Speakers. M. Erhan Yildiz, PhD. Sergio Vargas

Transcription

1 Speakers M. Erhan Yildiz, PhD Director of Global Applications responsable for Bakery & Snacks, Dairy, Batters and Breadings, Meats and Savory teams. Collaborating with Ingredion for 10 years. PhD in Food Science, Rutgers University and post-doctoral education from Princeton University. With more than 10 patents and journal articles. Sergio Vargas Technical Leader in Bakery Segment at Ingredion México, focused on adding value to customers by identifying opportunities in cost savings, process knowledge, best practice sharing and health and wellness demands. Food Chemist from La Salle University, México. 1

2 Gluten free products: a unique sensory experience M. ERHAN YILDIZ, PHD., SR. MANAGER GLOBAL APPLICATIONS SERGIO VARGAS, TECHNICAL SERVICE LEADER BAKERY SEPTEMBER 21ST. 2016

3 Outline The evolution of the trend Customer needs (Market Overview) Gluten-free Bakery Challenges Pulses: the natural fit for gluten & wheat-free baked goods Closing gaps through ingredient technology Highlights 3

4 The evolution of the Gluten-free trend

5 It all started with the Celiac Disease Gluten proteins trigger an autoimmune reaction in small intestine It causes damage to the inner surface of the small intestine and an inability to absorb certain nutrients Cause abdominal pain and diarrhea Decreased absorption of nutrients can cause vitamin deficiencies Only current cure for celiac disease is a Gluten-free diet 5

6 The difference between celiac disease, gluten intolerance, non-celiac gluten sensitivity and wheat allergy Gluten intolerance = referring to the entire category of gluten issues Immune overreaction Internal threat = autoimmune problem External threat = allergic reaction Celiac disease = inherited autoimmune disorder affecting digestive process of small intestine =both food intolerance and autoimmune disorder Non-celiac gluten sensitivity = causes the body to mount stress response (often GI symptoms), often called gluten intolerance Wheat allergy = causes the immune system to respond to a food protein because it considers it dangerous to the body when it actually isn t Symptoms = abdominal pain, bloating, diarrhea, risk for malnutrition, osteoporosis or anemia Symptoms = headache, foggy mind, joint pain, numbness in legs, arms or fingers Symptoms = skin rash, itching, swelling, trouble breathing, wheezing and loss of consciousness 6

7 Gluten & Common Sources Gluten is a protein which occurs naturally in wheat, barley and rye Common Sources of Gluten: Wheat Kamut (Khorasan Wheat) Spelt (Dinkel Wheat, Hulled wheat) Durum (Durum Wheat) Semolina (Coarse Grind Durum Wheat) Farina (Soft Wheat) Bulgur (White Wheat) Cracked Wheat Graham flour (Whole Wheat Flour, Special Grind) Barley Rye Triticale (Hybrid Wheat and Rye)

8 Mega Trends Health & Wellness Gluten-free Mexico is one of the countries with the highest percentages of celiacs Driver for gluten-free diet Prevalence # of consumers (1) Celiac Disease % +/- 3 million consumers (2) Free-from Lifestyle ~30% +/- 37 million consumers (3) Mexican population look want to lose weight +60% +/- 75 million consumers Source: (1) Journal Of Pediatric Gastroenterology and Nutrition, Oct 2014 (2): Nielsen Homescan, Año móvil 14 a febrero. (3): Nielsen. Tendencias del mundo saludable. Nov

9 Mega Trends Health & Nutrition Gluten-free What does it look like today? Of those who eat Gluten-free foods do so because 65% 36% 27% healthier sensitivity weight loss 7% 4% reduce inflammation depression Source: 1. Journal Of Pediatric Gastroenterology and Nutrition, Mintel 2014, based on a North American Study 3. Nielsen Homescan,

10 The development of the Gluten-free market Trend 1.0 Medicalised Food 2.0 Taste & Texture 3.0 Nutrition & Clean Label Glutenfree claim Addressing a medical need Differentiator Natural and Nutrition Plus Type Technology consumer Lifestyle consumer Mass market consumer Need Celiac Gluten sensitivity Self-diagnosed Lose weight Nutritional health Gluten-free as part of wider health debate High Consumer commitment Low We are here Source: New Nutrition business and Horizon presentation at the Free From Summit 2015 from FDIN 10

