From Gluten-free to Whole Grain: Formulating On-trend Products

Heather MaskusProject Manager, Canadian International Grains Institute

May 4th, 20162016 Protein Trends & Technologies Seminar

• Created in 1972

• Independent organization

• Funding: Farmers, Government

of Canada (AAFC) and industry

partners

• Mission: Creating profitable

opportunities for Canadian field

crops; wheat, pulses, barley

What is Cigi?

2016 International Year of Pulses

Opportunities for Pulse Ingredients

Canadian Pulses

5Black

WHOLE SEED DEHULLEDSPLIT

GROUND FLAKED FRACTIONATED

Pulse Flour

Whole pulse flour is a healthy

food ingredient containing fibre,

protein, vitamins and minerals

Pulse flour is a nutrient

dense ingredient. Key

minerals include iron,

potassium, magnesium

and zinc. It is also rich in

B-vitamins folate, thiamin

and niacin.

Nutritional AdvantagePROTEIN

(%)STARCH

(%)FIBRE

(%)FAT (%)

Pea 20 – 27 42 – 49 15 1.0 - 1.7

Bean 20 – 34 32 – 45 23 0.7 - 2.3

Lentil 21 – 30 42 – 49 14 1.0 - 1.3

Chickpea 18 – 31 33 – 44 25 4.4 - 6.9

Soy (de-fatted) 47 38 18 1

Corn (de-germed) 6 83 2 1

Wheat (de-branned) 10 – 15 73 2 2

Source: Canadian Grain Commission

Nutrition and Health Research

Other Advantages

• Sustainable protein

• Non-GMO

• Low allergenicity

• Clean label

• Global recognition

PRODUCT APPLICATIONS

Breakfast Cereals

Extruded Snacks

Pasta

Noodles

Bread (Gluten- free & Whole Wheat)

Gluten-free Crackers

Extruded Breakfast CrispsWhole Red Lentil Flour (1% salt, 2.5% sugar)

Pin Mill Coarse Pin Mill Fine Hammer Mill Stone Mill

Bulk Density Texture Bowl Life Sensory Characteristics

Pin Mill Coarse 174.3 580.3 Strong lentil flavour, very hard texture

Pin Mill Fine 120.5 358.3 Strong lentil flavour, chewy on outside, hard on inside

Hammer Mill 200.1 641.6 Mild lentil flavour, crunchy

Stone Mill 176.8 513.8 Strong lentil flavour, quiet “pop”, sticky

Extrusion Processing completed at Saskatchewan Food Industry Development Centre

Breakfast Cereal FormulationBased on previous study results optimizing extruded product quality.• 31.5% Corn Meal

• 56.5% Pea Flour/Semolina

• 6.5% Pea Fibre

• 0.5% Salt

• 5% Sugar

Corn Meal

Pea Flour or Semolina

Pea Fibre

SaltSugar

Breakfast Cereal Formulation

Extrusion Processing-Optimized Product

Whole Pea Semolina

Conditions – rep 1, rep2Water flow rate (kg/h)- 2.1, 2.4Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 537, 650Cutter speed (rpm)- 1178, 1207Temperature (°C)- 107, 109Pressure (kPa)- 700, 300

Refined Pea Semolina

Conditions – rep 1, rep2Water flow rate (kg/h)- 2.1, 2.1Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 655, 655Cutter speed (rpm)- 1079, 1122Temperature (°C)- 106, 106Pressure (kPa)- 400, 400

Whole Pea Flour

Conditions – rep 1, rep2Water flow rate (kg/h)- 2.5, 2.2Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 602, 602Cutter speed (rpm)- 1051, 1221Temperature (°C)- 109, 110Pressure (kPa)- 300, 300

Refined Pea Flour

Conditions – rep 1, rep2Water flow rate (kg/h)- 2.5, 2.5Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 537, 673Cutter speed (rpm)- 1093, 1122Temperature (°C)- 109, 109Pressure (kPa)- 300, 200

Effects of Processing on Protein Content of Extruded Pea Based Breakfast Cereals

0.00

5.00

10.00

15.00

20.00

25.00

30.00

1. Whole Pea 2. Pea Roller Milling 3. Blending; pea, corn,fibre, sugar, salt

4. Optimized ExtrusionProcessing (as is moisture)

Pro

tein

Co

nte

nt

(%, d

wb

un

less

oth

erw

ise

ind

icat

ed

)

Coarse Semolina Refined Pea Flour Whole Coarse Semolina

Whole Pea Flour Retail Corn Cereal Control Corn Cereal (Cigi)

Yellow Pea Flakes Target

0

1

2

3

4

5

6

Flour Protein Quality/30g(Quantity*AAS*Protein Digestibility

(87.9% PC))

Blend Protein Quality(Quantity*AAS*Protein Digestibility

(87.9% PC))

Breakfast Cereal Protein Quality(Quantity*AAS*Protein Digestibility

87.9)

Qu

alit

y P

rote

in (

g/3

0g

serv

ing)

Coarse Semolina Refined Pea Flour Whole Coarse Semolina

Whole Pea Flour Retail Corn Cereal Control Corn Cereal (Cigi)

