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Gluten free pasta production Bühler AG Stefanie Hardtmann Basic technological aspects
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Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

Mar 29, 2019

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Page 1: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

Gluten free

pasta

production

Bühler AG Stefanie Hardtmann

Basic technological

aspects

Page 2: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

2 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Corporate Presentation.

About Bühler.

Page 3: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

3 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Bühler at a glance. Global market leader with strong roots in local markets.

Group turnover (sales) 2014: CHF 2,332 million.

Around 10,600 employees.

Present in nearly 140 countries.

Today, 80 service stations globally, +12 stations compared to 2013.

Production sites in all regions.

Up to 5% of turnover invested in research & development.

Consistently high quality standard worldwide.

100% family-owned.

Page 4: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

4 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Snacks & Pasta

Sweets

Grain processing

Bühler offers industrial process technologies and solutions in two main markets.

Food Advanced Materials

Raw materials

Manufacturing

Logistics

Technology & process engineering

Services

Bühler

Optics

Automotive

Electronics

Nutritious foods

Parts and coatings

Basic foods & feed

Page 5: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

5 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Spirit of discovery. Continuous high investments in R&D.

4.2% of turnover invested in R&D

in CHF million

Industry Experts.

Customers.

Employees.

Suppliers.

State-of-the-art innovation management.

Bühler Innovation Board.

Page 6: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

6 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Business Area Value Nutrition.

Our solutions

Innovative process solutions for the feed and food industries:

from feed for cattle and poultry to aqua feed and pet food, to pasta and

Asian noodles, to cereals and snacks as well as oilseeds.

VALUE NUTRITION

Key facts

Around 40% of the global pasta production takes place on Bühler machines. In addition,

35% of cereals, 30% of oilseeds, and 20% of feedstuff are processed with Bühler solutions.

The core technologies relate to the areas of extrusion, drying and flaking.

Our customers

International, regional and local feed & food producing companies

including feed mills but also flour and oil mills in 140 countries

all over the world.

Page 7: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

7 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Agenda

1

2

3

4

6

Technological challenge

Process for production of gluten free pasta

Why is starch gelatinization important?

The role of amylose as “glue”

Raw material requirements

Market drivers

Page 8: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

8 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Market drivers gluten-free pasta

1. Gluten free as dietetic product

2. Gluten free as alternative to

common pasta

- People suffering from celiac

disease don’t tolerate gluten

(0.01 to 0.5 % of the population)

- General tendency of consumers

towards “low allergen” and “gluten

free” nutrition

-Use of local non-wheat grains for pasta

-Use of cheaper non-wheat grains

-Transformation of low value by-products (e.g.

broken rice) into value added food product

like pasta

- Consumers looking for food diversity

Page 9: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

9 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

What’s the challenges in producing pasta from gluten free raw material like rice and corn

Rice and maize contain proteins

(~7 to 12 %)….

…...but, the proteins are not able to

form a strong elastic network like

gluten

Therefore, for pasta from gluten free

raw material starch needs to be

gelatinized to act as “glue.

Note different microstructure of natural rice

and of rice pasta (protein is stained green).

50 µm

Natural rice

Rice pasta

Page 10: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

10 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Starch gel of gelatinised starch builds

continuous phase

Continuous phase of protein

Wheat pasta Corn pasta

Wheat pasta and corn pasta are very different in terms of microstructure

Page 11: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

11 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Conventional wheat pasta Gluten free pasta

Protein is the “glue” Protein (Gluten) network

provides framework

of pasta

Starch is a filler Starch granules are

embedded in protein

network

Starch is the “glue” Gelatinized starch

provides framework

of pasta

Small protein

patches (no relevance for

texture)

is embedded in

starch gel

Main difference between conventional wheat pasta and

gluten-free pasta

Page 12: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

12 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

The Polymatik pasta press is perfectly suited for producing gluten free pasta

Nativ, gluten-free

raw material

Additive Poly-C-one®

c 0.5-1.0 % of flour

Press head

Mixer/Kneader

Vacuum

Steam

Press-

cylinder

Water

Mixing & Kneading in co-rotating twin-screw

extruder

Forced conveying in the twin-screw enables

„first-in first-out“

Page 13: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

13 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Industrial short goods line for the production of gluten-free pasta

