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 – info@daymer.com 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