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Gluten-free Ingredients & Formulation Approaches DILEK UZUNALIOGLU, PH.D. MAY 2016 2016 B&CMA TECHNICAL CONFERENCE
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Page 1: Gluten-free Ingredients & Formulation · PDF fileGluten-free Ingredients & Formulation Approaches DILEKUZUNALIOGLU, PH.D. ... Gluten-free Market. Gluten-free Bakery Market 4 ... Globalization

Gluten-free Ingredients & Formulation Approaches

DILEK UZUNALIOGLU, PH.D.

MAY 2016

2016 B&CMA TECHNICAL CONFERENCE

Page 2: Gluten-free Ingredients & Formulation · PDF fileGluten-free Ingredients & Formulation Approaches DILEKUZUNALIOGLU, PH.D. ... Gluten-free Market. Gluten-free Bakery Market 4 ... Globalization

• Gluten-free Bakery Market Overview

• Gluten-free Bakery Challenges

• Gluten-free Ingredients & Formulation Approaches

• Starches and Flours Used as Bulk Flours and Texturizers in Gluten-Free Formulations

• Use of Pulse Flours in Gluten-free Formulations

• Use of Gums in Gluten-free Formulations

Outline

2Copyright® 2016 by Ingredion Incorporated

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Science-based problem-solvingfrom Ingredion Idea Labs

Gluten-free Market

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Gluten-free Bakery Market

4

Source: Packaged Facts January 2015

*

Compound Annual Growth Rate 2010-2014 = 34%

Compound Annual Growth Rate 2014-2019= 19.2%Estimated

US Retail Sales of

Gluten-free Foods in Key

Categories, $ Sales

(in millions)

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5

The Consumer

Copyright® 2016 by Ingredion Incorporated

Source:1. Gluten-Free Foods and Beverages in the U.S., 4th Edition, October 17, 2012 2. NPD, March 6, 2013

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Science-based problem-solvingfrom Ingredion Idea Labs

Gluten-free Formulation Challenges, Ingredients & Holistic Formulation Approach

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7

• Lack of viscosity or elasticity of the wheat-containing dough leading to difficulties in processibility and machinability

Processing

• Reduced volume, lack of an even cell structure• Dry, crumbly, grainy texture • Poor crust color and development• Grainy flavor

TextureTasteAppearance

• Shorter shelf-life/ Increased staling rates due to increased water mobility

Shelf-life

• Lack of protein, nutrients and fiber• Use of high levels of sugars and fats to mask the texture and flavor challenges

Nutritional Profile

Gluten-free Bakery Formulation Challenges

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8

Functionality of Ingredients Used

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Type Examples Usage Level Function

Native Flours and Starches Corn, Potato, Rice, Tapioca, Sorghum, Amaranth, Buckwheat, Quinoa, Soy, Millet, Teff, Bean, Pea, Nut

• 20-50% • Bulk/Backbone of the recipe

• Texture modifier: Body, elasticity & chewiness, crumb structure

Cook-up Native Functional or Modified Starches

Corn, Tapioca, Rice, Potato • 20-50% • Texture modifier: Body, elasticity & chewiness, crumb structure

• Freeze-Thaw Stability

Pre-gelatinized Native Functional or Modified Starches

Corn, Tapioca, Rice, Potato • 2-10% • Dough viscosity control

• Texture modifier

• Prevent staling

Proteins Whey Protein, Soy Protein, Zein, Egg White Powder, Pulse Proteins

• 2-5% • Build structure• Color development

Other Hydrocolloids/Gums

Xanthan Gum, Guar Gum, Cellulose Gum, Alginates, Konjac, Psyllium Husk

• -.5-3% • Dough viscosity control

• Texture modifier

• Prevent staling

• Freeze-thaw stability

Use combination of ingredient to match dough rheology and final product texture is key!

