ENZYMES in TORTILLAS and FLAT BREADS Dilek Austin, Ph.D. Baking Technical Services Novozymes North America, Franklinton, NC IBIE 2016-October 11,

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1 ENZYMES in TORTILLAS and FLAT BREADS Dilek Austin, Ph.D. Baking Technical Services Novozymes North America, Franklinton, NC IBIE 2016-October 11, 2016

2 Outline Introduction to ENZYMES Enzymes in FLOUR TORTILLAS Enzymes in CORN TORTILLAS Enzymes in FLAT BREADS Q&A

3 Introduction to Enzymes

4 Nature: Source of enzymes

5 Enzymes are natural Active proteins In all living organisms Plant Animal Microorganisms-fungal, bacterial Specific Works under mild conditions Replaces/reduces chemicals

An example on benefits of fresh-keeping enzymes A solution lets producers optimize their distribution, and offers consumers bread that s soft, elastic and moist to the last

7 An example on benefits of fresh-keeping enzymes A solution lets producers optimize their distribution, and offers consumers bread that s soft, elastic and moist to the last slice Enzymes for fresh-keeping Baking Distribution Sale from primary store Bread that s soft, moist, elastic during storage Optimised transportation Less food waste Less food waste

8 How enzymes work

9 Important process parameters for enzymes ph Temperature Water Enzyme dosage Substrate Stabilizers Inhibitors ph effect Temperature effect Oxygen Contact time

10 Enzymes maintains tortilla freshness Stale tortillas/flat breads are firm and they crack when folded, become unacceptable to consumers Enzymes can; Extend shelf-life Improve dough handling and machinability Enhance mixing tolerance Replace/reduce chemicals

11 Enzymes in flour tortillas

12 Flour tortillas Short baking time 1 Dries quickly Flexibility maintenance is important 2 Shortenings, emulsifiers, vital gluten, dough relaxers are critical Consumers desire less ingredients Clean label is vital

13 Enzymes used in flour tortillas Enzymes Alpha-amylase Fresh keeping Maintenance of softness, flexibility and moistness of tortillas up to six months Ingredient reduction Ingredient replacement L-cysteine/SMS Gums Emulsifiers Vital gluten

14 Flour tortillas SIX WEEK-storage With enzymes: Flexible, no cracking Without enzymes: Undesirable cracks Novozymes internal data

15 Novozymes new Alpha-amylase maintains the flexibility over FIVE MONTHS No enzyme New Alpha-amylase Novozymes internal data

16 Score SIX WEEK-storage (industrial production) --Performance increases with dosage increase of the new Alpha-amylase Rollability Softness Flexibility Rollability test: 1.0 cm diameter-dowel 1=breaks easily 5=no cracking Sensorial Softness 1=very hard 5=very soft ppm Sensorial Flexibility: 1=very brittle 5=very flexible

No enzyme New enzyme Breaking force-g The

Extensibility 400 30 300 200 100 25 20 15

17 No enzyme New enzyme Breaking force-g The new Alpha-amylase (industrial production) --Stronger & more extensible tortillas increases over time Breaking force Extensibility Extensibility-mm Weeks of storage

0% on flour weight usage Guar gum is a commonly used

18 Ingredient replacement by New Alphaamylase Gums/hydrocolloids % on flour weight usage Guar gum is a commonly used hydrocolloid Emulsifiers % on flour weight usage Mono- and di-glycerides is a commonly used emulsifier 18

Breaking force-g Extensibility-mm The new Alpha-amylase makes strong and extensible tortillas WITHOUT Guar gum and Mono- and di-glycerides (industrial production) 350 Breaking force-g

19 Breaking force-g Extensibility-mm The new Alpha-amylase makes strong and extensible tortillas WITHOUT Guar gum and Mono- and di-glycerides (industrial production) 350 Breaking force-g Extensibility-mm NO ENZYME Guar gum replaced with enzyme Mono-di glycerides replaced with enzyme Guar gum+mono-di glycerides replaced with enzyme 0 Instrumental tortilla strength (breaking force). Using a Texture Analyzer (TA.XT2-Tortilla Burst Rig; TA-108a 7/16 diameter acrylic cylinder probe to puncture the tortillas), breaking force was defined as the force to rupture the tortillas

Total sensory scores The new Alpha-amylase makes soft, flexible, strong, and moist tortillas WITHOUT guar gum and Mono- and diglycerides (industrial production) 20 18 16 14 12 10 8 6 4 NO ENZYME Guar

20 Total sensory scores The new Alpha-amylase makes soft, flexible, strong, and moist tortillas WITHOUT guar gum and Mono- and diglycerides (industrial production) NO ENZYME Guar gum replaced with enzyme Mono-di glycerides replaced with enzyme Guar gum+mono-di glycerides replaced with enzyme Total sensory scores were defined as the sum of sensorial scores for flexibility, softness, moistness, and strength. Sensory evaluation conducted by a panel of 10 people. 1 to 5 scale; 1 being the worst; 5 being the best.

