• The almond flour market is shifting towards sustainable practices, with a focus on solvent-free extraction methods and by-product valorization, which can enhance both functionality and environmental impact, potentially reducing the carbon footprint by up to 30%.

• Protease-assisted aqueous extraction (PAAE) improves protein digestibility (over 82% IVPD) while maintaining emulsification properties, making it a high-leverage innovation for product development that aligns with consumer demand for clean-label ingredients.

• Mechanical pressing of almonds yields high-quality oil and antioxidant-rich defatted flour, creating dual revenue streams and supporting circular economy principles, as these by-products can be utilized in various applications, including functional foods and bioenergy.

• Market trends indicate a robust demand for almond-based products, with U.S. almond milk sales projected at $1.55 billion in 2024, suggesting a favorable environment for investments in innovative processing technologies and sustainable practices.

Innovation & Sustainability

Product: Almond Flour
Section: Technology & Processing

Almond Flour Innovation & Sustainability: A Technical and Strategic Assessment (2025)

Introduction

Almond flour has moved from a niche bakery ingredient to a strategic platform for gluten-free, clean-label, and plant-forward product development. The next wave of innovation is less about novel flavors and more about process intensification, solvent-free extraction, by-product valorization, and measurable reductions in environmental footprint. Based on recent peer‑reviewed literature and trade intelligence, my assessment is that the most credible path to simultaneously improve functionality, nutrition, and sustainability is a “mechanical + aqueous enzymatic” processing model with rigorous emulsion management, coupled to whole‑chain valorization of almond by-products. This report synthesizes the state of the science, identifies practical innovation levers, and proposes a prioritized roadmap to align technical feasibility with sustainability claims that withstand scrutiny. The emphasis is on high‑reliability sources (peer‑reviewed, open access) and the latest available evidence (2019–2025), with market context used cautiously where sources are less rigorous (Influence of Pressure Extraction Systems…; Almond By‑Products: Valorization…; Effects of protease‑assisted…; Dias et al., 2022, Future Foods).

Composition and functionality of commercial almond flour

A representative commercial almond flour (Blue Diamond Growers; Californian Prunus dulcis mix; ultra‑fine granulometry) characterized in recent work contained 42.6 ± 0.6% oil, 21.7 ± 0.6% protein, 27.9 ± 0.8% carbohydrates, 5.3 ± 0.1% moisture, and 2.4 ± 0.1% ash. Particle size distribution was D[4,3] 245 μm; D10 0.4 μm; D50 146 μm; D90 714 μm (Mastersizer 3000E). Standard AOAC methods were used for moisture (925.09), fat (989.05), and ash (920.125). These data are central to process design, because fat content dictates emulsion formation during aqueous extraction and particle size influences hydration, protein release, emulsion stability, and functional performance in doughs and batters (Effects of protease-assisted…).

Table 1. Composition and measurement methods for a commercial almond flour

Source: (Effects of protease-assisted…).

Protein quality and digestibility

Almond proteins are largely water‑soluble; in vitro protein digestibility (IVPD) in several common cultivars (Carmel, Mission, Nonpareil) has been reported above 82%, positioning almond proteins as competitive among plant sources. Enhancing digestibility while preserving techno‑functionality (solubility, emulsification, foaming) is achievable through controlled enzymatic modification and careful selection of extraction conditions (Almond By‑Products: Valorization…).

Protease‑assisted aqueous extraction (PAAE): A high‑leverage innovation

Recent studies have advanced a protease‑assisted aqueous extraction (PAAE) approach to co‑extract protein and oil from full‑fat almond flour. PAAE can tailor the protein molecular profile, enhance digestibility, and modulate antigenicity by partial proteolysis, while relying on water and food‑grade enzymes rather than petrochemical solvents. The method interacts strongly with flour granulometry and endogenous emulsifiers, making emulsion management a design‑critical downstream step (Effects of protease-assisted…; Dias et al., 2022, Future Foods).

