Food & Process Innovations

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Lenard McDowell
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1 Food & Process Innovations A value chain and material science approach for maize processing Beatrice Conde-Petit & Sahar Nikouie Adl 2015

2 Innovations for a better world Build knowledge & develop technologies to deliver safe, affordable and nutritious foods that meet local taste and lifestyle using local crops, and contribute to sustainable value chains. 2 Bühler Food & Process Innovations Conde & Nikouie Adl 2015

3 Cereals are the cornerstone of nutrition around the globe Maize, Rice and Wheat sum up to Mio MT pa Production in Mio MT Maize Rice, paddy Wheat Potatoes Cassava Soybeans Barley Sorghum Oats 0 Source: FAO Bühler

countries in per capita consumption Lesotho 328 g/person/day Malawi 293

4 MAIZE USA the largest producer for feed & Africa the biggest consumer as food Data for 2013 from FAOSTAT Average production Top 5 countries in per capita consumption Lesotho 328 g/person/day Malawi 293 Mexico 267 Zimbabwe 241 South Africa 222 Estimation from Ranum et al, Bühler

maize (protein) Desire for affordable convenience Little value

5 The challenges for maize as food in Africa High post-harvest losses Contamination with Aflatoxin Limited nutritional value of maize (protein) Desire for affordable convenience Little value from by- products (bran) Low milling yield of some new varieties 5 Bühler

6 Sustainable value chains for good nutrition from maize Post harvest handling for reducing losses Solutions to reduce aflatoxin contamination Cost efficient processing technology Value from by-products for nutrition = Safe, affordable tasty, convenient & healthy food Retailers Growers Post harvest handlers Agro food convertors Food processors Retailers Consumers Solution / Technology Providers 6 Bühler

7 Sustainable value chains for good nutrition from maize Post harvest handling for reducing losses Solutions to reduce aflatoxin contamination Cost efficient processing technology Value from by-products for nutrition = Safe, affordable tasty & healty food Science Marktet Technology Retailers Grower Post hervest handler Agro food convertor Food processor Engineering Retailer Consumer Solution / Technology Providers 7 Bühler

8 Solutions for safeguarding the value of maize Isigayo- A small scale maize mill Aflatoxin reduction in maize milling Bühler B.Conde l 2014

texture as traditional Convenient preparation The challenge:

9 Imparting convenience to a traditional South African foods The market: Traditional foods The goal: Shelf stable flour Taste & texture as traditional Convenient preparation The challenge: Affordable processes that meet the consumer needs 9 Bühler B.Conde l 2014

10 Maize structure and composition Composition Structure 72 % starch 10 % protein 4 % fat 12 % fibre Bran Endosperm Germ 10 Bühler

11 A material science approach to understand & tailor food structures and processes State diagrams of starch Conde-Petit, B., Zweifel C., (unpublished 2000) Structure at different length scales 11 Bühler

12 Glass transitions and melting of starch can be measured by calorimetry (DSC) T g Water 10 % wb Amylopectin Amylose-lipid T m AP T m AL Water 70 % wb 12 Bühler Starch and Gluten free pasta B. Conde 2010

13 Defining optimum precooking based on state diagram of starch limited medium excess moisture Amylose-lipid complexes Amylopectin (Gelatinization) Limited water is preferred for efficient drying of end product Extrusion Steaming 13 Bühler

14 Structure and cooking behaviour of maize products precooked convenience products Traditional raw maize for pap Pap Porridge Porridge low viscosity Microstructure Increasing degree of cell disintegration and starch swelling & solubilization (gelatinization) Pap from raw maize Pap Porridge Porridge (low viscosity) RVA viscosity 1) [Pa s] > Gel stability Index 2) >25 hot water dispersible Cooking behavior 1 h 5-2 min hot water dispersible Convenience Traditional quick cooking instant instant 1) Final RVA 12 % solids 2) Gel firmness x Elasticity/ 100 in g. 25 % solids after cooling for 12 h at 5 C 14 Bühler

15 Convenience for maize: structure and cooking behavior precooked convenience products Traditional raw maize for pap Pap Porridge Porridge low viscosity Microstructure Increasing degree of cell disintegration and starch swelling & solubilization (gelatinization) Pap from raw maize Pap Porridge Porridge (low viscosity) RVA viscosity 1) [Pa s] > Gel stability Index 2) > 25 hot water dispersible Cooking behavior 1 h 5-2 min hot water dispersible Convenience Traditional quick cooking instant instant 1) Final RVA 12 % solids 2) Gel firmness x Elasticity/ 100 in g. 25 % solids after cooling for 12 h at 5 C 15 Bühler

98 C lower end 90-130 higher end SME [Wh/kg] static lower end 20-100 higher end Processing time 1 h higher end 30 min -

16 Defining the process variables for targeted material transformation precooked convenience products Traditional Raw maize for pap Pap Porridge Porridge low viscosity Moisture content [g / 100g] >75 higher end lower end Temperature [ C] 98 C lower end higher end SME [Wh/kg] static lower end higher end Processing time 1 h higher end 30 min - 30 s lower end Technology Traditional cooking Steaming, flaking, drying & grinding Extrusion, drying & grinding 16 Bühler

17 Extrusion: an established technology for innovative solutions Flour Intake Mixer Feeder to Extrusion Extrusion Drying & Cooling Grinding 17 Bühler

18 18 Bühler

19 19 Bühler Instant & Quick Cooking Maize Analytics Lab 2012

20 Tailoring maize cooking behavior and texture through processing 10 % solids 20 Bühler Instant Maize Meal B. Conde 2012

INCREASING WHOLE GRAIN INTAKE : A TECHNICAL PERSPECTIVE

INCREASING WHOLE GRAIN INTAKE : A TECHNICAL PERSPECTIVE Prof Dr Ir Sugiyono MAppSc. Dept Food Science and Technology Bogor Agricultural University Mobile : 0812 1318 058 Email : sugiyono@ipb.ac.id Outline