21 Enzymes in corn tortillas

are critical Consumers desire STRONG and FLEXIBLE tortillas Fresh keeping

22 Corn tortillas Short baking time Stale faster than flour tortillas Maintenance of flexibility is important Enzymes Alpha-amylase Lipase Gums are critical Consumers desire STRONG and FLEXIBLE tortillas Fresh keeping Maintenance of softness and flexibility Reduction of masa stickiness Processing ease

23 Corn tortillas Ten day-old tortillas With enzymes: Flexible, no cracking Without enzymes: undesirable cracks

24 Two-week old corn tortillas Alpha-amylase improves corn tortilla strength during storage Strong Combining Maltogenic Amylase with CMC or Wheat Gluten to Prevent Amylopectin Recrystallization and Delay Corn Tortilla Staling. Francisco J. Bueso, Lloyd W. Rooney, Ralph D. Waniska, and Laura Silva. Cereal Chemistry. September/October 2004, Volume 81 (5) Weak ppm Alpha-amylase 40 ppm Alpha-amylase day 5 day 11

25 Sticky dough Masa dough Non-sticky dough Hard dough NO ENZYME 20 ppm Alphaamylase 40 ppm Alphaamylase 20 ppm Lipase 40 ppm Lipase Less sticky and softer corn masa obtained with an Alphaamylase and a Lipase Soft 20 dough 0 NO ENZYME 20 ppm Alpha-amylase 40 ppm Lipase Novozymes internal data-equipment: TA.XT2

26 Enzymes in flat breads

27 Flat breads Difficult to retain softness even for one day 1 Quickly becomes stale and chewy No technology offers longer freshness 2 Reheating of frozen flat bread results in a very dry and elastic bread Maintenance of softness is important Enzymes can help to retain the softness

28 Enzymes used in flat breads Enzymes Alpha-amylase Lipase Fresh keeping Maintenance of softness and flexibility

Day 3 7 5 3 Breaks easily 1 NO ENZYME 5 ppm

29 Alpha-amylase maintains and improves flat bread softness for three days Very flexible 9 Day 1 Day Breaks easily 1 NO ENZYME 5 ppm Alphaamylase 10 ppm Alphaamylase Novozymes internal data

A Lipase makes softer Naan dough and softer Naan Soft 10 8 6 Dough softness 4 2 Firm 0 without enzyme

30 A Lipase makes softer Naan dough and softer Naan Soft Dough softness 4 2 Firm 0 without enzyme 250 ppm Lipase Naan softness Soft Novozymes internal data Firm 0 without enzyme 250 ppm Lipase

31 Frozen Naan Dough softness Soft 10 8 A lipase gives 22% more 6 mechanical and sensorial softness compared to those without enzymes after 40 days of Firm no enzymes 250 ppm Lipase storage under frozen condition at C Soft Naan softness 50 Novozymes internal data Firm 0 no enzyme 250 ppm Lipase Novozymes internal data

32 Chapatti with a lipase --excellent dough property and better softness Firm 750 no enzymes 250 ppm lipase Soft 0 30 min after baking 3 hrs after baking Novozymes internal data Novozymes internal data

33 Enzymes are natural Enzymes Maintain freshly baked quality of tortillas/flat breads Improve dough handling and machinability Enhance mixing tolerance Replace/reduce chemicals

Chapter 10 - Enzymes: Extending shelf life and eating quality of tortillas Dilek Lemlioglu-Austin A good source for enzymes and tortillas Summary Industrial Enzymes

34 Chapter 10 - Enzymes: Extending shelf life and eating quality of tortillas Dilek Lemlioglu-Austin A good source for enzymes and tortillas Summary Industrial Enzymes used in baking operation Enzymes used in Tortillas Enzymes in Wheat Flour Tortillas Enzymes used in Corn Tortillas

36 Increasing Potassium: The New Sodium Reduction Strategy in Chemically Leavened Goods Dinnie Jordan CEO 11 th October 2016

37 Contents 1. Why we need potassium 2. Balancing sodium and potassium 3. Introducing potassium in baked goods while delivering sodium reduction 4. Take home message 1

38 Maintains body fluid levels Synergistic relationship with sodium Helps to excrete excess sodium Maintains healthy bones Activates nerve impulses 2

39 Recommended Potassium Levels Average potassium consumption in the US is: ~2547mg/day More than 98% of US adults are deficient in potassium dietary guidelines: 4700mg/day = 4700mg 3

Geneva, World Health Organization (WHO), 2012.