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DIAL-IN®TechnologyThe shortest path to perfect texture and sweetness

9Copyright® 2016 by Ingredion Incorporated

• Benchmarking wheat-containing and gluten-free products

• Identifying gaps using Descriptive Sensory Analysis

• Developing solutions to minimize the gaps

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Gap Measured Using Descriptive Sensory Analysis

10

Cohesiveness of Mass:The degree to which a chewed product forms a bolus/ball/holds together

Wheat-containing Benchmark

Wheat-containing Benchmark

Loose

LowHigh

Compact

Roughness of Mass:The amount of graininess as perceived on the surface of the product during its mastication

Gluten-free Market Samples

Gluten-free Market Samples

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Experimental Approach

11Copyright® 2016 by Ingredion Incorporated

Process

• Dispersibility, Dough Rheology, Machinability, Handling

Descriptive Sensory Analysis

• Cohesiveness, Graininess, Dissolvability, Hardness, Denseness, Firmness, Springiness, Mouth CoatingFinal Product

Measurements

• Hardness via Texture Analyzer, Yield, Height, Moisture, Cost

Preliminary Screening

Optimization DOE

Final Optimal Composition

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Texture Mapping

Grainy

C

2

M

Smooth

Dry

Crumbly

Grainy

Moist

Chewy

Cookie

2

Muffin

Muffin: Gluten-free Flour System

Commercial Cookie Benchmark: Gluten free

Commercial Muffin Benchmark: Gluten free

Cookie: Gluten-free Four System

Commercial Cookie Benchmark: Wheat containing

Commercial Muffin Benchmark: Wheat containing

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Desirable Nutrition ProfileChocolate Chip Cookie

140-180 Calories

7-9 g.

2-4 g.

20-24 g.

0-2 g.

15-20 g.

1-2 g.

WHEAT BASED

Ingredients True %

Native Functional Flour 19.25

Butter, Soft 17.49

Light Brown Sugar 11.65

Medium Invert Sugar 9.00

Cane Juice 3.66

Eggs 8.38

White Rice Flour 4.00

Corn Starch 3.20

Vanilla 0.40

Salt 0.35

Baking Soda 0.28

Xanthan Gum 0.13

Semi Sweet Chocolate Chips 22.21

Total 100.00

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Science-based problem-solvingfrom Ingredion Idea Labs

Key Starches and Flours Used in Gluten-free Formulations

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Every Starch is Different

15

SOURCE TYPEDIAMETER

(µm)SHAPE

AMYLOSE

CONTENT

IODINE

STAINSEM

Corn Cereal 5 – 26Round,

polygonal22 – 28 Blue

Waxy Corn Cereal 5 – 26Round,

polygonal< 1 Red-violet

Tapioca Root 5 – 25Truncated,

oval17 – 22 Blue

Potato Root 15 – 100Oval,

spherical23 Blue

Wheat Cereal 2 – 35Round,

lenticular17 – 27 Blue

Rice Cereal 3 – 8Polygonal,

angular16 – 17 Blue

Sago Pith 15 – 65Oval,

truncated26 Blue

High Amylose

CornCereal 3 – 24

Round,

elongated50 – 90 Blue So

urces: Ingredion, John F Robyt, C.W. Wong and al

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16

Waxy Maize

Wheat

Tapioca

Potato

Maize

36 g starch, anhydrous

starch + H2O = 490 g

rapid heating to 50°C, then 1,5 °C/min

to 95°C, maintain 20 min

cooling to 30°C -1,5°C/min

Brabender

10 20 30 40 50 60 70 80 90

minutes

2600

2400

1600

1400

1200

1000

800

600

400

200

95° C 95 + 20 minutes 30° C

[BU]

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Comparative Viscosity Profile

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Key Gluten-free Starches and Flours

17

Ingredient Functionality

Rice Flour • Mild taste small granule size, smooth texture• Very digestible and no allergenic• Gives body, but turns quite dense when used on its own

Corn Starch • Typical maize flavor, creamy to yellow color• Gives a light crumb structure• Good setting properties but fast staling

Tapioca Starch / Tapioca Flour

• Adds some elasticity, chewiness (prevents from crumbling)