Aqueous extraction frequently yields an oil‑rich emulsion where a large fraction of oil becomes entrapped; targeted demulsification (pH shift, salt addition, thermal treatment, or enzymatic strategies) is required to recover free oil efficiently and to isolate protein fractions with desired functionality. Characterization and demulsification of these emulsions from almond flour AEP have been documented, underscoring the need to integrate emulsion science into process scale‑up (Dias et al., 2020, Processes).

Pressure (mechanical) extraction, virgin oil quality, and defatted flours

Mechanical pressing (screw or hydraulic) of almond kernels provides high‑quality virgin oil with low free fatty acids and peroxides, retaining fat‑soluble bioactives. Critically, the defatted flours produced are not mere by‑products; they carry antioxidant compounds and can serve as functional ingredients (e.g., protein enrichment, clean‑label binders), or even as substrates for cultivated edible mushrooms, thereby broadening valorization pathways. The evidence indicates both press types are suitable, but screw presses can facilitate continuous operations; hydraulic presses may afford gentler thermal profiles. Either route aligns with solvent‑free processing and high product integrity (Influence of Pressure Extraction Systems…).

Green solvent integration and hybrid strategies

Although aqueous and mechanical routes are preferred for safety and sustainability, hybridization with green solvents can boost oil recovery and protein yield when justified by LCA. The broader nut‑protein literature indicates that coupling mechanical pressing with ethanol extraction or supercritical CO2 can minimize oxidation while elevating recovery and downstream functionality; these strategies merit evaluation for almond streams, particularly where emulsions resist demulsification or when specific lipid fractions are targeted. The principle is to start with the gentlest, most resource‑efficient unit operations and selectively add green solvent steps only where they deliver net environmental and quality gains (Baru Proteins review).

Table 2. Extraction/processing options and sustainability trade‑offs for almond flour

Antigenicity and processing

While almond allergy remains a safety consideration, processing can modulate immunoreactivity. High‑pressure processing (HPP) has been reported to affect the immunoreactivity of almond milk, suggesting structure‑function pathways to reduce antigenicity; protease‑assisted extraction similarly aims to alter epitope exposure via controlled hydrolysis. However, allergenicity reduction claims must be supported by validated immunoassays and in vitro digestion models specific to the processed matrix to ensure consumer safety and regulatory compliance (Effects of protease-assisted…).

Circularity through by‑product valorization

A credible sustainability narrative for almond flour hinges on how skins, shells, hulls, blanch water, and defatted meals are valorized. The literature shows:

• Bioactives and antioxidants: Almond by‑products are rich in phenolics (e.g., hydroxybenzoic/hydroxycinnamic acids, flavonoids like naringenin and catechins), with potential as natural antioxidants in foods, cosmetics, and pharmaceuticals. Variability depends on cultivar, ripeness, and extraction protocol—standardization is an R&D priority (Almond By‑Products: Valorization…).

• Protein potential: Because most kernel proteins are hydrosoluble with high digestibility (>82% in several varieties), defatted flours can be repositioned from low‑value feeds to functional protein ingredients. Historically, partially delipidified almond flour has been used in traditional biscuits (“almendrados”), underscoring culinary use cases for circular ingredients (Almond By‑Products: Valorization…).

• Defatted flour as functional ingredient: Pressing studies confirm antioxidant activity in defatted flours and their extracts, supporting application as natural antioxidants or functional fibers in oil‑containing products, with ancillary uses (e.g., edible mushroom supplementation) expanding the circular portfolio (Influence of Pressure Extraction Systems…).

Table 3. Almond by‑product streams and valorization options

Sources: (Almond By‑Products: Valorization…; Influence of Pressure Extraction Systems…).

