Clean Labels: Overcoming the Top Production Hurdles

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1 Clean Labels: Overcoming the Top Production Hurdles February 7, 2108 Aaron Clanton, Manager of Baking Training Quality, AIB International, Inc. Holly Mockus, Senior Product Manager, Alchemy Systems

2 Welcome! Audio Options: Choose Mic & Speakers to use computer speakers Choose Telephone to dial in using info provided All lines are in listen-only mode Please post your questions any time Q&A will be at the end of the webinar #alchemywebinar 2

3 Introduce Speakers Aaron Clanton Manager of Baking Training Quality Holly Mockus Senior Product Manager 3

4 Agenda 1. The definition of a clean label 2. How to eliminate functional ingredients 3. Processing challenges in baking 4. Clean label options 5. Managing label change 6. Resources 7. Q&A

5 The Definition of a Clean Label

6 What is a Clean Label? For Consumers For Industry 6

7 Consumers are Looking for Transparency Consumers are looking for Simple ingredient lists Recognizable ingredients No artificial ingredients No chemicals Minimally processed products 7

8 Industry Hurdles No regulatory definition of clean exists The term organic is regulated and certified in many countries including: US, EU, Canada, Japan, China, Australia, Brazil, India, and others Natural is more loosely defined and regulated Many countries do not define it (including CODEX) 8

9 US Natural Policy FDA Not defined, but policy statement issued in 1993 Product contains NO: Artificial or synthetic ingredients Added coloring, regardless of the source USDA Labeling guidance issued Product contains NO: Artificial flavor or flavoring Coloring ingredient Chemical preservative Artificial or synthetic ingredients Minimally processed 9

10 How to Eliminate Functional Ingredients

National Organic Program Other retailers, customers, consumer

11 What Should be Removed? Depends on list Whole Food s unacceptable ingredients list National Organic Program Other retailers, customers, consumer groups Source: USDA NOP list: 7 CFR &

12 Making Clean Products Remove: Artificial flavors Non natural colors Chemical preservatives Synthetically produced ingredients Ask your supplier to verify natural or synthetic produced 12

13 White Pan Bread Label Enriched bleached flour (wheat flour, malted barley flour, niacin, reduced iron, thiamin mononitrate, riboflavin, folic acid), water, high fructose corn syrup. Contains 2% or less of salt, yeast, soybean and/or cottonseed oils, wheat gluten, monocalcium phosphate, calcium sulfate, ammonium sulfate, corn starch, dough conditioners (may contain one or more of the following: mono- and diglycerides, ethoxylated mono- and diglycerides, sodium stearoyl lactylate, calcium stearoyl lactylate, calcium peroxide, DATEM, ascorbic acid, azodicarbonamide, enzymes), wheat starch, soy lecithin, calcium propionate (preservative), soy flour. 13

14 White Pan Bread Label Enriched bleached flour (wheat flour, malted barley flour, niacin, reduced iron, thiamin mononitrate, riboflavin, folic acid), water, high fructose corn syrup. Contains 2% or less of salt, yeast, soybean and/or cottonseed oils, wheat gluten, monocalcium phosphate, calcium sulfate, ammonium sulfate, corn starch, dough conditioners (may contain one or more of the following: mono- and diglycerides, ethoxylated mono- and diglycerides, sodium stearoyl lactylate, calcium stearoyl lactylate, calcium peroxide, DATEM, ascorbic acid, azodicarbonamide, enzymes), wheat starch, soy lecithin, calcium propionate (preservative), soy flour. 14

15 White Pan Bread Label Enriched bleached flour (wheat flour, malted barley flour, niacin, reduced iron, thiamin mononitrate, riboflavin, folic acid), water, high fructose corn syrup. Contains 2% or less of salt, yeast, soybean and/or cottonseed oils, wheat gluten, monocalcium phosphate, calcium sulfate, ammonium sulfate, corn starch, dough conditioners (may contain one or more of the following: mono- and diglycerides, ethoxylated mono- and diglycerides, sodium stearoyl lactylate, calcium stearoyl lactylate, calcium peroxide, DATEM, ascorbic acid, azodicarbonamide, enzymes), wheat starch, soy lecithin, calcium propionate (preservative), soy flour. 15

