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From Shell to Spread: Game Changer for Nut Spreads

RE-NUT AG | November 26, 2025

What we’re talking about

At RE-NUT®, we don’t just make almond milk. We transform the whole nut, shell included, into high‑value ingredients. One of the most exciting is our in‑shell almond flour, which captures the full nutritional and structural potential of the almond (shell + kernel). And it’s not just for baking or milks, this flour is uniquely suited for nut spreads, butters and creams. Here’s why forward‑thinking food manufacturers should pay attention.

How Nut Spreads are Typically Made

Nut harvesting and shelling / hulling
- Nuts are harvested, then shelled (or hulled) to remove the hard outer shell / hull using mechanical crackers, rollers, blowers, destoners, magnets and sorting systems.
- For almonds and many tree nuts, the shell (or hull) is discarded (or used for low‑value byproducts like feed, bedding or bioenergy).
Dry‑roasting (or sometimes blanching / peeling)
- Shelled nuts are typically dry‑roasted in large ovens (batch or continuous), which develops flavor, aroma and the characteristic “nutty” notes.
- For some nuts (especially peanuts) a blanching or peeling step follows to remove skins, for a smoother final paste.
Cooling & quality sorting
- After roasting, nuts are cooled (to stabilize moisture & temperature) and sorted to remove defective or foreign kernels.
Grinding / milling into paste
- Nuts are ground in industrial grinders / mills (colloid mills, stone mills, high‑shear grinders) to produce a paste — smooth (butter), crunchy (with some particle retention), or somewhere in between.
- This paste can then directly become “nut butter,” or can undergo further processing (emulsification, mixing with oils, stabilizers, sweeteners) to create spreads, chocolate‑nut creams, or confectionery fillings.
Formulation (optional) — for spreads, chocolate creams, etc.
- Many commercial spreads add ingredients beyond pure nut paste: vegetable oils or fats (to stabilize, adjust consistency), emulsifiers, sweeteners (sugar, syrup), salt, stabilizers — especially if the product is a flavored chocolate‑nut spread or spread meant for shelf stability.
- This is especially common in widely sold spreads (e.g. chocolate‑hazelnut spreads) — to ensure texture, shelf life, spreadability, and low cost.
Homogenization / Emulsification / Packaging
- For smooth texture and stable fat‑oil distribution, pastes are emulsified/homogenized, cooled and then filled into jars or containers.
- Quality control checks include verifying texture (smoothness or controlled crunchiness), absence of contaminants, compliance with food safety regulations (e.g. for aflatoxin in nuts, microbial standards, labeling standards).

The RE‑NUT® In‑Shell Approach

RE‑NUT’s in‑shell processing flips the conventional script and the results can be particularly advantageous for couples of products like nut spreads, nut flours, and nut‑based creams for confectionery, bakery, or snack manufacturers. Here’s how:

Whole‑nut usage (kernel + shell): Because RE‑NUT processes the nut with the shell, the shell material (rich in fiber, potentially valuable phytonutrients) becomes part of the edible output. This maximizes yield per nut and reduces waste.
High‑yield nut‑paste / flour as base ingredient: Instead of starting from shelled kernels only, manufacturers can source nut‑paste or flour from RE‑NUT that already includes shell‑derived fiber and bulk, improving nutritional profile (fiber, micronutrients, structure) compared to conventional paste/flour.
Cleaner ingredient list & circularity: Because RE‑NUT’s flour is derived from “whole nut only,” you can reduce or eliminate the need for certain additives or fillers (e.g. external fiber, bulking agents), aligning with clean‑label trends and avoiding over‑processing.
Cost and resource efficiency: More output per harvested nut means reduced raw‑material costs for the same or greater end‑product volume. For large‑scale spread producers, this can significantly improve margin or competitive advantage.
Texture & nutritional differentiation: A stretch-level nut‑paste or flour that includes shell-based fiber + kernel content might yield spreads with unique mouthfeel: more “robust,” fiber‑rich, slightly textured, but still smooth. This is of high appeal to health‑ or fiber‑focused consumers.
Scalability and supply‑chain simplification: Since RE‑NUT’s process consolidates shelling, milling, and upcycling into one integrated system, spread manufacturers don’t need separate shell‑waste handling, disposal, or by‑product management, everything is delivered as ready‑to‑use flour/paste.

What This Means for Spread Manufacturers

By using RE‑NUT’s in‑shell nut‑flour / nut‑paste, manufacturers of spreads, creams, bakery fillings, or confectionery creams can benefit from:

Enhanced nutritional profile (higher fiber, possibly improved micronutrient retention)
Clean‑label, “whole‑nut” heritage, strong for natural, health, sustainability‑focused branding
Better yield per raw nut → lower cost per kg of final product
Simplified raw‑material procurement and waste handling
Potential for novel textures and product differentiation (e.g. “High‑Fiber Almond Spread”, “Whole‑Nut Paste”, “Incycled Nut Cream Filling”)

What this means for the nut‑spread market

The almond butter / nut butter market is booming — driven by health‑conscious consumers seeking clean-label, plant-based, high-protein spreads.
Consumers’ demand is shifting toward natural, additive-free, nutrient-dense spreads — exactly the kind of product possible with in‑shell almond flour.
For manufacturers, integrating in‑shell flour could deliver cost savings + product differentiation. Clean-label nuts + sustainability + nutritional strength = a strong positioning for premium spreads or snacks.

A summary of the opportunity:

Benefit	Opportunity for Your Spread / Confectionery Business
High protein & fiber, natural almonds only	Market as a clean-label, high‑nutrient spread (ideal for health‑conscious / flexitarian customers)
Higher yield from whole nuts	Lower raw‑material costs per kg — better margins on bulk production
Gluten‑free, plant-based	Target vegan, keto, gluten‑free, and allergy‑friendly segments
Shell-inclusive circular process	Boost sustainability credentials — attract eco-conscious brands / consumers
Stable, industrial‑ready flour	Easily scale up production; consistent texture and quality batch after batch

A Glimpse Ahead: More Nuts, More Possibilities

While right now RE-NUT’s focus is on almond flour, the in‑shell technology is nut‑agnostic. This opens doors to future explorations — hazelnut flour for chocolate‑hazelnut spreads, peanut flour for “clean peanut butter”, cashew flour for butter and creams, or multi‑nut blends for unique taste, texture, and nutritional profiles.

Ready for Scale: From Pilot to 2027 Launch

All these benefits will soon be available at an industrial scale. RE-NUT® is currently building out the Blueprint Line, our first full-scale production line for in-shell almond processing, located in North America. This state-of-the-art facility, to be operational by Q1 2027, will mark the commercial debut of in-shell almond flour.

Ready to innovate with us? Get in touch to learn more about our early partnership program, obtain sample batches for testing, or schedule a demo. Together, let’s create the next generation of confections that are not only irresistibly delicious, but also rich in goodness and rooted in sustainability. The future of nut-powered, better-for-you treats is almost here, and we’d be thrilled to have you on board.

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