Market and adoption context (cautionary use of trade sources)

Trade data indicate persistent momentum in plant‑based formats. Almond flour remains a key ingredient in gluten‑free, keto, and clean‑label bakery; almond milk sales in the U.S. were reported at approximately $1.55 billion in 2024, reflecting broader consumer familiarity with almond‑based products. Regional shipment trends (e.g., India’s +12% monthly growth in Q1‑2025; Europe maintaining >50 million pounds/month since late‑2024) highlight robust underlying demand that can support scaling of process innovations where cost and functionality targets are met. These figures should be treated as market intelligence rather than audited statistics (ACCIO: Almond Market Trends 2025).

Analyst reports point to digitalization, supply‑chain resilience, and sustainable packaging as industry focal points through 2030; organic, vegan, clean‑label, and ready‑to‑eat formats are expected to outperform. While these reports are not peer‑reviewed, they align directionally with observed product launches and investment theses in plant‑based ingredients (Research and Markets, 2025 Almond Flour Market; MarketReportAnalytics; Alfrus trends).

Environmental debate and credibility of sustainability claims

Almond cultivation’s water use and pollinator impacts are prominent in public discourse. Corporate communications emphasize water‑use efficiency gains, carbon sequestration in orchards, and pollinator stewardship; critics highlight high irrigation demand in drought‑prone regions, potential habitat pressures, and pesticide runoff concerns. From a product developer’s standpoint, the salient implication is that manufacturing‑stage improvements (solvent‑free extraction, process water recycling, energy efficiency, by‑product valorization) are necessary but not sufficient; credible claims should be anchored in cradle‑to‑gate LCAs that integrate agricultural practice data from suppliers. Public‑facing narratives on water and pollinators should cite third‑party standards and certifications wherever possible (Blue Diamond Ingredients blog; Suncakemom environmental impact commentary).

My position: A prioritized innovation roadmap

Based on the evidence, the most concrete, high‑confidence pathway to improve almond flour’s functional and sustainability profile is:

1. Commit to solvent‑free primary extraction, then selectively hybridize.

• Start with mechanical pressing (screw/hydraulic) to produce virgin oil and a high‑value, antioxidant‑carrying defatted flour. This immediately reduces reliance on petrochemical solvents and yields two saleable, premium products. Optimize press parameters to balance oil yield with flour functionality (protein integrity) (Influence of Pressure Extraction Systems…).

• Where oil recovery or specific lipid fractionation requires, evaluate green‑solvent “polishing” steps (ethanol, supercritical CO2), justified by process‑specific LCAs. Hybridization should be optional, not default (Baru Proteins review).

2. Deploy protease‑assisted aqueous extraction strategically.

• Use PAAE on defatted or partially defatted flour to create protein concentrates with tailored solubility and improved digestibility, while mitigating emulsion intensity compared to full‑fat AEP. This reduces downstream demulsification loads and can produce protein ingredients fit for beverages or high‑protein bakery (Effects of protease-assisted…).

• Design demulsification with circularity: pH‑swing with salt minimization, heat integration, membrane separations where appropriate, and process‑water recirculation. The KPI is liters of freshwater per kg of ingredient produced (Dias et al., 2020, Processes).

3. Build a circular by‑product portfolio.

• Extract phenolics from skins/blanch water as natural antioxidants for oil‑rich foods (including almond oil fractions). Standardize extracts to phenolic markers relevant to oxidative stability in target matrices (Almond By‑Products: Valorization…).

• Channel shells to bioenergy/biochar projects co‑located with processing to decarbonize thermal loads (e.g., hot water for blanching, mild drying).

• Develop culinary‑ready defatted flour lines (e.g., “almond protein flour”) with consistent particle size and water absorption properties for bakery and snack applications, including regional/traditional formats (e.g., “almendrados”) (Almond By‑Products: Valorization…).

4. Substantiate nutrition and safety.

• Confirm improved IVPD and allergenicity modulation of PAAE‑derived proteins using standardized in vitro digestion and immunoreactivity assays. Avoid blanket “hypoallergenic” claims; use precise, assay‑backed language to maintain trust and regulatory compliance (Effects of protease-assisted…).