16 Additives Often Removed Ingredient Category Ingredients Function Oxidizing agents Bromates, iodates, calcium peroxide, azodicarbonamide Strength, volume Bleaching agents Chlorine, benzoyl peroxide Whiten flour Emulsifiers Sodium (and calcium) stearoyl lactylate, exthoxylated mono, DATEM, sucrose esters, polysorbates Strength, texture, emulsification Preservatives Propionates, sorbates, benzoates Mold control Stabilizers Modified food starch, synthetic hydrocolloids Provide texture Colors Artificial colors Color Flavors Artificial flavors Flavor Antioxidants TBHQ, BHT, BHA, EDTA Oxidative stability 16

17 Processing Challenges in Baking

18 Processing Challenges Removing ingredients provides processing tolerance Alternative ingredients are more expensive Bakeries are low margin and must maintain high production throughputs, speeds 18

19 Clean Label Requires for Baking Industry A return to baking basics: Time Temperature ph/tta Mixing, fermentation, proofing, baking, and cooling times Ingredients, dough, batter, in-process, baking, and cooling temperatures Throughout process of dough, batter, sponges, finished product Water Hardness Understand incoming water hardness 19

20 Time & Temperature In order to achieve a finished product that is consistent: Day to day Shift to shift Dough to dough Loaf to loaf We must control the time and temperature of the process 20

21 Removal of Functional Ingredients Removing or replacing artificial ingredients can lead to textural, quality, and shelf-life changes in the product Preservative removal can lead to microbial growth (mold) Consumer expectations of product shelf-life 21

22 Shelf-life Concerns for Consumers Visible mold growth = spoilage Firmness or crumbliness of crumb Loss of flexibility Dryness Flavor loss and/or change Loss of shine or migration of color 22

23 Control of Mold Minimize contamination of products with mold Implement control factors that enhance mold growth Establish clear expected shelf-life Utilize mold inhibitors (preservatives) 23

24 Factors Affecting Mold Growth Temperature ph Source of oxygen Nutrients (carbon, hydrogen, nitrogen) Moisture / water activity Time 24

25 Clean Label Options

26 Alternative Ingredients Ingredient Category Ingredients Clean label options Oxidizing agents Bromates, iodates, calcium peroxide, azodicarbonamide Ascorbic acid, enzymes, gluten Bleaching agents Chlorine, benzoyl peroxide Enzymes, soy flour Emulsifiers Sodium (and calcium) stearoyl lactylate, ethoxylated mono, DATEM, sucrose esters, polysorbates Enzymes, lecithin, natural hydrocolloids Preservatives Propionates, sorbates, benzoates Fermentates, vinegar, raisin juice concentrate, live cultures Dough relaxers L-cysteine, sodium bisulfite Enzymes, inactive yeast 26

27 What are Enzymes? Proteins Not living organisms Produced by fermentation Enzymes are catalysts Substrate specific Amylase attacks only amylose Protease only attacks protein 27

28 Reaction Rate Affected By: ph Moisture (a w ) Concentrations Time Enzyme and substrate Temperature Q10 rule: double reaction rate for every 10 C (18 F) increase 28

29 POLL What commonly used ingredients contains active enzymes? Flour Yeast Non-diastatic malt Honey None, you have to add enzymes 29

30 Potential Problems with Using Enzymes Variable levels of purity Difficult to compare Use bake test Effectiveness varies with processing conditions Generally reduce process tolerance Narrow optimum ph ranges Require time to work 30

31 Bake Temperature Potential Problems with Enzymes Enzymes have a narrow window of activity: Baking Profile Bake Time Longer activity time Shorter activity time 31

32 Process Temperature Profiling Use recording thermometers in proof box or oven Side to side variations Temperature at each level or zone Monitor internal temperature of dough Temperatures over time Verify microbial kill achieved 32

33 Temperature Profile of Oven 33

34 Managing Label Change

35 Yes No POLL Will your facility or organization be affected by label changes during 2018? Not sure 35

36 Stats 2016 Food and Health survey by the International Food Information Council 47% of consumers look at the ingredients list when making a purchasing decision 41% defined a healthy eating style, as limited or no artificial ingredients or preservatives 29% defined natural food as associated with having no preservatives or additives 27% said when shopping health concerns influence their choice of food 23% indicated they are more likely to buy food with a health claim on the package than food without 36

