Novel ingredients in Free-From Food manufacturing
Dale WhitemanTechnical Development Manager
Daymer Ingredients
Who are ?
Food Ingredient distributor established 2003 based in Atherstone on Stour, Warwickshire providing:-
stabiliser systems texturiser blends starches and modified starches maltodextrins, dextrose & glucose proteins and emulsifiers yeast extracts and HVPs natural savoury flavours gums and hydrocolloids dairy ingredients
An ever growing area
Can even lead to nut free “nuts”............
Limagrain Céréales Ingrédients Nutricorn Nuts Announced beginning of September Maize based toasted corn germ Nutty texture, flavour and aroma
Free From Ingredients
Gluten free Is Xanthan the only answer?
Dairy Free Completely dairy free Lactose free dairy ingredients
Egg free
Free From Ingredients
Gluten free
Function of glutenDifferent products have different requirements
Bread and cakes Provides an elastic network controlling air cell
size during formation of dough and cooking On cooking gluten coagulates interacting with
other proteins and fat to control toughness and elasticity of structure
Pasta Elasticity Al dente texture/chewability
Gluten free bakery
Flour replacement
Typically combinations of corn and potato starch, rice flour, tapioca flour and occasionally include other flours e.g. Buckwheat
Ratios depend on end application Bread flour
Assorted blends used, all need additional gluten replacers to function
Pasta Primarily corn flour Occasionally rice based but can become gummy
on cooking Frying batter
Usually rice flour based
Gluten free bakery
Common options to replace gluten Xanthan,
Can lead to crumb hardening & gummy mouthfeel Xanthan alone can control air cell size but volume often
restricted May not be suitable for all
Egg proteins Currently unstable pricing Brings another allergen issue
Guar gum Availability Cost!!
Gluten free bakery
HPMC (Hydroxypropylmethylcellulose) Used successfully with corn starch/rice flour blend Can be tricky to disperse in water
better if premixed with other materials Typical application rate 2%
Enhances volume Controls air cell size and distribution Reduces staling
Current research Food Hydrocolloids Issue 30 Vol 1 (Jan 2013) p393-400 Clear demonstration of improvement to commercial gluten
free flours using HPMC with or without buckwheat flour
Gluten free bakery
Other cellulose based materials WellenceTM
Combination of HPMC and CMC specially modified for application
Gives excellent volume increase and air cell control Relatively low addition rate
Without WellenceTM
With WellenceTM
Gluten free bakery
Vegetable proteins Combinations of potato or pea proteins with a blend
of corn starch, rice flour and potato starch More even air cell distribution, enhances volume,
improves surface browning
Control With 1.6% Solanic potato protein isolate
Gluten free bakery
Vegetable fibre Insoluble pea fibre
Proposed as a guar substitute appears to work well with bread and cakes at
between 2:1 to 2.5:1substitution level some cost benefit while maintaining dough
viscosity on kneading
Gluten free bakery
Future technology? Sourdough approach (University College Cork)
Selected lactic acid bacteria and enzymes used to treat wheat flour to produce fully hydrolysed wheat flour with <10ppm gluten
Lactic acid bacteria produce exopolysaccharides i.e. Materials similar to xanthan
Small scale studies seem to indicate no toxicity to coeliac patients however much larger studies are required to confirm safety of this approach
Gluten free Processed meat
Replacement of breadcrumbs and rusk Used as a binder in sausage and burgers
Found in over 90% of sausages Usually based on wheat flour Reduce moisture/fat loss on cooking
maintaining juiciness Usual GF alternatives
Higher fat meat content Soy flour
Daymer option for low fat gluten free Blend of potato starches and rice flour
Dairy free
Basic functions of milk proteins Emulsification Foam stabilisation Structuring e.g. cheese Glazing
Typical alternatives Soya
Brings another allergen issue GM free requirements of many customers Unless high quality/price can bring flavour or colour problems
Egg Another potential allergen Pricing currently very unstable
Dairy free emulsification
Newer options for emulsifying Non dairy proteins including-
Other vegetable proteins (pea, potato, rice) Generally successful although flavour or colour
issues can still be found unless high quality ingredients used
Animal proteins Gelatin Fish gelatin
Dairy free
More recent options Modified starch (Starch sodium octenyl succinate) E1450
Some emulsifying capacity Typical addition rate 0.5-1%
α–Cyclodextrin Novel Foods approval gained 2008 Can be effective in a range of applications such
as sauces, mayonnaise etc Optimum effect at high oil levels Limitations on pH and heat treatment during
emulsification
Dairy free - foam
Current usual stabiliser choices Egg albumen – see earlier issues! Soy protein isolates Gelatin and other animal protein
More recent options
Potato and pea proteins
E1450 Starch octenylsuccinate Emulsifies but may also contribute to aeration
α–Cyclodextrin Can double overrun on non protein systems
Combinations of cellulose ethers and surface active materials e.g. E481 SSL which is already found in many bread improvers
Dairy free
Analogue cheese Blends of modified starches
Selected to control firmness and melting properties as well as emulsify fat
Made using standard processed cheese equipment
Other hydrocolloids can be added to improve properties like stretch
Lactose free
Lactose free milk powders Typical Skim milk powder 50% lactose Lactose removed by a combination of
ultrafiltration and enzyme hydrolysis to <0.1% Some conversion to glucose & galactose Overall increase in protein content
Dairy & Egg free - glazes
Milk and egg wash glazes Seal surface Add sheen Enhance browning
Alternatives Based on dextrins and starches Addition of vegetable proteins such as potato
can enhance finishControl Milk glaze Egg glaze
Images from “The Fresh Loaf”www.thefreshloaf.com
Egg free - Emulsification
Similar solutions to dairy free
Egg free mayonnaise dressings
Combinations of modified starches can provide the emulsification and viscosity provided by egg at a range of fat levels
Do you have a challenge for Daymer?
Further Contact
email – [email protected] telephone - +44 (0)1789 450 131 web – http://www.daymer.com
linkedin – http://www.linkedin.com/company/daymer-ingredients-limited twitter – http://twitter.com/daymerfood