11 Customer needs in Gluten-free

12 Global & México Gluten-free launches 11,829 New Product Launches with a Gluten-free Claim - Global 13,713 20,215 26,939 31,624 24, YTD Aug 117 New Product Launches with a Gluten-free Claim - Mexico YTD Aug Gluten-free Launches by Sub-Category in Mexico YTD Aug 7% 6% 7% 9% 10% 10% 14% 11% 13% 13% Snack/Cereal/Energy Bars Rice/Nut/Grain & Seed Based Drinks Meat Products Potato Snacks Baking Ingredients & Mixes Fruit Snacks Sweet Biscuits/Cookies Corn-Based Snacks Vitamins & Dietary Supplements Bread & Bread Products Source: Mintel GNPD, Bakery NPLs with gluten-free claim 12

13 Gluten-free Bakery - product examples Gluten-free + Less Fat Gluten-free + Natural Gluten-free + Whole Grain Gluten-free + Sugar Free Source: Mintel GNPD, Bakery NPLs with gluten-free claim 13

14 Gluten-free formulation challenges

15 Gluten-free formulation challenges Shelf-life Nutritional Profile Texture Taste Appearance Processing 15

16 Processing - Lack of viscosity or elasticity of the wheatcontaining dough leading to difficulties in processability and machinability Gluten gives strength and elasticity to the dough Holds gas and allows dough to rise Develops bread shape when baking Damaged starch improves dough hydration Good functionality in the oven: Low gelatinisation and high pasting temperatures Water transfer from coagulated gluten to wheat starch Relatively well cooked despite low energy and water levels Amylose sets the crumb structure upon cooling Glutenin Gliadin Gluten 16

17 Gluten-free bread formulation - toolbox approach Water 35-45% GF Flours & starches («bulk») 20-50% Wheat starch replacement Gums 0.5-3% Proteins 2-5% Wheat gluten replacement Fibres % Enzymes ppm Emulsifiers 0.5% Fats, oils, humectants 2-5% 17

18 Functionality of Ingredients Used 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 Pre-gelatinized Native Functional or Modified Starches Corn, Tapioca, Rice, Potato 20-50% Texture modifier: Body, elasticity & chewiness, crumb structure Freeze-Thaw Stability Corn, Tapioca, Rice, Potato 2-10% Dough viscosity control Texture modifier Prevent staling Proteins Other Hydrocolloids/Gums Whey Protein, Soy Protein, Zein, Egg White Powder, Pulse Proteins Xanthan Gum, Guar Gum, Cellulose Gum, Alginates, Konjac, Psyllium Husk 2-5% Build structure Color development 0.5-3% Dough viscosity control Texture modifier Prevent staling Freeze-thaw stability Use combination of ingredient to match dough rheology and final product texture is key! 18

19 Typical Defects of Commercial Products Biscuits/Cookies Grittiness Sandiness Lack of bite Taste Cake/Muffin Lack of volume Crumbliness Dryness Gumminess Taste Nutritional profile Bread Lack of volume Lack of elasticity Dryness Gumminess Not homogeneous Crumb Taste Nutritional profile Increased Functionality of Gluten Bakery Products vs. Gluten Functionality 19

20 Texture, Taste & Appearance - Reduced volume, lack of an even cell structure. - Dry, crumbly, grainy texture. - Poor crust color and development. - Grainy flavor Retail Glutenfree Bread 20

21 Gap Measured Using Descriptive Sensory Analysis Cohesiveness of Mass: The degree to which a chewed product forms a bolus/ball/holds together Gluten-free Market Samples Wheat-containing Benchmark Loose Compact Roughness of Mass: The amount of graininess as perceived on the surface of the product during its mastication Gluten-free Market Samples Wheat-containing Benchmark High Low 21

22 Descriptive Sensory Analysis

23 Texture Mapping Commercial Cookie Benchmark: Gluten-free Commercial Muffin Benchmark: Gluten-free Smooth Commercial Cookie Benchmark: Wheat containing Commercial Muffin Benchmark: Wheat containing Dry Crumbly M C Moist Chewy 2 Grainy 23

24 Shelf-life - Shorter shelf-life/ Increased staling rates due to increased water mobility Texture Analysis Results Crumb Firmness Retail GF Breads Peak Force Average (g) Retail Wheat Breads Higher the score, the firmer the crumb 24

25 Nutritional Profile - Lack of protein, nutrients and fiber. - Use of high levels of sugars and fats to mask the texture and flavor challenges Increase protein content Increase fiber content Gluten-free Cost more Usually more calories Regular Often less sugar Less sodium in most cases 25

26 Pulses are nutritional powerhouses High in protein High in dietary fiber Rich in minerals (iron, zinc, phosphorus) Source of B vitamins and folic acid 26

27 Pulses support many of the label claims consumers are looking for VEGETARIAN NON-GMO OPTIONS GLUTEN-FREE LOW GLYCEMIC INDEX 27

