gluten-free ingredients & formulation approaches · removing gluten results in formulation...
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Gluten-free Ingredients & Formulation Approaches
DILEK UZUNALIOGLU, PH.D. BUSINESS SCIENTIST, TEAM LEADER, GLOBAL APPLICATIONS,
INGREDION INCORPORATED
OCT 2016
IBIE INTERNATIONAL BAKING INDUSTRY EXPOSITION
• Gluten-free Bakery Challenges
• Gluten-free Ingredients
– Flours, Starches, Gums
• Holistic Formulation Approach to Gluten-free Formulation
• Enhancing the Nutrition and Texture: Pulse Flours and Proteins
Outline
2Copyright® 2016 by Ingredion Incorporated
Science-based problem-solvingfrom Ingredion Idea Labs
Gluten-free Formulation Challenges, Ingredients & Holistic Formulation Approach
4
• Lack of viscosity or elasticity of the wheat-containing dough leading to difficulties in processibility and machinability
Processing
• Reduced volume, lack of an even cell structure
• Dry, crumbly, grainy texture
• Poor crust color and development
• Grainy flavor
Texture
Taste
Appearance
• Shorter shelf-life/ Increased staling rates due to increased water mobilityShelf-life
• Lack of protein, nutrients and fiber
• Use of high levels of sugars and fats to mask the texture and flavor challenges
Nutritional Profile
Gluten-free Bakery Formulation Challenges
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5
Functionality of Ingredients Used
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Type Examples Usage Level Function
Native Flours and Starches Corn, Potato, Rice, Tapioca, Sorghum,
Amaranth, Buckwheat, Quinoa, Soy,
Millet, Teff, Bean, Pea, Nut
• 20-50% • Bulk/Backbone of the recipe
• Texture modifier: Body, elasticity &
chewiness, crumb structure
Cook-up Native
Functional or Modified
Starches
Corn, Tapioca, Rice, Potato • 20-50% • Texture modifier: Body, elasticity &
chewiness, crumb structure
• Freeze-Thaw Stability
Pre-gelatinized Native
Functional or Modified
Starches
Corn, Tapioca, Rice, Potato • 2-10% • Dough viscosity control
• Texture modifier
• Prevent staling
Proteins Whey Protein, Soy Protein, Zein, Egg
White Powder, Pulse Proteins
• 2-5% • Build structure
• Color development
Other
Hydrocolloids/Gums
Xanthan Gum, Guar Gum, Cellulose
Gum, Alginates, Konjac, Psyllium Husk
• -.5-3% • Dough viscosity control
• Texture modifier
• Prevent staling
• Freeze-thaw stability
Use combination of ingredients to match dough rheology
and final product texture is key!
Science-based problem-solvingfrom Ingredion Idea Labs
Key Starches and Flours Used in Gluten-free Formulations
Key Gluten-free Starches and Flours
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Ingredient Functionality
Rice Flour • Mild taste small granule size, smooth texture
• Very digestible and no allergenic
• Gives body, but turns quite dense when used on
its own
Corn Starch • Typical maize flavor, creamy to yellow color
• Gives a light crumb structure
• Good setting properties but fast staling
Tapioca Starch /
Tapioca Flour
• Adds some elasticity, chewiness (prevents from
crumbling)
• Gives good moisture, lightness, fine crumb
structure
Potato Starch /
Potato Flour
• High water absorption, gives moisture to the end
product
• Quite bland in taste at low levels
• Recipe concentration effect / Good cost in use
Corn
Tapioca
Potato
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• Gums provide viscosity, elasticity and produce
favorable textural attributes that are lost when gluten
is removed
• Gums work synergistically with ingredients such as starches
and other gums to produce various textural attributes
–Change in rheology
–Gel Formation
– Viscosity
– Film forming
Gums
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Use of Gums in Gluten-free Formulations
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Product Functionality
XanthanBatter viscosity and cohesive
texture
GuarBatter viscosity, freeze/thaw stability
and moisture retention
CMCCell structure and moisture
retention
HPMCStructure and set during baking due
to thermal gelling characteristics
Gum
ArabicEmulsification and film formation
LBG
Batter viscosity, cohesive texture,
