Air Nuts: innovation and technology for a healthy and sustainable snack

The challenge

The Basque company Uriarte Iturrate, part of the Ecolumber Group, set out to revolutionise the nuts market by creating a healthy, sustainable, high value-added snack. The challenge was to develop an innovative product in terms of texture and composition that preserved the full flavour and nutritional benefits of nuts, while offering a lower caloric density and aligning with emerging trends in responsible consumption.

The solution

A four-year research project led to the creation of Air Nuts, a pioneering snack that incorporates up to 86% nuts within an expanded, porous structure.

AZTI’s team developed a patented expansion technology, specifically designed for this product, which significantly reduces caloric density without compromising sensory quality.

In addition, the project combined technological innovation, sustainability, and a strong market focus, driving the development of new industrial processes and strengthening the competitiveness of the Basque food sector.

The results

• Launch of Air Nuts, an innovative, healthy, and sustainable snack.
• Reduction in caloric density thanks to patented technology.
• International recognition, including awards such as Best Taste of the Year 2022 in the UK, Carrefour Award for Best SME, and the BTEM 2024 Award for Process Innovation.
• Positive economic and social impact: growth of the Ecolumber Group, 12 jobs created (50% women), and international expansion with presence in retail chains such as Sainsbury’s and Marks & Spencer.
• An example of successful collaboration between industry and a technology centre, demonstrating how shared innovation drives sustainable development and industrial competitiveness.