Optimized formulation of a fortified mineral supplement from Moringa oleifera extract marc: A sustainable waste-to-value approach

Abstract

Large-scale extraction of bioactive compounds from Moringa oleifera leaves results in the generation of a significant amount of leftover marc, which is often discarded despite its substantial mineral content. This study presents an innovative waste-to-value approach in which moringa extract marc is repurposed into a nutrient-dense tablet formulation through controlled incineration, ensuring the retention of essential minerals while eliminating organic matter. The resulting moringa leaf ash was fortified with ascorbic acid and folic acid to increase iron bioavailability, immune support, and metabolic function. The formulation was systematically optimized via central composite design followed by response surface methodology. The optimized formulation exhibited excellent mechanical properties, with a friability of 0.027%, hardness of 5.5 kg, and disintegration time of 723 s. In vitro drug release followed first-order kinetics, with 95.2% drug release within 90 minutes. Elemental analysis confirmed significant levels of calcium (72.52 mg/g), iron (12.36 mg/g), and magnesium (11.24 mg/g). Toxicological assessment verified that the heavy metal content remained within permissible safety limits, and stability studies conducted over 12 months demonstrated minimal degradation. This study demonstrates the industrial and nutraceutical potential of moringa leaf ash-based supplements to address micronutrient deficiencies and malnutrition, particularly in low-resource settings.

Highlights

Introduction

Moringa oleifera, often referred to as the ‘miracle tree,’ is widely recognized for its exceptional nutritional and medicinal properties. The leaves contain a diverse array of essential vitamins (A, C, E, and B-complexes), minerals (calcium, iron, magnesium, zinc, and copper), proteins, and bioactive compounds, contributing to their widespread application in functional foods, dietary supplements, and herbal medicine (Gambo et al., 2021). Owing to its impressive antioxidant, anti-inflammatory, and antimicrobial activities, moringa has gained increasing prominence in the global nutraceutical market. The increasing demand for herbal Moringa-based formulations has fuelled the large-scale extraction of bioactive compounds for commercial applications in pharmaceuticals, cosmetics, and functional foods (Gull et al., 2025, Dahiya and Garg, 2024). However, the extraction process generates a substantial amount of residual plant material, which is often discarded despite its rich mineral profile. This industrial byproduct, if effectively utilized, could serve as a valuable source of essential nutrients (Spigno and De Faveri, 2007, Bonilla et al., 1999, Skrzypczak et al., 2020). The waste-to-value paradigm offers an opportunity to convert this underutilized moringa extract marc into a sustainable mineral supplement (Muhlack et al., 2018, Regolo et al., 2024).

Malnutrition is a significant global health isse, impacting millions of lives, especially in developing nations where access to nutritious food is scarce. Moreover, the available allopathic supplements are costly and associated with various adverse reactions in individuals. Therefore, M. oleifera is considered a potential herbal drug for the prevention and treatment of malnutrition owing to its high nutritional content (Sokhela et al., 2023). The plant is rich in high mineral contents, but traditional methods of extraction are not very effective in retaining the mineral content of the plant (Dahiya and Garg, 2025). Additionally, crude plant material contains a significant amount of antinutrients, which hinder the absorption of nutrients into the body from the herbal dosage form (Faizal et al., 2023). Controlled incineration facilitates the removal of organic matter while concentrating minerals, leading to the development of nutrient-dense ash which offers a cost-effective and eco-friendly alternative to synthetic supplements (Dahiya and Garg, 2025).

Plant-based ash (Bhasma) is a scientifically valuable and culturally significant supplement with a long history in Ayurvedic medicine. Its rich mineral content, detoxifying properties, and therapeutic potential make it an ideal candidate for herbal nutraceutical formulations with a potential of combatting micronutrient deficiencies and malnutrition worldwide (Pal et al., 2014, Bhosale and Pawar, 2024). The incorporation of ash into a tablet dosage form further enhances its practicality by allowing for controlled dosage, ease of transportation, and extended shelf life. The study was designed to formulate optimized tablets containing ash of moringa leaf extract marc. To further enhance the nutritional efficacy of the formulated tablets, fortification with ascorbic acid and folic acid was incorporated into the design. Ascorbic acid plays a crucial role in enhancing the bioavailability of nonheme iron from moringa leaf ash, facilitating better absorption and improving iron deficiency anemia treatment. (Yin et al., 2022, Ali et al., 2024). Folic acid, on the other hand, is essential for red blood cell formation, DNA synthesis, and neural development, making it particularly beneficial for maternal health and overall metabolic function (Shulpekova et al., 2021, Ismail et al., 2023). By integrating these micronutrients, the fortified moringa leaf ash tablet offers a well-rounded, plant-based supplement capable of addressing multiple nutritional deficiencies in a single formulation. To ensure the efficacy of the formulation, a systematic approach was adopted, including drug-excipient compatibility analysis via Fourier transform infrared (FTIR) spectroscopy and formulation optimization via advanced statistical tools such as central composite design (CCD) and response surface methodology (RSM) (Singh et al., 2023, Pham et al., 2023). This ensures that the formulation meets pharmaceutical quality standards while maintaining the nutritional benefits of moringa leaf ash. Key formulation parameters, including disintegration time, friability, and hardness, were optimized to ensure a balance between mechanical strength and rapid dissolution, which are critical factors for ensuring efficacy and patient acceptability (Peter and Sesaazi, 2022).

Therefore, the major objective of this research was to develop a mineral-rich tablet formulation utilizing M. oleifera extract marc to provide a cost-effective and sustainable solution for addressing malnutrition. This research contributes significantly to the circular economy model by demonstrating the industrial feasibility of repurposing moringa processing waste into high-value dietary supplements.

Despite its promising applications, this study has certain limitations, particularly the need for further clinical validation to establish long-term bioavailability and therapeutic efficacy. Future research directions should explore pharmacokinetic assessments, scalability for industrial production, and fortification with additional bioactive compounds to increase nutritional and therapeutic benefits. Integrating moringa-based mineral supplements into public health interventions could serve as a cost-effective strategy for addressing global micronutrient deficiencies.

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Materials

The formulation development involved the use of ascorbic acid, folic acid, starch, crospovidone, lactose, and talc as key ingredients. Ascorbic acid and lactose were procured from Loba Chemie, whereas folic acid was obtained from Fluka Goldie. Starch and talc were sourced from CDH, and crospovidone was acquired from Researchlab. Furthermore, all reagents and chemicals utilized in the study were of analytical grade.

Sanju Dahiya, Munish Garg, Optimized formulation of a fortified mineral supplement from Moringa oleifera extract marc: A sustainable waste-to-value approach, Food and Bioproducts Processing, 2025, ISSN 0960-3085, https://doi.org/10.1016/j.fbp.2025.06.011.