How Alchemy Gisborne and Callaghan Innovation developed an automated finger lime processing method and a high-value product line
At a glance
- Alchemy Gisborne partnered with Callaghan Innovation to transform the way finger limes are processed and create new value from second-grade fruit.
- A prototype machine was developed to automate pearl extraction with minimal damage and waste.
- Callaghan Innovation’s Biotechnologies Group enabled the creation of premium shelf-stable ingredients, including freeze-dried pearls, stabilised fresh pearls, peel powder, and citrus oil.
Thanks to the innovative partnership with Callaghan Innovation, we have successfully developed a prototype machine to extract finger lime pearls with precision and minimal waste. This project has significantly enhanced the potential speed of processing finger limes. This will enable us to scale up operations whilst producing a high-quality product and keep costs down.
Jason Galloway, Alchemy Gisborne
Unlocking the value of processing-grade fruit
Known as “citrus caviar”, the unique pearl-shaped pulp of finger limes is a premium ingredient in growing demand across food and beverage markets. The leaf and peel can also be used for oil and dried extract, enabling additional high-value applications.
Alchemy Gisborne is exploring these opportunities to improve the commercial potential of second-grade fruit. However, due to the fruit’s fragile composition, the current processing method was labour-intensive and time-consuming. Each lime had to be carefully broken open, and the pearls removed by hand without popping them or contaminating them with bitter peel oil.
To overcome these barriers and expand production, Alchemy Gisborne approached Callaghan Innovation to develop a scalable processing method and a new line of shelf-stable ingredients that make use of the entire fruit.
Exploring automated solutions and product opportunities
Through the Bioresource Processing Alliance, Callaghan Innovation brought together a multidisciplinary group of R&D specialists to design and build a proof-of-concept machine to automate the delicate task of extracting pearls. The prototype successfully separated pearls from peel with minimal damage, reducing waste and processing time.
With pearls and peels cleanly separated, the Biotechnologies Group focused on developing premium shelf-stable products. This downstream work has opened multiple commercial pathways for Alchemy Gisborne, including:
- Freeze-dried pearl and peel products
- Preserved, shelf-stable pearl products
- Peel powder for use in food, beverage, and nutraceuticals
- Citrus oil extracts for food, cosmetics, and fragrances
By enabling full utilisation of second-grade fruit, the project supports processing scale-up while laying the foundation for a zero-waste approach to product development.
The trials to maximise the use of the whole fruit have enabled us to start developing a number of products which will eliminate waste and enhance our returns.
Jason Galloway, Alchemy Gisborne
End-to-end support for product and process development
Whether you're looking to create new products, eliminate waste, or enhance returns, the Biotechnologies Group are here to help. Talk to us to explore how we can help turn ideas into scalable, high-value outcomes.