• Gives good moisture, lightness, fine crumb structure

Potato Starch / Potato Flour

• High water absorption, gives moisture to the end product

• Quite bland in taste at low levels• Recipe concentration effect / Good cost in use

Corn

Tapioca

Potato

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Science-based problem-solvingfrom Ingredion Idea Labs

Enhancing the Nutrition & Texture: Pulse Flours & Proteins

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19

What is a Pulse? Legumes

Soybeans

Peanuts

PulsesDried Beans, Dried Peas, Chickpeas, Lentils

Fresh Peas

Fresh Beans

Chickpeas

Dried Beans

Lentils

Dried Peas

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20

Plant Fixing NitrogenLower Energy Requirement

Increased Water Use Efficiency

Source: Hoekstra and Chapagain, Globalization of Water, U. of Twente, Waterfootprint.org National Geographic, April 2010

• 43 gallons of water required to

produce one pound of pulses

• 1,857 gallons of water required to

produce one pound of beef

1,857Gallons/ lbs

43Gallons/

lbs

Pulses

756Gallons/

lbs

469Gallons/

lbs

• Pulses Use Less Non-Renewable

Energy Relative to Other Crops

• 70% of the non-renewable energy

used in cropping systems in

western Canada is attributable to

fertilizers

Source: (Zentner et al. 2004)

• Pulses produce their own fertilizer

by fixing nitrogen

Sustainable Agriculture

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Consumers Want What Pulses Have

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New Product Launches

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• The United Nations declared 2016 as the International Year of Pulses (IYP).

• The IYP 2016 aims to increase the public awareness of the nutritional benefits of pulses as part of sustainable food production and towards food security and nutrition.

2016 is the International Year of Pulses

23

Source: http://www.fao.org/pulses-2016/en/

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Media Coverage

24

Highlights:

• 600+ Online Media Channels have covered IYP.

• The Social Media campaign has generated 145M impressions on Twitter, 2.5M impressions on Instagram and has reached 14.3M consumers on Facebook.

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Pulse Ingredients

Pulse Ingredients

• Pulse Protein Concentrates• 55-60% protein d.b.• Pulse Flours• 10-25% protein d.b.• Derived from• peas• faba beans• lentils• chickpeas

Functionality

• Emulsification

• Texture• Gelation

• Water-holding• Adhesion• Film Forming

Value Propositions

• Enhance textureand provide moist mouthfeel• Good synergy with other gluten-freeflours• Proteinenhancement

• Soy proteins replacement

Labelling & Nutritional

• Natural

• Non-GMO• Gluten-free & Grain-free

• Hypoallergenic• High Protein, High Lysine

• High Dietary Fiber• Low Glycemic Index

• High in Micronutrients

Peas Lentils ChickpeasFaba Beans

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Production of Pulse Ingredients

Minimum 20% Protein d.b.

Coarse & Medium

Pulse Flour

55-85% fiberMinimum 10% protein

d.b.55-60% proteins d.b

High Starch Pulse Flour

Pulse ProteinPulse Bran

Pulse Seeds

Dehulling Spliting

Minimunm 20% Protein d.b.

FinePulse Flour

11 22

33 44

Sieving

Pulse Hulls

Milling &Air classificationMilling

Milling

Pulse Splits

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• “C-type” crystallization pattern (a mix of “A” and “B” types)

• High amylose content (~30-35 % amylose)

• High degree of retrogradation

• High thermal stability

• Relatively high resistance to shear thinning

• Moderate swelling power

• High gelatinization temperature (>60oC)

• High gel elasticity

Pulse Starch

27

Soft candies

SEM image of Faba bean starch

SEM image of yellow pea starch

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Extruded Snacks Noodles

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Nutritional Quality

• 9 Essential amino acids - cannot be made by the body, must come from food.

