Smoke Technology Overview. March 12th 2016
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1 Smoke Technology Overview March 12th 2016
2 AGENDA: - Process technology (Obtainment); - Flavor profiles and applications; - Texture and Coloring; - Preservative Function; - Other benefits (Sustainability). March 12th Taste & Nutrition
3 Smoke Technology Overview Obtainment 3 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
4 Why Use Smoke? Smoke is diverse and multifunctional. FLAVOR Phenols Acids COLOR Acids Carbonyls TEXTURE Acids Carbonyls PRESERVE Acids Carbonyls 4 Taste & Nutrition
5 Liquid Smoke: How It s Made Water Shower Aqueous FracGon (liquid smoke) Organic FracGon (tar) Other Gases Sawdust from Mill Water Vapor Smoke Vapor Aqueous Condensate Sawdust Dryer Dried Sawdust Pyrolysis Furnace Char 5 Taste & Nutrition
6 Pyrolysis:Destructive Distillation no Oxygen 6 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
7 Pyrolysis:Destructive Distillation no Oxygen 7 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
8 AddiGonal Processes Additional Operations DisGllaG on Go p r o Ads Liquid /L i q u i d Extr acgon on G a r o Evap 8 Taste & Nutrition n CONNECTED. UNIQUE. INNOVATIVE.
9 Choosing the Right Smoke for Your Application Considerations Desired flavor and color Considerations (cont.) Smoke delivery formats Very little flavor to heavy smoke, ashy flavor Water soluble liquid Golden light brown to reds to black Spray-dried powder Regulatory constraints Natural, non-gmo, no polysorbate, etc. Compatibility with other ingredients Neutralized or low-acid if mixed with nitrite Oil soluble liquid Concentrated super-smokes Buffered / alkalized smokes Method of application Topical Injection Mixing Casing / Netting Solubility in solutions 9 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
10 Kerry s Smoke Portfolio Standard Smokes Hardwood Hickory Mesquite Artisan & Flavoured Smokes Campfire Apple Flavor Infused Maple Flavor Infused Jalapeno Flavor Infused Zesti Smokes Applewood Pecan Deli Black Deli Red Deli 10 Taste & Nutrition FLAVOR COLOR TEXTURE PRESERVE
11 Smoke Types Aqueous Liquid Smokes Primary Smokes Soluble Smokes Brine-soluble Smokes Concentrated Supersmokes Buffered / Alkalized Smokes Oil-soluble Smoke Flavors Dry Smoke Powders Smoke Flavor Infused Spray Dried 11 Taste & Nutrition
12 Primary Smokes Basic liquid smoke after the heavy tars have been removed Available in Hardwood, Hickory or Mesquite flavors Applications Atomization BBQ sauces Usage: % 12 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
13 Soluble Smokes Liquid smoke processed to work well in drench solutions, brines and marinades Addition of polysorbate Patented filtration to make naturally soluble Applications Direct addition to product Water solubility is needed Usage: % Drench Usage: 5 50% of drench solution 13 Taste & Nutrition
14 Brine-soluble Smokes Soluble smoke buffered to be compatible with sodium nitrite in a brine solution **Must be used when adding to a brine containing Sodium Nitrite. ApplicaGons Direct addigon to product (bacon and ham are most common) Usage: % Any ph sensigve applicagons or where a strong acid flavor is undesirable Any applicagon where it is not pracgcal to apply smoke to the exterior of the product 14 Taste & Nutrition
15 Concentrated Supersmokes Liquid Smoke concentrated by evaporation Applications Drench Usage: 5 50% of drench solution Casings and nettings International shipment 15 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
16 Oil-soluble Smokes Liquid-liquid extraction to separate oil soluble phenolic flavors Applications Direct addition to products where water solubility is not required and adequate mixing can be achieved Products with little or no water added Plating onto carriers for seasoning blends Usage: % of total formula 16 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