cell structure and freeze/thaw
stability
A combination of
Corn Starch, Gum
Arabic, Xanthan gum
and Guar gum
provides volume,
uniform cell
structure,
suspension and
moisture retention
A combination of
Potato Starch,
Tapioca Starch and
Guar gum provides a
soft crumb
structure, volume
and moisture
retention
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Gum No Gum
Gum No Gum
Science-based problem-solvingfrom Ingredion Idea Labs
Holistic Formulation Approach to Gluten-free Formulation
DIAL-IN® TechnologyThe shortest path to perfect texture and sweetness
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• Benchmarking
wheat-containing
and gluten-free
products
• Identifying gaps
using Descriptive
Sensory Analysis
• Developing
solutions to
minimize the gaps
Gap Measured Using Descriptive Sensory Analysis
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Cohesiveness of Mass: The degree to which a chewed product forms a bolus/ball/holds
together
Wheat-containing
Benchmark
Wheat-containing
Benchmark
Loose
LowHigh
Compact
Roughness of Mass: The amount of graininess as perceived on the surface of the product
during its mastication
Gluten-free
Market Samples
Gluten-free
Market Samples
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Experimental Approach
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Process
• Dispersibility, Dough Rheology,
Machinability, Handling
Descriptive Sensory Analysis
• Cohesiveness, Graininess,
Dissolvability, Hardness,
Denseness, Firmness, Springiness,
Mouth Coating
Final Product Measurements
• Hardness via Texture Analyzer, Yield, Height, Moisture, Cost
Preliminary Screening
Optimization DOE
Final Optimal Composition
Texture Mapping
Grainy
C
2
M
Smooth
Dry
Crumbly
Grainy
Moist
Chewy
Cookie
2
Muffin
Muffin: Gluten-free Flour System
Commercial Cookie Benchmark:
Gluten free
Commercial Muffin Benchmark:
Gluten free
Cookie: Gluten-free Four System
Commercial Cookie Benchmark: Wheat
containing
Commercial Muffin Benchmark:
Wheat containing
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Desirable Nutrition ProfileChocolate Chip Cookie
140-180 Calories
7-9 g.
2-4 g.
20-24 g.
0-2 g.
15-20 g.
1-2 g.
WHEAT BASED
Ingredients True %
Gluten-fee Flour System (Tapioca
Flour, Rice Flour)
19.25
Butter, Soft 17.49
Light Brown Sugar 11.65
Medium Invert Sugar 9.00
Cane Juice 3.66
Eggs 8.38
White Rice Flour 4.00
Corn Starch 3.20
Vanilla 0.40
Salt 0.35
Baking Soda 0.28
Xanthan Gum 0.13
Semi Sweet Chocolate Chips 22.21
Total 100.00
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Procedure
•Dissolve the syrup into lukewarm water (77°F), add yeast and psyllium husk to
hydrate for 1.5 minutes.
•Premix the dry ingredients.
•Add dry ingredients to water solution.
•Add oil on top of dry ingredients, mix for 2 min on slow to obtain firm dough.
•Grease bread loaf pans; weigh dough at 520g; mould and place in the baking pans.
•Proof for 60 min at 95°F (35°C)/85% RH.
•Bake at 400°F (204°C), one steam injection at beginning of bake, for 30 - 33 minutes.
Ingredients Bakers %
Modified tapioca, potato & corn starch 100.00
Psyllium HUSK 5.84
Granulated Sugar 8.27
Egg White Powder 3.74
Salt 2.04
HPMC K4M 4.06
High Fructose Corn Syrup 5.09
Canola Oil 12.19
Water 100.00
Yeast, Instant 1.63
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Gluten-free Bread
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Modified
Solution
Clean Label
Solution
Retail Gluten-
FreeRetail Wheat
Containing
Modified tapioca, potato & corn
starch
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Gluten-free Bread
20
Ingredion gluten-free
samples scored closely
to wheat breads
Peak
Forc
e A
vera
ge (
g)
Retail GF Breads
Retail Wheat Breads
Clean Label
Solution
Modified Solution
Modified Solution
Native Solutions
Modified tapioca, potato
& corn starch solution
breads stored in
ambient conditions
extended shelf-life up
to 21 days
Peak
Forc
e A
vera
ge (
g)
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Gluten-free Bread Improved Ambient Shelf-life
Science-based problem-solvingfrom Ingredion Idea Labs
Enhancing the Nutrition & Texture: Pulse Flours & Proteins
What are Pulses?