40 Deficiency in Potassium Leads to Fatigue and muscle weakness Inactive reflexes Anemia Headaches Swollen glands Diabetes WHO Guideline: Potassium intake for adults and children, Geneva, World Health Organization (WHO), increase potassium intake from food to reduce blood pressure and the risk of cardiovascular disease, stroke and coronary heart disease in adults. 4

Potassium Nutrition Fact Labels : 2015 Dietary Guidelines Advisory Committee Report Potassium is a nutrient Americans don t always get enough of,

consumption was evident across the population, particular concern for middle-aged and older adults, who are at increased risk for cardiovascular

41 Potassium Nutrition Fact Labels : 2015 Dietary Guidelines Advisory Committee Report Potassium is a nutrient Americans don t always get enough of, according to the nationwide food consumption surveys a potassium deficiency increases the risk factors for artery, kidney and heart disease under consumption was evident across the population, particular concern for middle-aged and older adults, who are at increased risk for cardiovascular diseases.. critical for health, as deficiency affects numerous organ systems including the musculoskeletal, renal, and cardiovascular systems. 5

42 How Can the Baking Industry Assist Consumer s Dietary Needs? 6

43 Average US sodium intake: 3400mg/day Advised to decrease to: 2300mg/day Total decrease of 1100mg/day 32% decrease Average US potassium intake: 2790mg/day Advised to increase to: 4700mg/day Total increase of 1910mg/day 68% increase 7

44 Sources of Sodium in Bakery Products Sodium chloride (salt) 49% sodium Sodium bicarbonate 27% sodium Sodium phosphate (SAPP) 21% sodium 8

45 Potassium Alternatives Potassium chloride Potassium bicarbonate There is no potassium alternative for SAPP 9

46 Potassium Chloride Not so effective at controlling yeast fermentation Less effective preservative than sodium chloride Not so functional in bread products KCl Large particles slow to dissolve Too much causes taste issues 10

weight basis) Traditionally very coarse KHCO 3 Large particles don

47 Potassium Bicarbonate Like sodium bicarbonate it s just a carrier of CO 2 Provides less CO 2 compared to sodium bicarbonate (on a weight basis) Traditionally very coarse KHCO 3 Large particles don t fully dissolve Control reactivity with acidulants - they stay the same 11

48 Traditional Potassium Bicarbonate Unsightly spotting caused by coarse particles Localised areas of high ph Poor volume and colour Metallic taste KUDOS TM Potassium Bicarbonate Full dissolution even in dough products Even crumb ph Excellent volume and colour No noticeable metallic taste 12

49 Salt System ~50/50 NaCl/KCl mixture Leavening System 100% potassium bicarbonate + SAPP 13

50 Balancing Sodium and Potassium in Practice 14

How to Reduce Sodium? Salt @1.125% Sodium bicarbonate @0.55% Sodium acid pyrophosphate @ 0.75% Salt @0.5625% Sodium bicarbonate @0.

51 How to Reduce Sodium? Sodium Sodium acid 0.75% Sodium Sodium acid 0.75% PER 100g: PER 100g: Sodium = 749mg Potassium = zero Sodium = 528mg Potassium = zero ACHIEVES: 29.6% reduction in sodium 15

Further Sodium Reduction AND Delivery of Potassium Salt @1.125% Sodium bicarbonate @0.55% Sodium acid pyrophosphate @ 0.75% Salt @0.5625% Potassium bicarbonate @0.

52 Further Sodium Reduction AND Delivery of Potassium Sodium Sodium acid 0.75% Potassium Sodium acid 0.75% PER 100g: Sodium = 749mg Potassium = zero PER 100g: Sodium = 377mg Potassium = 260mg ACHIEVES: 49.7% reduction in sodium 5.5% RDA of potassium 16

53 Further Reduce Sodium and MASSIVELY Increase Potassium Sodium Sodium acid 0.75% Potassium Potassium Sodium acid 0.75% PER 100g: Sodium = 749mg Potassium = zero PER 100g: Sodium = 377mg Potassium = 558mg ACHIEVES: 49.7% reduction in sodium 11.9% RDA of potassium 17

54 Why Should we Introduce Potassium to Baked Products? Potassium is essential for maintaining cardiovascular health, as well as renal health and enables functioning of the central nervous system. Using KUDOS Potassium Bicarbonate can contribute up to the US target potassium level (4700mg). Potassium based ingredient solutions bring sodium and potassium into balance. KUDOS Potassium Bicarbonate is tailor made for chemically leavened goods. 18

Don t contribute to the national health problems with sodium based ingredients. Do contribute to the national health solution with potassium alternatives.

55 Don t contribute to the national health problems with sodium based ingredients. Do contribute to the national health solution with potassium alternatives. It is our responsibility to ensure the products we manufacture are as healthy as possible for consumers and do not negatively impact their health. We have the power to make a real positive difference to the health of everyone. Prevention is better than cure. So what are you waiting for? Take Home Message 19

56 Kudos Blends at IBIE 2016 Please visit us at booth 819, hall N 1-4 Our experts in raising agent technology and low sodium solutions will be on hand to answer any questions you may have. 20

57 The leading supplier of technically driven raising agents Tel: +44 (0)

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