Water: From Cost to Capital

In 2026, the global tomato processing market is no longer just competing on yield and flavor; it is competing on water circularity. As investments in wastewater treatment reach record highs—often consuming up to 20% of a plant’s capital expenditure—the industry is proving that “green” initiatives can directly fortify the bottom line. This transition from “compliance cost” to “strategic asset” is driven by a new generation of processing giants who treat effluent as a secondary raw material rather than a liability.

Internal Recycling

At the forefront of internal reuse is the Barilla Group, which has transformed its Rubbiano plant in Parma into a global benchmark for the sauce industry. As part of a massive €168 million “Energy & Water Plan” launched in 2024, Barilla invested over €5 million specifically into Rubbiano’s water infrastructure. According to their 2024 Sustainability Report, these upgrades allowed the facility to recover 62,000 m³ of water between 2022 and 2024. This effort contributed to a staggering 164% increase in recycled water volumes across Barilla’s sites in water-stressed regions, with a long-term goal to increase this index by 250% by 2030. Similarly, Mutti Parma has implemented a “stratified” water quality system, enabling them to recycle up to 80% of their total water intake. By partitioning their supply, Mutti ensures that water used for the initial transport and washing of raw tomatoes is treated and recycled for the same purpose, reserving fresh aqueduct water solely for final production stages.

Biogas and Nutrient Recovery

For the large-scale commodity processors like the Conesa Group and Sugal, wastewater is being re-imagined as a fuel source. Conesa, which processes over 1.8 million tons of tomatoes annually, utilizes anaerobic digestion reactors to capture biomethane from high-organic-load wash water. This process turns the dissolved sugars and starches of the tomato stream into a renewable energy source that powers the very evaporators used to create tomato paste. Meanwhile, the Sugal Group has focused on “closing the nutrient loop.” Supported by a $50 million investment program backed by the International Finance Corporation (IFC) in 2023, Sugal has modernized its facilities to prioritize water efficiency and sludge valorization. The organic solids filtered from their wastewater are no longer sent to landfills; instead, they are processed into soil enhancers and returned to the farmers in their supply chain, reducing the need for synthetic fertilizers.

Large-Scale Agricultural Symbiosis

In North America, the strategy often leverages vast geographical footprints to turn wastewater into agricultural gold. Conagra Brands operates a massive year-round tomato and bean processing facility in Oakdale, California, where the primary investment is in “fertigation” systems. Treated process water is directed to nearly 1,500 acres of local farmland, where it serves as both irrigation and a nutrient supply for crops. This model is mirrored by The Morning Star Company, which utilizes a specialized Bacteria Acclimatizing System (BAS) to handle the extreme “organic spikes” of the 90-day harvest season without requiring massive new concrete tanks. Taking this symbiosis further, Ingomar Packing Company recently partnered with Botanical Water Technologies to harvest evaporative steam, turning it into a potable water source for local California communities. These biotechnological and community-focused approaches allow plants to maintain high-speed throughput while protecting local groundwater.

Cross-Industry Innovation

The sheer purity levels now achievable in wastewater treatment are beginning to blur the lines between “waste” and “consumer product.” While the tomato industry focuses on irrigation and energy, other sectors are demonstrating just how far this technology can go. A notable example from late 2025 was the commercial launch of “Shower Hour IPA” and “Laundry Club Kölsch” by Epic Cleantec and Devil’s Canyon Brewing Co., beers brewed entirely from highly purified recycled greywater. In the tech sector, Elon Musk’s xAI “Colossus” supercomputer in Memphis is currently cooled by treated municipal wastewater, saving millions of gallons of drinking water daily.

For tomato processors, these examples serve as a proof-of-concept for the next decade: treated effluent is no longer “dirty water” to be hidden, but a high-purity input that can cool a server, power a boiler, or even—eventually—become an ingredient in the next generation of sustainable beverages.

Sources: Barilla, Food Processing, ProFood World, Mutti, Osmosis Investment Management, NCR Biochemicals, Governing Magazine, FoodBev Media