Circular Egg: circular economy serving the poultry supply chain

Every year the Italian agribusiness industry generates millions of tons of vegetable by-products. If properly valorized, these wastes can become a useful resource to reduce waste and close production cycles. In parallel, there is growingscientific and industrial interest in the use of insects, particularly soldier fly(Hermetia illucens) larvae, as an alternative protein source. This approach allows agro-food residues to be recovered and integrated into an efficient and regenerative production model. The result is lower consumption of natural resources, more sustainable livestock farming and a truly circular supply chain.

A concrete example of integrating plant waste recovery with the use of insects as a sustainable protein source is the Circular Egg project. This is the result of a Piedmontese collaboration between Fantolino, a company with more than 50 years of experience in the production of quality fresh eggs, BEF Biosystems, a technical partner specializing in insect-applied biotechnology, and theUniversity of Gastronomic Sciences in Pollenzo.

Part of the NODES – Digital and Sustainable Northwest program, the project is a step toward transforming the traditional poultry supply chain into a regenerative model. Plant waste is used as a substrate for growing larvae, which then become food for laying hens. This closes the nutrient loop and results in an efficient, sustainable and replicable production system.

A circular model based on agro-industrial symbiosis and innovation

The initiative was developed over more than two years of research and experimentation, with phases of analysis, zootechnical experimentation, environmental evaluation and sensory testing of the final product.

Through collaboration with BEF Biosystems, the project implemented an agro-industrial symbiosis system, in which plant residues from the food industry, such as fruit, vegetable and grain waste, are transformed into protein biomass through controlled rearing of Hermetia illucens(black soldier fly) larvae.

Larvae, which are rich in high-quality protein and lipids, are incorporated into the diets of laying hens, partially replacing conventional plant protein sources such as soy. This approach reduces dependence on imported raw materials and CO₂ emissions associated with the production and transportation of conventional feed.

In addition, incorporating larvae into the diet also has positive effects on the welfare of the hens, making the diet more varied, natural and in line with the typical feeding behavior of the species. Each egg produced thus makes it possible to recover about 60 grams of plant by-products, turning them into a resource instead of intended for waste.

Acceptability and comparison with traditional eggs

Once the production phase was completed, theacceptability of the derived products was assessed, which depends on multiple factors, including socio-demographic characteristics, psychological and behavioral aspects of consumers, as well as perceptions of safety and quality. For this, an integrated and multidisciplinary approach was adopted, capable of analyzing both the production system and consumer choices, in order to promote the conscious adoption of “Circular Eggs.”

The project followed a structured experimental path, involving two research units of theUniversity of Gastronomic Sciences in Pollenzo (UNISG), coordinated by Prof. Luisa Torri and Prof. Franco Fassio. The main research activities on the one hand involved the evaluation of the circular business model and the stakeholders that can be involved, while on the other, consumer perception was studied through a questionnaire submitted to more than 400 participants, aimed at investigating knowledge, attitudes and propensity to purchase. Finally, comparative sensory tests between conventional and circular eggs analyzed parameters such as color, aroma, taste and texture, confirming the quality of the new product.

Achievements and future prospects

The results showed a significant reduction in organic waste along the supply chain and more efficient use of resources. In addition, the project demonstrated optimal reuse of by-products along the value chain, turning them into tangible value for the entire production cycle.

From a sensory point of view, Circular Eggs exhibit quality parameters equal to or better than those of conventional eggs, with a more intense yolk and harmonious texture, demonstrating the full nutritional and commercial compatibility of the circular model.

Thanks to the positive outcome of the research and the scientific validation of the process, the Circular Egg is now available on the market in more than 130 Esselunga stores in Lombardy and Piedmont. This is the first Italian example of industrial application of the circular economy in the poultry sector.

The project is therefore an important step toward a more responsible and innovative poultry supply chain, and Fantolino’s experience shows how agrifood waste can be transformed into resources, combining biotechnology, animal welfare, and supply chain innovation in a replicable and scalable model. In this regard, Fantolino will continue to invest in research to optimize each stage of the supply chain, including the use of broken egg shells as substrate for feeding larvae, with the goal of making the production cycle increasingly circular.

References

Cover photo by Fantolino