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<p>Eggshells, a calcium-rich byproduct of the agri-food industry, remain vastly underutilized despite their promising potential as sustainable feed additives. This study aimed to convert industrial eggshell waste into a microbiologically safe and nutritionally effective calcium supplement for poultry. A central composite design (CCD) was employed to optimize key processing parameters drying temperature, time, and particle size using water activity (WA) as a stability marker. The optimized powders were characterized by XRD and FTIR, confirming the preservation of the calcite crystalline phase. Structural comparisons revealed close similarities to commercial CaCO₃, with subtle differences linked to biogenic origin. In vitro digestion assays demonstrated superior calcium solubility of eggshell powder compared to commercial CaCO₃, suggesting enhanced bioavailability. Microbiological analyses confirmed the hygienic safety of the processed material, with no detectable pathogens. A short-term in vivo trial on Lohmann Brown hens showed that replacing commercial CaCO₃ with eggshell-derived calcium resulted in comparable egg weights and improved shell strength, with a peak value of 46.3&#xa0;N at week 65. Economic evaluation revealed a production cost of approximately 0.45 €/kg, significantly lower than commercial CaCO₃ (0.75–1.5 €/kg). Life cycle analysis further indicated a 60% reduction in carbon emissions per kilogram of product. Together, these findings demonstrate that eggshell valorization can deliver nutritional, economic, and environmental co-benefits. By integrating process optimization, functional validation, and sustainability assessment, this work presents a scalable and circular solution for calcium supplementation in poultry feed. The approach aligns with global objectives for waste recovery, decarbonization, and responsible resource use in animal production systems.</p> Graphical Abstract <p></p>

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Sustainable Production of Calcium from Eggshells for Poultry Feed: CCD Optimization, Characterization, and In vitro/In vivo Bioavailability Testing

  • 期刊论文

  • 发表日期：

    2026年3月30日

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  • Malek Bouhjar,
  • Boutheina Rzig,
  • Nizar BellakhaL

摘要

Eggshells, a calcium-rich byproduct of the agri-food industry, remain vastly underutilized despite their promising potential as sustainable feed additives. This study aimed to convert industrial eggshell waste into a microbiologically safe and nutritionally effective calcium supplement for poultry. A central composite design (CCD) was employed to optimize key processing parameters drying temperature, time, and particle size using water activity (WA) as a stability marker. The optimized powders were characterized by XRD and FTIR, confirming the preservation of the calcite crystalline phase. Structural comparisons revealed close similarities to commercial CaCO₃, with subtle differences linked to biogenic origin. In vitro digestion assays demonstrated superior calcium solubility of eggshell powder compared to commercial CaCO₃, suggesting enhanced bioavailability. Microbiological analyses confirmed the hygienic safety of the processed material, with no detectable pathogens. A short-term in vivo trial on Lohmann Brown hens showed that replacing commercial CaCO₃ with eggshell-derived calcium resulted in comparable egg weights and improved shell strength, with a peak value of 46.3 N at week 65. Economic evaluation revealed a production cost of approximately 0.45 €/kg, significantly lower than commercial CaCO₃ (0.75–1.5 €/kg). Life cycle analysis further indicated a 60% reduction in carbon emissions per kilogram of product. Together, these findings demonstrate that eggshell valorization can deliver nutritional, economic, and environmental co-benefits. By integrating process optimization, functional validation, and sustainability assessment, this work presents a scalable and circular solution for calcium supplementation in poultry feed. The approach aligns with global objectives for waste recovery, decarbonization, and responsible resource use in animal production systems.

Graphical Abstract