17 Dry Smoke Powders Smoke-infused ingredients smoked dried onto salt, spices or flours Spray dried smoke powder smoke dried onto a maltodextrin carrier Applications Seasoning blends, rubs, marinades, glazes, snack seasonings Soups, sauces, dressings, prepared meals Dough Usage: % of total formula 17 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
18 Smokes as Browning Agents Kerry Smoke Fractions provide browning with or without traditional smoke flavor Sugar-derived browning agents also available At different concentrations and varied heating periods, different levels of browning can be achieved. Deli- style Turkey Breast Drenched w/ Zes9 Browning Agents for 15 Seconds Complete Genera9on 40% ConcentraGon 6- minute post- drench heagng Zes9 Advantage 40% ConcentraGon 6- minute post- drench heagng Zes9 Brown Deli 40% ConcentraGon 6- minute post- drench heagng 18 Taste & Nutrition Zes9 Red Deli 40% ConcentraGon 6- minute post- drench heagng Zes9 Brown Deli 40% ConcentraGon 2- minute post- drench heagng Zes9 BA Premium 3% ConcentraGon 6- minute post- drench heagng Zes9 Brown Deli LF 40% ConcentraGon 6- minute post- drench heagng
19 Smokes as Antimicrobials Antimicrobial Benefits Inhibit bacterial growth Kill pathogens (listeria, salmonella, etc.) Inhibit mold growth Other Benefits of Zesti AM Products Clean Label: labeled as Flavor for USDA products Low-to-no flavor impact on finished product Diverse application Meat & Poultry Fish & Seafood Fruits Dairy Products Patented process 19 Taste & Nutrition
20 Pathogen Control: Case Study According to the test results, Zesti AM killed Listeria monocytogenes and inhibited the bacteria s subsequent growth on treated hot dogs The retail brand with the highest Listeria growth (indicated in blue) was dipped in a ZesG AM bath to test the inhibigon of Listeria monocytogenes growth. * Study conducted by Oklahoma State University Control ZesG AM Treated 20 Taste & Nutrition
21 Freshkeeping: Case Study Freshness preserved on beef and pork 10 days aaer packing Right: Control Le(: Zes< AM5 surface applied (sprayed) 21 Taste & Nutrition
22 Smoke: Sustainability 22 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
23 Only Water Vapor / CO2 Air Emissions 23 Taste & Nutrition
24 Nearly Carbon Neutral Main raw material is sawdust Waste material from sawmills-reduces landfill waste Tar Waste Stream: by-product of liquid smoke is wood tar Used as Bio Fuel for sawdust dryers Methane Gas Methane produced in pyrolization of sawdust is captured as used as fuel for furnaces Char Used as Bio Fuel for outdoor cooking (e.g. charcoal briquettes) 24 Taste & Nutrition CONNECTED. UNIQUE. INNOVATIVE.
25 Air Permits Sawdust dryer and furnaces are proactively managed to keep the following pollutants below Clean Air Act Title V minimums: Particulates Organic Compounds Sulfur Dioxide Nitrogen Oxides Carbon Monoxide Our plant s pollutant control efficiency is up to 98.5% for particulates and organic compounds. These proactive measures were significant enough to warrant the TN Association of Business to award our plant the Excellence in Air Quality Award. 25 Taste & Nutrition
26 Liquid Smoke vs. Traditional Smoking Using liquid smoke in place of traditional smoking greatly reduces emissions 26 Taste & Nutrition
27 Traditional Smoke vs. Natural Smoke Flavor Traditional Smoke PARTICULATES 80% of Smoke Volume Fly Ash Resins Tars (some known carcinogens) SOLID COMPOUNDS Char None VAPOR COMPOUNDS Natural Smoke Flavor PARTICULATES No Fly Ash Reduced/Eliminated Resins Greatly Reduced Tars SOLID COMPOUNDS VAPOR/LIQUID COMPOUNDS Organic Acids Smoke Flavor (phenols) Carbonyls OTHER COMPOUNDS CO, Alcohols etc. Organic Acids Smoke Flavor (phenols) Carbonyls OTHER COMPOUNDS None 27 Taste & Nutrition
28 Traditional Smoke vs. Natural Smoke Flavor Smoke condensates Wood Smoking 28 Taste & Nutrition
29 Feria Tecnolacteos / Carneos Bogotá April/2016 GRACIAS POR TODO! Thanks, THATS ALL FOLKS! QUESTIONS??? Rafael Santos LATAM Business Development Manager Kerry Taste and Nutrition rafael.santos@kerry.com 29 Taste & Nutrition
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