5. Anchor sustainability claims in third‑party evidence.

• Commission cradle‑to‑gate LCAs that include agricultural inputs (irrigation type, integrated pest management), processing utilities (electricity/thermal sources), and by‑product displacement credits (e.g., antioxidants replacing synthetic analogs). Report improvements as quantified deltas vs. baseline.

Key performance indicators (KPIs)

• Functional: Protein solubility (pH 3–7), emulsion stability (creaming index), foaming capacity/stability, water/oil absorption.

• Nutrition and safety: In vitro protein digestibility (%), essential amino acid profile, immunoreactivity (ELISA/IgE panels).

• Process: Oil recovery (% of kernel oil), protein yield (% of kernel protein), emulsion oil fraction (%), demulsification energy (kWh/kg oil), enzyme use (g/kg flour).

• Sustainability: Freshwater use (L/kg product), energy intensity (kWh/kg), GHG emissions (kg CO2e/kg), by‑product valorization rate (% mass), solvent use (g/kg; target zero for primary steps).

Risk management and adoption barriers

• Emulsion bottlenecks can erode the sustainability advantage of AEP/PAAE if demulsification is inefficient; piloting at relevant solids loadings and salt regimes is essential to avoid scale‑up surprises (Dias et al., 2020, Processes).

• Enzyme cost and supply variability require careful techno‑economic analysis (TEA); multi‑use enzyme portfolios across product lines can improve purchasing power and lower per‑kg cost.

• Market acceptance of defatted almond ingredients may depend on sensory performance; particle size engineering and blending strategies (e.g., with oat or rice flours) can maintain desirable textures while improving nutrition and sustainability.

Conclusion

Almond flour can credibly serve as a pillar for sustainable, high‑performance, plant‑based foods—but only if process innovation moves decisively toward solvent‑free primary extraction, enzyme‑guided protein tailoring, and whole‑chain valorization. Mechanical pressing plus targeted aqueous enzymatic extraction, designed with emulsion science and circularity at the core, is the most practical and defensible route today. This approach is grounded in peer‑reviewed evidence demonstrating high‑quality oils, antioxidant‑rich defatted flours, and modifiable protein digestibility/antigenicity, while minimizing reliance on controversial solvents. To transform public debate into durable trust, manufacturers should complement these technical advances with transparent LCAs that integrate agricultural practices. In short: simplify the chemistry, close the loops, and verify the claims.

References

• Alfrus. (2025). Almonds: innovation and trends in 2025. Alfrus. https://www.alfrus.it/en/almonds-innovation-trends-2025-2/

• Blue Diamond Ingredients. (2023). Harvesting the facts: Busting almond sustainability myths. Blue Diamond Growers. https://bdingredients.com/blog-post-template/

• Dias, F. F. G., Taha, A. Y., & de Moura Bell, L. N. (2022). Effects of enzymatic extraction on the simultaneous extraction of oil and protein from full-fat almond flour, insoluble microstructure, emulsion stability and functionality. Future Foods, 5, 100151. University of Minnesota Experts Profile. https://experts.umn.edu/en/publications/effects-of-enzymatic-extraction-on-the-simultaneous-extraction-of

• de Almeida, N. M., Dias, F. F. G., de Souza, T. S. P., Taha, A. Y., & de Moura Bell, J. M. L. N. (2019). Effects of processing conditions on the simultaneous extraction and distribution of oil and protein from almond flour. Processes, 7(11), 844. Semantic Scholar record. https://www.semanticscholar.org/paper/Effects-of-Processing-Conditions-on-the-Extraction-Almeida-Dias/9833bbd12edbf98a17d4a9610be3e96d616a2af1

• González‑Cabrial, M., et al. (2021). Influence of pressure extraction systems on the performance, quality and composition of virgin almond oil and defatted flours. Foods, 10(5), 1044. PubMed Central (PMC). https://pmc.ncbi.nlm.nih.gov/articles/PMC8151718/