– Histidine

– Isoleucine

– Leucine

– Phenylalanine

– Threonine

– Valine

Impact of Pulse Protein Amino Acids Composition on Product Formulation

28

Deficient in pulse protein

Functionality/Product Property

• E.g. Tendency of Browning (at neutral pH, with reducing sugars)– High Lysine content

– Lysine is a substrate of Maillard reaction

No pulseWith Pulse– Methionine

– Tryptophan

ε-amino group

– Lysine Abundant in pulse protein

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Pulse Flour has similar/higher protein content as wheat flour, but…

29

14.5812.1

9.5

5.9

02468

10121416

Yellow PeaFlour V-6000

Wheat Flour(All Purpose)

Corn Flour Rice Flour

Protein (% d.m.)

HOMECRAFT® Pulse Flour*

* This one has higher starch content, lower protein content

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• Pulse protein v.s. Wheat protein

…but very different protein composition

30

PulsesProteinfractions

Wheat

10 – 30% Albumin 5 – 15%

40 – 80% Globulin 5 – 10%

10% Glutelin 30 – 50%

0 – 5% Prolamin 30 – 50%

≈ 80% soluble protein

≈ 80% insoluble protein

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Wheat Gluten Formation

31

Not a one-to-one replacement for wheat flour if gluten formation is requiredEducated guess: ☺ Soup☺ Batters & Breadings☺ Cake, cracker, cookies

� Bread, seitan http://www.perten.com/Products/Glutomatic/About-gluten/

(Baumann 2015)-Buhler Group

• Wheat proteins is high in Cysteine content

– Disulfide bond formation

• Pulse protein is low in Cysteine content

– Limited disulfide bond formation

Starch

Protein

Kneading

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• Market drivers

– Health, clean label and taste driving growth in the snack segment

– New ingredients for gluten and high protein snack applications

• What Pulse Flour, Protein and Fibers can do

– Controlled Expansion

– Differentiated Texture

– High Protein

– High Dietary Fiber

– Low Fat, Differentiated Texture without frying

– Unique Taste, Aroma and Flavor

Extruded Crisps

All in Gluten-free,

Non-GMO

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Extruded Crisps with Pulse Ingredients

33

Extruded Crisp A Extruded Crisp B

Faba Bean Concentrate (min 60% protein in d.b.)

96.5%

Sugar 2.5%

Salt 1.0%

Faba Bean Flour (min 10% protein in d.b.)

60.5%

Faba Bean Concentrate (min 60% protein in d.b.)

25.5%

Pea Fiber 80 10.5%

Sugar 2..5%

Salt 1.0%Texture: Dense, hard and crunchy., loose and gritty bolus Texture: Airy, crispy.

dissolves quickly, low toothpacking.

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Pulse Ingredients in Gluten-free Bakery

34

Crackers & Biscuits

Protein enrichment ��������

Improved browning ��������

Improved smoothness ����

Improved bite ����

Differentiation (taste, color) ����

���� Pulse flours ���� Pulse Proteins

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Copyright® 2016 by Ingredion Incorporated

Gluten Free Hummus CrackerPre-gelatinized Tapioca Flour provides a crunchy texture while helping with dough handling and sheeting.

Chickpea Flour and GF Flour System (tapioca flour, rice flour) are gluten-free flours used in the formula to replace wheat flour.

Globe® Glucose Syrup, Non-GMO ingredient primarily contributes to sweetness and binding.

Ingredients Percent (%)

Chickpea Flour 25.48

GF Flour System (Tapioca Flour, Rice Flour 25.48

Pregel Tapioca Flour 7.39

Monocalcium Phosphate 0.76

Baking Soda 0.76

Salt 0.81

Buttermilk Powder 2.15

Dill, Freeze Dried 0.35

Vinegar Powder 0.71

Garlic Powder 0.27

Onion powder 0.27

Parsley, Freeze Dried 0.16

Granulated Sugar 1.40

Pepper, Ground Black 0.11

Palm Shortening 7.90

Water 23.76

Globe® 63 DE Glucose Syrup, Non-GMO 2.24

Total: 100.00

1. Preheat convection oven to 375°F. 2. Combine dill, parsley, water, and HFCS in bowl allowing herbs to hydrate for 30 minutes.3. Combine remaining dry ingredients in mixing bowl with paddle at speed 1 for 90 seconds.4. Add shortening and continue mixing for 90 seconds.5. Slowly add the hydrated herb mixture to bowl and mix with paddle for 1 minute. 6. Switch to dough hook and continue mixing at speed 1 for another 3 minutes. 7. Sheet dough to about 1.5 mm thickness. Cut and dock with cracker cutter.8. Place crackers on perforated sheet tray and bake for 3-6 minutes depending on thickness.9. Remove crackers and let cool on sheet tray. 10. If applying a topical seasoning or salt, coat the crackers evenly with it before they cool.