Industrial applications so far for rice and corn flours

E.g. Bühler short goods C-line for 1400 kg dried pasta/hour

Page 14: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

14 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Industrial short goods line for the production of gluten-free pasta

Industrial applications so far for rice and corn flours

E.g. Bühler short goods C-line for 1400 kg dried pasta/hour

Dryer Zone B2 Cooler

Zone D1

Cartrapen

Pre-Dryer Zone B1 Polymatik-Press

Raw materials dosing systems

MSDA MSDF

Shaking predryer

Zone A1

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15 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Industrial long goods line for the production of gluten-free pasta

Industrial applications so far for rice and corn flours

E.g. Bühler long goods C-line for 1200 kg dried pasta/hour

Polymatik®

Spreader

Pre dryer A

Dryer B

Stabilisation C 1 Moistening C 2

Cooler D

Page 16: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

16 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

HT

drying

Moisture content [g/100 g wb]

Tem

pera

ture

[°C

]

Tg of starch

native

flour Extrusion

Mixing & Kneading

with H2O & steam

Tm

Melting

of starch

HT drying

HT drying

conventional

wheat pasta

gluten free

pasta

Comparison of extrusion conditions for wheat pasta and gluten free pasta in the state diagram of starch

Page 17: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

17 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Heating in

presence of water

Melting, swelling &

amylose leaching

Native wheat starch

Upon processing of gluten free pasta the starch is gelatinized in the Polymatik press

After heating in excess water to 90°C

gelatinized

starch

native

starch

Page 18: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

18 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

HT drying of gluten free pasta contributes to strengthening the amylose network structure.

Endo

Native rice flour with Poly C Starch is native and the amylose-lipid

complexes have low degree of perfection

Rice pasta after extrusion Starch is gelatinized and two forms

of amylose-lipid complexes exist

Rice after HT drying Further perfectioning of the amlyose-

lipid complexes has taken place

gelatinization

Melting of

amylose-lipid

complexes

Rice pasta will not fall apart

during cooking and presents

low levels of stickiness

Page 19: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

19 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Suitable raw material for gluten-free pasta.

Flours and starches of gluten-free cereals

like rice or maize

Flours of pseudo-cereals like Amaranth,

Buckwheat, Millet or Quinoa

General requirements:

- Granulation of the flours

100 % < 250 µm

15 % < 125 µm

- Amylose content > 20 %

- Fat content < 1-1.5 %

- Ash content as low as possible (< 0.7 %)

- Note the special technical requirements for raw material handling for dietetic products

Page 20: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

20 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Raw material requirements – Additives.

Additive Poly-C-one - Promotes starch (amylose) complexation and yields pasta with high

firmness, low cooking loss and low stickiness

- Acts as lubricant and reduces stickiness of pasta at the die during cutting.

- Poly-C-one is a specially designed emulsifier E471 (mono- and diglycerides of food fatty acids)

- Amount to be added 0.5% – 1% of flour quantity Additive Beta-Carotene

- Optional additive for rice or white maize flour to give pasta of yellow color

- Amount to be added 0.02% of flour quantity

Additive Curcumin

- Optional additive for rice or white maize flour to give pasta of yellow color

- Amount to be added 0.2 % of flour quantity

Page 21: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

21 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015

Target product qualities of gluten-free pasta processed by

Polymatik.

Quality-benchmark for gluten-

free pasta is wheat pasta

Good texture features of cooked

pasta

- bite > 0.8 N

High surface integrity of cooked pasta

- cooking loss < 5%

Gelatinization degree 50 - 70%

(enzymatic method)

Gluten content < 20 mg/kg dried pasta

Page 22: Gluten free pasta production | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015 Market drivers gluten-free pasta 1. Gluten

Thank you!