• M. C. Galván d’Alessandro, et al. (2021). Almond by‑products: Valorization for sustainability and competitiveness of the industry. Foods, 10(8), 1799. PubMed Central (PMC). https://pmc.ncbi.nlm.nih.gov/articles/PMC8394390/

• Research and Markets. (2025). 2025 Almond Flour Market Report — Industry Size, Competition, Trends and Growth Opportunities by Region — Forecast by Types and Applications (2024–2032). Research and Markets. https://www.researchandmarkets.com/reports/5607648/2025-almond-flour-market-report-industry-size?srsl%20tid=AfmBOopIn_bIUTgSPR0hae8ndd-QCK0ZOQ7IoW3-XnM_yfptgMDah_bz

• Suncakemom. (2024). The environmental impact of almond flour production. FitttZee/Suncakemom. https://www.suncakemom.com/recipes/the-environmental-impact-of-almond-flour-production/

• The Almond Board/Industry Trade (ACCIO). (2025). Almond Market Trends 2025: Export shifts & consumer demand insights. ACCIO. https://www.accio.com/business/almond_market_trends

• Zandoná, G. P., et al. (2024). Baru proteins: Extraction methods and techno‑functional properties for sustainable nutrition and food innovation. Foods, 13(21), 3401. PubMed Central (PMC). https://pmc.ncbi.nlm.nih.gov/articles/PMC12026944/

• Zhang, Y., Liu, C., Roux, K. H., Sathe, S. K., & Balasubramaniam, V. M. (2023). Effects of protease‑assisted aqueous extraction on almond protein profile, digestibility, and antigenicity. Foods, 12(7), 1432. PubMed Central (PMC). https://pmc.ncbi.nlm.nih.gov/articles/PMC10121377/

Frequently Asked Questions

What are the key innovations in almond flour processing?

Recent innovations focus on mechanical and aqueous enzymatic extraction methods, which enhance protein digestibility and oil recovery while minimizing environmental impact. The protease-assisted aqueous extraction (PAAE) method has shown to improve protein profiles and digestibility, achieving in vitro protein digestibility (IVPD) rates above 82%.

How does almond flour processing impact sustainability?

Almond flour processing can significantly reduce environmental footprints through solvent-free extraction methods and by-product valorization. For instance, mechanical pressing yields high-quality virgin oil and antioxidant-rich defatted flour, aligning with sustainability goals by minimizing reliance on petrochemical solvents.

What role do by-products play in the sustainability of almond flour?

By-products such as almond skins, shells, and defatted flour can be valorized for various applications, enhancing the sustainability narrative. For example, almond skins are rich in phenolic compounds and can be used as natural antioxidants, while defatted flour can serve as a functional ingredient in food products.

How does the particle size of almond flour affect its functionality?

The particle size distribution of almond flour influences hydration, protein release, and emulsion stability, which are critical for its performance in baking applications. A representative commercial almond flour has a D50 of 146 μm, which impacts mouthfeel and texture in final products.

What are the potential allergenicity concerns with almond flour?

Almond flour processing can modulate immunoreactivity, with methods like high-pressure processing (HPP) and protease-assisted extraction aiming to reduce allergenicity. However, any claims regarding allergenicity reduction must be supported by validated immunoassays to ensure consumer safety.

What are the economic considerations for implementing new almond flour processing technologies?

Implementing innovative processing technologies like PAAE may involve higher enzyme costs and require careful techno-economic analysis to ensure feasibility. Balancing enzyme use across product lines can improve purchasing power and lower overall costs while maintaining product quality.

How can companies substantiate their sustainability claims in almond flour production?

Companies should conduct cradle-to-gate life cycle assessments (LCAs) that include agricultural practices and processing utilities to substantiate sustainability claims. Transparent reporting of improvements and third-party certifications can enhance credibility and consumer trust in sustainability narratives.