35

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Gluten Free Snack Crackers

1. Preheat oven to 295°F2. Sift dry ingredients together. Place dry ingredients in Hobart mixer bowl with sugars and butter 3. Mix at speed 1 with paddle until mixture resembles coarse sand4. Add water, vanilla extract, and syrup to bowl. Mix at speed 1 until a cohesive dough forms5. Wrap dough in plastic wrap and chill in refrigerator for ~10 minutes or until ~ 70°F6. Sheet dough out to 3 ~ 3.5mm thickness. Cut shapes and place on baking sheet 7. Bake 23-28 minutes depending on cookie size and oven. If using convection oven cut baking time to 6-14 minutes 8. Let cookies cool on sheet

Ingredients Percent (%)

Faba Bean Flour 35.47

Faba Bean Protein 5.07

Pregel Tapioca Flour 2.57

Pregel Corn Starch 2.57

Shortening 10.29

Granulated Sugar 8.38

Brown Sugar 7.09

Salt 0.80

Baking Powder 0.40

Baking Soda 0.40

Xanthan Gum 0.40

Vanilla Extract 1.03

Globe® 63DE Corn Syrup 4.03

Globe® 42DE Corn Syrup 4.05

Non-fat Dry Milk Powder 2.03

Ground Cinnamon 0.85

Water 14.56

Total: 100.00

Faba Ben Flour is gluten-free faba bean flour used in the formula to replace wheat flour.

Faba Bean Protein used in the formula to increase the protein content.

Pre-gelatinized Tapioca Flour provides a crunchy texture while helping with dough handling and sheeting.

Pre-gelatinized Corn Starch provides expansion and a crunchy texture.

GLOBE® 42 DE Glucose Syrup and GLOBE® 63 DE Glucose Syrup ingredients primarily contribute to sweetness.

36

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Science-based problem-solvingfrom Ingredion Idea Labs

Gums Used in Gluten-free Formulations

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• Gums provide viscosity, elasticity and produce favorable textural attributes that are lost when gluten is removed

• Gums work synergistically with ingredients such as starches and other gums to produce various textural attributes

–Change in rheology

–Gel Formation

– Viscosity

– Film forming

Gums

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Use of Gums in Gluten-free Formulations

39

Product Functionality

XanthanBatter viscosity and cohesive texture

GuarBatter viscosity, freeze/thaw stability and moisture retention

CMCCell structure and moisture retention

HPMCStructure and set during baking due to thermal gelling characteristics

Gum Arabic

Emulsification and film formation

LBGBatter viscosity, cohesive texture, cell structure and freeze/thaw stability

A combination of Corn Starch, Gum Arabic, Xanthan gum and Guar gum provides volume, uniform cell structure, suspension and moisture retention

A combination of Potato Starch, Tapioca Starch and Guar gum provides a soft crumb structure, volume and moisture retention

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Gum No Gum

Gum No Gum

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Key Takeaways

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More consumers than ever switching to gluten-free diet

Gluten is essential component of taste and texture of food products through its unique functional properties

Removing gluten results in formulation challenges to build back the texture and eating experience

A holistic formulation approach with key functional ingredients are shown to replace gluten without compromising the eating quality, processing and shelf-life

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Science-based problem-solvingfrom Ingredion Idea Labs

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Thank You & Questions?

Dilek Uzunalioglu, Ph.D., Business [email protected]

908-685-5294

Copyright® 2016 by Ingredion Incorporated