concentrations of Migang (0.1–2.0%) as the emulsifier. The crackers were then baked at 170–190°C for five minutes and analyzed for texture, moisture content, and oil retention.

Breakthrough Results: Comparing Rice Bran with Synthetic Emulsifiers

The study’s findings revealed that Migang performed better than synthetic emulsifiers in several key aspects. One of the most significant advantages was its moisture retention properties.

Crackers made with Migang maintained 9.2% moisture, which was higher than those made with glycerin esters (7.8%), sugar esters (6.5%), and soy lecithin (8.1%).

This improved moisture balance resulted in a perfect texture, making the crackers both crunchy and tender a crucial factor for consumer appeal.Additionally, Migang significantly reduced oil loss in the crackers.

Traditional emulsifiers often fail to prevent oil from leaking out during frying or baking, leading to an excessively greasy texture. However, Migang cut oil loss by 60%, keeping the crackers crisp without excessive fat content.

The research also found that Migang enhanced tensile strength, meaning that crackers made with this emulsifier were less likely to break or crumble. This is because Migang created a stronger, more uniform structure within the cracker dough.

Structural analysis using scanning electron microscopy (SEM) showed that Migang-based crackers had  thin, evenly distributed cell walls and a network of uniform air pockets, making them both durable and pleasantly crispy.

Another key advantage of Migang is its clean-label appeal. Unlike synthetic emulsifiers, which often contain chemical additives, Migang is all-natural, gluten-free, and hypoallergenic. This makes it an attractive alternative for consumers seeking healthier, additive-free snacks.

Economic and Environmental Impact

Beyond its impact on snack quality, Migang has significant economic and environmental benefits. The research suggests that upcycling just one ton of rice bran into emulsifiers could repurpose 10–20% of global rice milling waste.

Given that South Korea alone produces 500,000 tons of rice bran annually, diverting even 10% of this waste into food production could save 50,000 tons from landfills.

From an economic standpoint, rice bran is an inexpensive raw material that is often discarded.Utilizing it in food production can lower ingredient costs while providing manufacturers with a sustainable alternative to synthetic emulsifiers.

The global emulsifier market, currently valued at $8.9 billion (2023), presents a lucrative opportunity for rice bran-based emulsifiers like Migang to capture a 5–10% market share by 2030.

Limitations and Future Directions

Despite these promising results, the study acknowledges a few limitations. One challenge is scaling Migang for mass production. While it performed well in lab tests, further research is needed to determine whether it can be consistently produced on an industrial scale.

• Additionally, the study used rice bran from a single South Korean factory, meaning results might vary depending on different rice varieties.
• Another consideration is cost efficiency while rice bran is inexpensive, the spray-drying process requires energy, which could affect overall production costs.

Future research should explore how Migang can be used in other food products beyond crackers. Its emulsifying properties make it a promising ingredient for bread, cookies, and plant-based meat substitutes.

Testing in Real Snacks

The team used this rice bran powder to make rice crackers, comparing it against common synthetic additives. The results were impressive.

Crackers made with rice bran kept their moisture better (9.2% vs 7.8% in others), stayed less greasy (60% less oil loss), and were significantly stronger (20% more durable). These improvements mean better texture, longer shelf life, and fewer broken crackers during shipping.

Why Rice Bran Works So Well

Advanced microscope images showed that rice bran creates a more even structure in snacks, with thin, consistent walls and perfectly spaced air pockets. This ideal architecture explains why the crackers stay crisp yet tender, and why they hold together so well.

Chemical analysis confirmed that rice bran distributes evenly throughout the dough, something synthetic additives struggle to do as effectively.

Conclusion:

The development of Migang represents a significant breakthrough in sustainable food science. By repurposing nutrient-rich rice bran, researchers have created an ingredient that not only enhances snack quality but also helps reduce global food waste.

With the potential to lower reliance on synthetic additives, improve food texture, and support the clean-label movement, rice bran emulsifiers could revolutionize the snack food industry.

If just 30% of the world’s rice bran were upcycled into food ingredients, it could prevent 18 million tons of waste annually while reducing synthetic emulsifier use by 1.5 million tons.