Effects of Processing on Protein Quality of Extruded Pea Based Breakfast Cereals

Breakfast Cereals• Advantages

– Gluten-free

– Higher Protein Content and Quality

– Higher Fibre

• Challenges

– Colour

– Flavour

• Solutions

– Blending of grain ingredients

– Processing modifications

Corn MealPin Mill Fine 1 cm

Pin Mill Coarse 1 cm

Hammer Mill 1 cm

Stone Mill 1 cm

Roller Mill 1 cm

Extruded Snacks

Whole Yellow Pea Flour

1 cm

Pin Mill Coarse

Pin Mill Fine

Roller Mill Hammer Mill

Stone Mill

Expansion Index 3.8 3.6 4.9 4.0 4.1

Bulk Density (g/L) 31.8 39.7 17.5 28.4 35.5

Texture (N) 234.4 320.6 138.3 276.3 269.4

Extrusion Processing completed at Saskatchewan Food Industry Development Centre

Extruded Snacks• Advantages

• Extrusion of whole yellow pea flours is more controlled than for the split yellow pea flours. Additional fibre of whole yellow pea flours acts as a nucleation agent and controls air cell size of extrudates.

• Challenges– Direct expanded products made with whole yellow pea flour are

darker in colour and have a greater bulk density than split yellow pea flour.

– Coating with complementary flavours

– Small reference amount, difficult to make protein claim

• Solutions– Bending with other ingredients to improve nutrition, taste and texture

Pasta

• Pulse flour milling to produce low medium and high protein content flour

• Blended with durum semolina 30:70

Pasta

Pasta

Esey AssefawHead Asian Products and Pasta Department

Canadian International Grains Instituteeassefaw@cigi.ca

Pasta• Advantages

– Increase protein content, quality and nutrient density

– No change in cooking time

• Challenges– Dough crumb sticky, effects extrusion

– Darkening of pasta with HTST drying

– Drying cycle effects pasta cooked firmness

– Soluble proteins leached in cooking water

• Solutions– 2% reduction in water addition for yellow pea semolina

– Use LTLT drying profile to minimize colour changes

– Use fine semolina pulse ingredient and the LTLT drying profile for best appearance and cooked pasta firmness

Noodles

Sandwich sheeting for whole wheat noodles (Cigi Asian Products Department)

Processing method to improve end product quality

standard processing method

- 2 dough sheets are formed at first pass then 2 dough sheets are laminated to form 1 dough sheet on second pass

sandwich sheeting processing method

- 3 dough sheets are formed at first sheet forming pass then 3 dough sheets are laminated to form 1 dough sheet.

Esey AssefawHead Asian Products and Pasta Department

Canadian International Grains Instituteeassefaw@cigi.ca

Hoppers (where the noodle crumbs go to)

Three rolls in the first pass (sheet formation)

Rolls in the second pass (sheet lamination/compounding)

Sandwich sheeting for whole wheat noodles (Cigi)

3 hrs

24 hrs

Refined WW Sandwich

Sandwich sheeting for whole wheat noodles

Sandwich sheeting

used to improve noodle appearance

used to improve noodle texture

used to increase nutritional profile of noodle products

Gluten-Free Pan Bread

Gluten-Free Pan Bread

Gluten-free Pan Bread

• Improved nutritional profile of the bread– eligible for a dietary fibre nutrient content

claim.

• The addition of pulse flours resulted in breads with a firmer texture and smaller cell diameters compared to the control bread

• Among the three pulse types, the bread containing fava bean flour produced a bread with milder flavor

Whole Wheat Pan Bread Quality

Whole-wheat breads formulated with 15% whole yellow pea flours. Pea flours were milled using four methods

( L to R: Pin Mill Fine, Stone Mill, Hammer Mill, Roller Mill)

Whole Wheat Pan Bread

Yvonne SupeeneHead Bakery Technology Department

Canadian International Grains Instituteysupeene@cigi.ca

Whole Wheat Pan Bread QualityDough Properties Pan Bread Properties

Whole Yellow Pea

Flours

Handling after Mixing

Handling at Moulding

Loaf Height (mm)

Overall Bread Quality Score*

(/50)

Pin mill-fine Slightly sticky Non-sticky 124 50

Stone mill Slightly sticky Slightly sticky and slightly stiff

118 48

Hammer mill Sticky Sticky 118 41

Roller mill Very sticky Very sticky 121 38

Gluten-free Crackers• Pulse flours and pea fibre

crackers were more firm and generally thicker compared to the control cracker

• Yellow pea/pre-cooked navy bean best maintained its texture and produced the thinnest cracker

• Crackers made with the yellow pea/red lentil flour produced a cracker with the most desirable flavour

• Pulse flour improved nutritional profile of gluten-free cracker

– Source of fibre claim

Gluten-free Crackers

Key Messages

• Advantages– Complementary protein with cereals

– Sustainable source

– Global recognition

• Challenges– Flavour/texture

– Cost

– Meeting protein claims

• Solutions– Blending ingredients

– Pulse concentrates/isolates

Questions

Heather Maskus

Project Manager

Canadian International Grains Institute

hmaskus@cigi.ca