The tomato processing industry can be considered one of the most widespread food manufacturing industries all over the world, annually generating considerable quantities of residue and determining disposal issues associated not only with the wasting of invaluable resources but also with the rise of significant environmental burdens. In this regard, previous studies have widely ascertained that tomato by-products are still rich in valuable compounds, which, once recovered, could be utilized in different industrial sectors. Currently, conventional solvent extraction is the most widely used method for the recovery of these compounds from tomato pomace. Nevertheless, several well-known drawbacks derive from this process, including the use of large quantities of solvents and the difficulties of utilizing the residual biomass. To overcome these limitations, the recent advances in extraction techniques, including the modification of the process configuration and the use of complementary novel methods to modify or destroy vegetable cells, have greatly and effectively influenced the recovery of different compounds from plant matrices. This review contributes a comprehensive overview on the valorization of tomato processing by-products with a specific focus on the use of “green technologies”, including high-pressure homogenization (HPH), pulsed electric fields (PEF), supercritical fluid (SFE-CO₂), ultrasounds (UAE), and microwaves (MAE), suitable to enhancing the extractability of target compounds while reducing the solvent requirement and shortening the extraction time. The effects of conventional processes and the application of green technologies are critically analyzed, and their effectiveness on the recovery of lycopene, polyphenols, cutin, pectin, oil, and proteins from tomato residues is discussed, focusing on their strengths, drawbacks, and critical factors that contribute to maximizing the extraction yields of the target compounds. Moreover, to follow the “near zero discharge concept”, the utilization of a cascade approach to recover different valuable compounds and the exploitation of the residual biomass for biogas generation are also pointed out.

This study evaluates the feasibility of integrating pulsed electric field (PEF) technology with heat recovery for fruit juice pasteurization, comparing it to conventional high-temperature short-time (HTST) pasteurization. Three preheating temperature conditions (35 °C, 45 °C, and 55 °C) and varying heat recovery efficiencies have been assessed to analyze energy consumption, economic feasibility, and environmental impact. The results indicate that, while PEF pasteurization requires a higher initial investment, it improves energy efficiency, leading to significant reductions in utility costs. Across the tested configurations, PEF technology achieved reductions in electricity consumption by up to 20%, fuel gas usage by over 60%, greenhouse gas emissions by approximately 30%, and water consumption by 25%, compared to HTST. The optimal configuration of the PEF process, featuring a 35% waste heat recovery efficiency and a pre-heating temperature of 55 °C, has been identified as the most energy-efficient and sustainable solution, effectively reducing both water consumption and CO₂ emissions. A life cycle assessment has confirmed these environmental benefits, demonstrating reductions in global warming potential, fossil fuel consumption, and other impact categories. This study suggests that PEF technology can significantly contribute to more sustainable food processing by reducing environmental impacts, optimizing resource usage, and enhancing energy efficiency.

Microalgae are a promising source of valuable compounds, including proteins, pigments, lipids, vitamins, and ingredients for cosmetics and animal feed. Despite their potential, downstream processing remains a major bottleneck in microalgae biorefineries, particularly in achieving high extraction efficiency with low energy and chemical input. While several extraction methods exist, few balance efficiency with selectivity and sustainability. Recently, mild and selective techniques such as Pulsed Electric Field (PEF) and Enzymatic Hydrolysis (EH) have gained attention, both individually and in combination. This review provides the first comprehensive comparative analysis of PEF and EH, emphasizing their mechanisms of action, specific cellular targets, and potential for integration into a cascaded, wet-route biorefinery process. Studies involving PEF, EH, and their sequential application (PEF-EH and EH-PEF) are analyzed, focusing on microalgae species, operational conditions, and extraction yields. The advantages and challenges of each method, including compound selectivity, environmental impact, and economic feasibility, are critically evaluated. The goal is to gain insight into whether the synergistic use of PEF and EH can enhance the recovery of intracellular compounds while improving the overall sustainability and efficiency of microalgae-based bioprocessing.