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Pulses are the dried
seeds of plants in the
legume family. They
include:
• Peas
• Beans
• Lentils
• Chickpeas
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Food Protein Fat Starch & Sugar Fiber
Tapioca Flour 0.2 0.0 87.8 0.9
Whole Corn Flour 8.0 7.0 62.0 8.0
Whole Rice Flour 5.6 1.4 77.7 2.4
Whole Soy Flour 35.0 20.0 25.6 9.6
Whole Wheat Flour 13.2 2.5 61.3 10.0
Dry Pea 23.7 1.3 45.5 16.6
Lentil 26.3 1.1 45.0 13.6
Chickpea 24.4 5.9 41.1 8.7
Dry Bean 24.5 1.5 41.5 22.5
Pulses Composition vs. Other Grains
Exceptional Nutritional
Value
• High in Protein (High in Lysine), Dietary Fiber, Micro nutrients (Iron, Zinc, Selenium, -Carotene)
• Low-Glycemic Index (GI=40-55)
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Pulse Ingredients Benefits
Functionality
• Emulsification
• Texture
• Gelation
• Water-holding
• Adhesion
• Film Forming
Value Propositions
• Enhance texture and provide moist mouthfeel
• Good synergy with other gluten-free flours
• Protein enhancement
Labelling & Nutritional
• High Protein, High Lysine
• Natural
• High Dietary Fiber
• Gluten-free & Grain-free
• Low Glycemic Index
• High in Micronutrients
Peas Lentils ChickpeasFaba Beans
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Ingredients Bakers %
Modified Tapioca, Potato, Corn Starch 60.00
Native Functional Rice Flour 40.00
Flaxseed Meal 5.00
Psyllium HUSK 6.25
Egg White Powder 3.74
HPMC 2.00
Salt 2.04
Sugar 5.09
Yeast, Instant 1.63
Bread Crust Flavor 1.17
Olive Oil 12.19
Water 97.00
Ingredients Bakers %
Modified Tapioca, Potato, Corn Starch 60.00
Chickpea Flour (min 20% protein in d.b.) 20.00
Flaxseed Meal 5.00
Psyllium HUSK 6.25
HPMC 2.00
Salt 2.04
Sugar 5.09
Yeast, Instant 1.63
Bread Crust Flavor 1.17
Olive Oil 12.19
Water 99.98
• More open cell structure
• Balances chewiness, with crispy crust
• Remove egg whites in the formula:
formula cost reduction
• Texture impact-delivers Chewy texture
• Open cell structure
Gluten-free Pizza: Navigating Texture
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Gluten-free Tortilla
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Modified tapioca, potato,
corn starch mimics the
functionality of wheat flour
Chickpea flour is a gluten-free,
pulse-based flour, provides
moistness, color
Pregelatinized modified
tapioca starch is a cold water
swelling modified food starch
derived from tapioca helping with
dough stability during processing
Faba bean protein
concentrate helps with dough
handling, adds color, improves
elasticity
Ingredients Percent %
Modified tapioca, potato, corn starch 37.10
Chickpea Flour (min 20% protein in
d.b.)
14.00
Pregelatinized Modified Tapioca
Starch
6.00
Water 30.00
Vegetable oil 8.52
Faba Bean Protein (60% protein in
d.b.)
