PhenOlives patented a process that allows leftover olives from the oil industry to be made into flour. This development has the potential to extend an olive branch to significant material waste in oil processing while providing a ‘super-flour’ with numerous benefits.
The yield of oil made from olives is around 10-30 %, depending on the type of olive and the process itself. This leaves most of the harvested olives as a by-product. When it is estimated that as much as 90 % of the olives go unused by oil producers, the potential of efficiently repurposing them is great. The materials can be still valuable, aside from turning them into compost or animal feed.
The olive waste can become a nutritious olive flour that is gluten-free, high in fibers, low in calories and rich in antioxidants. It also has a neutral taste, making it versatile for use in diverse applications, and, via the patented process developed by PhenOlives, it is not only sustainable but also affordable. “One of the key aspects of PhenOlives’ patented process is the ability to control the level of polyphenols in the olive flour, ensuring a balanced flavor profile that makes it suitable for a wide array of culinary applications. We optimize the polyphenol level at 2,000–4,000 ppm, which, based on trials and experience, effectively avoids any bitterness,” according to Chen Lev-Ari, CEO, PhenOlives.
All of the olive benefits, fewer of the product’s calories
As a key component of the Mediterranean diet, olives and olive oil have long been associated with well-being. Derived from upcycled by-products, olive flour has many functional benefits, thanks to its high-fiber content and gluten-free nature. “Rich in dietary fiber and polyphenols, olive flour supports digestive health and aligns with the growing demand for plant-based, health-conscious ingredients,” PhenOlives’ CEO highlights.
It provides a nutritious gluten-free option while retaining great product texture and flavor, and it can replace part of the carbohydrates in traditional flour-based products, the company observes. Combined with other traditional flour ingredients, olive flour can be used to create a variety of baked goods, with each product incorporating a different percentage of olive flour relative to the total amount of flour used: pasta (50 %), bread (20 %), crackers (100%), cookies (30 %), brownies (30 %), muffins (50 %), and pizza crust (50 %), the company illustrates.
“Rich in dietary fiber and polyphenols, olive flour supports digestive health and aligns with the growing demand for plant-based, health-conscious ingredients.”
Chen Lev-Ari, CEO, PhenOlives
The production process of the flour begins after the olive oil extraction ends. In this way, beneficial polyphenols (antioxidants) are preserved, while also significantly reducing the fat and calorie content. The flour is high in antioxidants, particularly polyphenols such as hydroxytyrosol and tyrosol. It is high in fiber, from the olive pulp, and low in fat and calories compared to whole olive or olive oil. It also contains minerals and trace elements from the olives.
Product inspiration
PhenOlives carried out tests on different types of products to test its feasibility and possible formulations: “When incorporated into baked goods and pasta, olive flour subtly enhances flavor at low percentages (up to 10%), while maintaining texture. At higher levels (up to 30%), it creates a denser, crumblier texture with a more pronounced olive taste, making it an ideal ingredient for bakers and food manufacturers looking to enhance nutritional value,” Lev-Ari explains. The company’s research found that the flour proved to be versatile – it is suitable for a range of baked goods, from bread, pasta and crackers, to cookies and muffins. So far, PhenOlives has successfully incorporated olive flour into a range of products, including pasta, bread, crackers, cookies, brownies, muffins, and pizza crusts, using varying percentages of the flour.
The flour is suitable for various bakeries, from home bakeries to those on an industrial scale. The company is working with local chefs in Israel and across Europe to develop a range of new recipes using olive flour, and has received excellent feedback from them on working with it, they reveal. While possible product claims may vary depending on local regulations, the benefits of using the flour have been thoroughly tested. From the caloric values of the products, to their dietary fiber contents and antioxidant properties.
The expertise it can provide includes a library of tested recipe formulations, and ongoing technical assistance. Product development workshops are also organized, to share best practices. “Importantly, we also provide nutritional analysis and comprehensive ingredient information, ensuring they have everything they need for accurate labeling and consumer transparency,” he points out.
The process
The technology developed by PhenOlives prevents the oxidation of olive mill pomace. The system automatically separates the three key components of olive waste: seeds, pulp, and black water, directly within olive oil mills through advanced mechanization, the company says. “Unlike traditional methods, this process does not require chemicals, making it a truly natural and eco-friendly innovation,” Lev-Ari highlights.
By preventing oxidation at its source, this technology can make use of virtually 100% of the waste that would otherwise require disposal. “This not only reduces pollution caused by burning or landfill disposal but also provides a sustainable alternative for waste management,” Lev-Ari underlines. It is not only an opportunity for bakers using the flour, but also for olive mills, which can convert waste into valuable products.
PhenOlives will collaborate with olive mills to source the materials: the company provides mills with a system that makes the by-products usable. Then, they buy these by-products and run them through their own systems to separate the three main components – seeds, pulp, and black water. The seeds are used for energy and other products in development, and the pulp is turned into olive flour. The research is ongoing: “And, we are currently researching new products based on the rich nutrients found in the black water, particularly the polyphenols, the company explains.
“With this system, every part of the olive is repurposed into commercial and nutritional products, reducing waste while increasing market value. Among these products, olive flour has become the flagship innovation. Unlike conventional flour sources, no additional olives need to be cultivated for its production—making it a sustainable and resource-efficient ingredient,” the specialist from PhenOlives observes.
The technology is a patented innovation in its home country of Israel and is in the final stages of patent approval in Europe. The company is collaborating with industry experts and can conduct pilot production trials in baking facilities to ensure a smooth integration, including sensory analysis and consumer testing to understand market feedback.
The company plans to install a number of PhenOlives systems in olive mills over the next few years, primarily in Europe. It anticipates that the first products with olive flour will be launched in 2026.