Peeling is a key step in the industrial production of canned peeled tomatoes, vital for optimizing efficiency, yield, product quality, waste reduction, and environmental impact. This study presents a comparative assessment of the economic and environmental impacts of adopting innovative peeling technologies, including infrared (IR), ohmic heating-assisted lye (OH-lye), and ultrasound-assisted lye (US-lye) peeling, relative to conventional steam and lye peeling methods. Focusing on a medium-sized Italian tomato processor, the impacts of these methods on productivity, water and energy consumption, wastewater generation, and environmental footprint using Life Cycle Assessment (LCA) methodology, were evaluated. Findings indicated that adopting IR, OH-lye, and US-lye methods enhanced peelability (ease of peeling > 4.5) and increased production capacity by 2.6–9.2%, while reducing solid waste by 16–52% compared to conventional steam and lye methods. LCA results showed IR as the most environmentally favorable method, followed by steam, OH-lye, and US-lye, with conventional lye peeling being the least sustainable. OH-lye and IR methods also significantly reduce water and energy use, while US-lye shows higher demands in these areas. Additionally, OH-lye and IR methods require little or no NaOH, minimizing chemical consumption and wastewater production, which offers notable environmental and cost advantages. Overall, this preliminary study underscores economic and environmental potential for novel peeling technologies, encouraging industry consideration for adoption.

This study primarily aimed to enhance the extraction of cutin from industrial tomato peel residues. Initially, the conventional extraction process was optimized using response surface methodology (RSM). Subsequently, high-pressure homogenization (HPH) was introduced to improve extraction efficiency and sustainability. The optimization process focused on determining the optimal conditions for conventional extraction via chemical hydrolysis, including temperature (100–130 °C), time (15–120 min), and NaOH concentration (1–3%). The optimized conditions, determined as 130 °C, 120 min, and 3% NaOH solution, yielded a maximum cutin extraction of 32.5%. Furthermore, the results indicated that applying HPH pre-treatment to tomato peels before alkaline hydrolysis significantly increased the cutin extraction yield, reaching 46.1%. This represents an approximately 42% increase compared to the conventional process. Importantly, HPH pre-treatment enabled cutin extraction under milder conditions using a 2% NaOH solution, reducing NaOH usage by 33%, while still achieving a substantial cutin yield of 45.6%. FT-IR analysis confirmed that cutin obtained via both conventional and HPH-assisted extraction exhibited similar chemical structures, indicating that the main chemical groups and structure of cutin remained unaltered by HPH treatment. Furthermore, cutin extracts from both conventional and HPH-assisted extraction demonstrated thermal stability up to approximately 200 °C, with less than 5% weight loss according to TGA analysis. These findings underscore the potential of HPH technology to significantly enhance cutin extraction yield from tomato peel residues while utilizing milder chemical hydrolysis conditions, thereby promoting a more sustainable and efficient cutin extraction process.

Background: The tomato processing industry is a vital sector, with tomatoes being the primary vegetable for industrial transformation. To individuate potential actions to make the tomato processing industry more sustainable, a Life Cycle Assessment (LCA) was conducted for an Italian tomato processing company located in southern Italy. Methods: Foreground data were collected from the company, while background data were sourced from the Ecoinvent database. The assessment employed the CML-IA baseline (V3.5) method for midpoints and IMPACT 2002+ for endpoints. Results: The research revealed that a can of peeled tomatoes (400 g) and a bottle of tomato puree (500 g) were responsible for global warming potential (GWP) of 0.666 kg CO₂eq and 0.479 kg CO₂eq, respectively. The packaging phase is the primary contributor to adverse environmental effects and has been considered as the primary focus for improvement. The end-of-life (EoL) scenarios demonstrated that recycling packaging materials could significantly reduce CO₂ emissions by 46% and 48% for metal and glass packaging, respectively. Conclusions: Moreover, the replacement of tinplate cans with glass jars as alternative packaging materials for peeled tomatoes, and glass bottles with carton-based containers or stand-up pouches as alternative packaging materials for tomato puree emerged as more environmentally friendly options across various environmental impact categories.