1.69
Salt 0.69
Sugar 0.92
Glycerine 1.00
Xanthan gum 0.08
Total 100.00
Copyright® 2016 by Ingredion Incorporated
Copyright® 2016 by Ingredion Incorporated
Gluten Free Hummus Cracker
GF Flour System
(tapioca flour, rice flour)
is gluten-free flour used in
the formula to replace
wheat flour
Chickpea Flour is gluten-
free flours used in the
formula to replace wheat
flour, and provides softness
and flakiness to the product
Pre-gelatinized Tapioca
Flour provides a crunchy
texture while helping with
dough handling and sheeting
Ingredients Percent (%)
Chickpea Flour (min 20% protein in d.b.) 25.48
GF Flour System (Tapioca Flour, Rice
Flour)25.48
PregelTapioca Flour 7.39
Monocalcium Phosphate 0.76
Baking Soda 0.76
Salt 0.81
Buttermilk Powder 2.15
Dill, Freeze Dried 0.35
Vinegar Powder 0.71
Garlic Powder 0.27
Onion powder 0.27
Parsley, Freeze Dried 0.16
Granulated Sugar 1.40
Pepper, Ground Black 0.11
Palm Shortening 7.90
Water 23.76
63 DE Glucose Syrup, Non-GMO 2.24
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Key Takeaways
28Copyright® 2016 by Ingredion Incorporated
More consumers than ever switching to gluten-free diet
Gluten is essential component of taste and texture of food products through its unique functional properties
Removing gluten results in formulation challenges to build back the texture and eating experience
A holistic formulation approach with key functional ingredients are shown to replace gluten without compromising the eating quality, processing and shelf-life
Science-based problem-solvingfrom Ingredion Idea Labs
2929
Thank You & Questions?
Dilek Uzunalioglu, Ph.D., Business [email protected]
908-685-5294
Copyright® 2016 by Ingredion Incorporated
Guide for the Gluten-free Baker, Make-up Processing Solutions
Cesar Zelaya
Director of Bakery Technology
Handtmann Inc.
October 10th, 2016
Questions??
• Does your bakery needs to automate?
• Benefits:
• Cost Savings, Product Quality, Process Flexibility, Increased Capabilities
Agenda
• Objective
• Products to Automate
• Equipment Considerations
• Product and Process
• Engineering and Facilities
• Production Systems
• Conclusions and Review
• Questions ???
Objective
• To present a practical approach toautomate your gluten-free production,considering key factors related to theproduct, process and equipment involved.
Products to Automate
• High Demand Items/ Long Production Times• Sandwich Breads, Hot-Dog and Hamburger
Buns
• Labor Intensive SKU’s• Bagels, Pizza, Pies
• Product Quality and Consistency Issues• Bagels, Healthy Bars, Cookies
Products to Automate
• Product with Similar Processing Requirements• Sandwich Breads and Pound Cakes
• Muffins and Buns
• Bagels and Pizza
Equipment Selection:Product and Process• Most bakery equipment in the market was
not designed to handle gluten free• Consider Alternative Technologies
Vacuum Filler
Equipment Selection:Product and Process• Processing challenges to handle your
specific dough or batter formulations (absorption, sugar content)
• Quality attributes: crust and crumb structure, symmetry, volume, height, shelf life
Equipment Selection:Product and Process• Gentle handling of inclusions and particle
definition in your product (chocolate chips, blueberries)
• Accurate scaling 1-2% standard deviation depending on formulation
• Consistency and handmade look
Equipment Selection: Engineering and Facility
• Ability to increase capacity in the future
• Integration into existing production line
• Flexibility to produce multiple products in the same line, quick changeovers
• If you produce gluten and gluten free in the same facility and clean-ability of the equipment
• Equipment mobility if being used in different production areas or for sanitation purposes
• Consider leasing and trade-in options
Conclusions and Review
• Automating your gluten-free production process will bring Cost Savings, Product Quality, and Flexibility to your process and increase capabilities
• When you Automate your Process consider:• Selecting SKU’s with high demand and those that
bring the most savings (labor, processing times)• Focus on product quality and plan to expand your
scope of supply based on equipment capabilities• When selecting equipment considering your existing
layout, look for flexibility, addition of new products, and sanitation features
• Discuss financial options such as leasing and trade-in
Thank you!
Cesar ZelayaHandtmann, Inc. Director of Bakery Technology
(847) 808-1100(847) [email protected]
28690 N Ballard Dr. Lake Forest, IL 60045USA