28 Ingredient technology and formulation science to close gaps

29 Ingredients Used in Gluten-free Baking Pulse Proteins & Flours Amaranth Arrowroot Starch Bean Flour Buckwheat Corn Bran Corn Flour Corn Germ Corn Meal Corn Starch Millet Montina (Indian Rice Grass) Oat (Pure Uncontaminated) Quinoa Potato Flour Potato Starch Flour Rice Bran Rice Flour (White, Brown, Sweet) Rice Polish Rice Starch Flour Sorghum Flour Soy Flour Tapioca Starch Teff Amaranth Arrowroot Buckwheat Millet Quinoa Sorghum Soy Tapioca Teff Source: Gluten Intolerance Group,

30 Every starch is different SOURCE TYPE DIAMETER (µm) SHAPE AMYLOSE CONTENT IODINE STAIN SEM Corn Cereal 5 26 Round, polygonal Blue Waxy Corn Cereal 5 26 Tapioca Root 5 25 Potato Root Wheat Cereal 2 35 Rice Cereal 3 8 Sago Pith High Amylose Corn Cereal 3 24 Round, polygonal Truncated, oval Oval, spherical Round, lenticular Polygonal, angular Oval, truncated Round, elongated < 1 Redviolet Blue 23 Blue Blue Blue 26 Blue Blue Sources: Ingredion, John F Robyt, C.W. Wong and al 30

31 Commonly used Gluten-free starches and flours Potato starch High water absorption, gives moisture to the end product Quite bland in taste at low levels Recipe concentration effect / Good cost in use Maize starch Typical maize flavour, creamy to yellow color Gives a ligth crumb structure Generally undercooked in bakery applications: sandy mouthfeel Good setting properties but fast staling Tapioca starch / tapioca flour Adds elasticity, chewiness, reduced crumbling Gives good moisture, lightness, fine crumb structure Rice flour Mild taste Very digestible and no allergenic Smooth texture Gives body, but turns quite dense when used on its own 31

32 Comparative viscosity profiles C minutes 30 C Maize Potato r Tapioca Wheat Waxy Maize [BU] minutes 36 g starch, anhydrous starch + H2O = 490 g rapid heating to 50 C, t hen 1,5 C/min to 95 C, maintain 20 min cooling to 30 C -1,5 C/min 32

33 Gums 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 33

34 Use of gums in Gluten-free formulations Product Xanthan Guar CMC HPMC Functionality Batter viscosity and cohesive texture Batter viscosity, freeze/thaw stability and moisture retention Cell structure and moisture retention Structure and set during baking due to thermal gelling characteristics Gum No Gum A combination of Potato Starch, Tapioca Starch and Guar gum provides a soft crumb structure, volume and moisture retention Gum Arabic Emulsification and film formation LBG Batter viscosity, cohesive texture, cell structure and freeze/thaw stability Gum No Gum A combination of Corn Starch, Gum Arabic, Xanthan gum and Guar gum provides volume, uniform cell structure, suspension and moisture retention 34

35 Pulses Flour has similar/higher protein content as wheat flour, but Ingredion Pulse Flour Yellow Pea Flour V-6000 Protein (% d.m.) 12.1 Wheat Flour (All Purpose) 9.5 Corn Flour 5.9 Rice Flour * This one has higher starch content, lower protein content 35

36 Impact of Pulse Protein Amino Acids Composition on Product Formulation Nutritional Quality 9 Essential amino acids - cannot be made by the body, must come from food. Histidine Isoleucine Leucine Phenylalanine Threonine Valine Methionine Tryptophan Deficient in pulse protein Lysine Abundant 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 ε-amino group 36

37 Gluten-free formulation challenges addressed Shelf-life Nutritional Profile Texture Taste Appearance Processing 37

38 Key Takeaways 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 Flour and starch: not «bulk» but a an important part of GF bread formulation. Hydration is key to texture formation and stability A holistic formulation approach with key functional ingredients are shown to replace gluten without compromising the eating quality, processing and shelf-life 38

39 Thank You & Questions? 39

40 Appendix 40

41 Ingredion s Gluten-free capabilities Increase protein content Increase fiber content Improve eating quality and texture Ensure consistency and processability during production Keep freshness Simplify ingredient lists by replacing E-numbers 41

42 Ingredion Product Development Methodology Define Goals Identify Benchmark Measure Texture Analyse Gaps Design/ Confirm Realise Goals Leading gluten containing brand for the different categories Glutenfree containing bakery products Texture profiling: Of both gluten containing and GF products For key texture and sensory attributes > 400 trialed combinations in a structured DoE approach Test and confirm prediction a b 40 k 30 c j 0 d i e h f g 42