37 Stats In 2016: 4,591 new products carrying a U.S. Department of Agriculture-approved no additives or preservatives label introduced to the market 3,732 new genetically modified organism-free products 3,011 were organic 6,552 were low-to-no allergen 6,123 were gluten-free 5,056 claimed an environmentally friendly package Each of these categories has grown year-by-year since at least

38 Stats According to a global study by Cone Communications 91% of global consumers expect companies to make efforts to address environmental concerns 84% of shoppers seek out environmentally responsible products whenever possible 71% would pay more for a sustainable product PMMI reports 50% of food processing operations are affected by clean label

39 Change is Inevitable Label changes due to continuing changes in consumer preference and regulation require a strong change management process! Rigor Training Communication Reinforcement Accountability 39

40 Label Changes Finished Goods Work-In-Process Packaging Materials Raw Materials Formulation 40

41 Label Changes Formulation R&D personnel Labeling Regulations Allergens Functional Ingredients Anti-Microbials Kill Step Manufacturing Process Steps Packaging Finished Goods Work-In-Process Packaging Materials Raw Materials Formulation 41

42 Label Changes New Suppliers Onboarding Labeling requirements Specs Product identity Training programs Existing Suppliers Change management process Inventory, FIFO, FEFO Labeling requirements Product identity Training programs Finished Goods Work-In-Process Packaging Materials Raw Materials Formulation 42

43 Label Changes Packaging Suppliers Specifications Labeling procedures Change over procedures Film splices Materials appropriate for use Product contact Approval process Printing Lot codes Traceability Finished Goods Work-In-Process Packaging Materials Raw Materials Formulation 43

44 Label Changes Processing Procedures Change management Scheduling Inventory control Proper labeling throughout process Product identity Sanitation requirements Finished Goods Work-In-Process Packaging Materials Raw Materials Formulation 44

45 Label Changes Final Pack Change management Correct labels Change over procedures Packaging integrity Verify materials Bar code scanning Inner / outer materials match Finished Goods Work-In-Process Packaging Materials Raw Materials Formulation 45

Engage Your Employees with Alchemy Utilize/Customize Alchemy s multi-lingual courseware for new hire and refresher trainings on food safety topics Reinforce your training with coordinated

46 Engage Your Employees with Alchemy Utilize/Customize Alchemy s multi-lingual courseware for new hire and refresher trainings on food safety topics Reinforce your training with coordinated huddle guides, digital signage, and posters Promote employee-supervisor communication with an award-winning coaching app Ensure audit-ready automated documentation and real-time reporting 46

47 In Summary Switching to clean label ingredients Need tighter processing controls Return to baking basics of controlling time, temperatures, ph, and TTA Knowledge Exchange: Training Digestible format Contextually relevant Form new good habits Combat the forgetting curve Frequent Reminders Passive and Active Accountability Positive reinforcement Consequences 47

48 Resources

49 Baking Specialist Courses on Alchemy Academy With Alchemy and AIB s courses, baking professionals can: Drive higher productivity and reduce waste Enhance credibility with employers and customers Expand knowledge of baking fundamentals Accelerate the advancement of baking career Course Library: Function of Ingredients Bread Troubleshooting Bread Quality Baker s Math & Science Bread Manufacturing Process Hamburger Buns Tortillas Hearth Breads Pan Breads 49

Upcoming Webinars HACCP Today: Critical Controls Concepts Wednesday, Feb 28, 2018 10am PT 12pm CT 1pm ET Join this webinar to learn: How to overcome the challenges companies face with training Best

50 Upcoming Webinars HACCP Today: Critical Controls Concepts Wednesday, Feb 28, am PT 12pm CT 1pm ET Join this webinar to learn: How to overcome the challenges companies face with training Best practices for engaging your employees and earning their commitment The impact your food safety program has on productivity Wednesday, March 7, am PT 12pm CT 1pm ET Join this webinar to learn: The 14 key elements of HACCP Development and Implementation Maintaining effective monitoring, corrective action and verification procedures Performing HACCP Reassessments properly How to measure the success and effectiveness of a HACCP program Register on Alchemy s website under Upcoming Webinars! 50

51 THANK YOU

WE BAKE TO DIFFER E. Wiley Road Schaumburg, IL FAX: PH:

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