Post on 29-Mar-2019
transcript
Gluten free
pasta
production
Bühler AG Stefanie Hardtmann
Basic technological
aspects
2 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Corporate Presentation.
About Bühler.
3 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Bühler at a glance. Global market leader with strong roots in local markets.
Group turnover (sales) 2014: CHF 2,332 million.
Around 10,600 employees.
Present in nearly 140 countries.
Today, 80 service stations globally, +12 stations compared to 2013.
Production sites in all regions.
Up to 5% of turnover invested in research & development.
Consistently high quality standard worldwide.
100% family-owned.
4 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Snacks & Pasta
Sweets
Grain processing
Bühler offers industrial process technologies and solutions in two main markets.
Food Advanced Materials
Raw materials
Manufacturing
Logistics
Technology & process engineering
Services
Bühler
Optics
Automotive
Electronics
Nutritious foods
Parts and coatings
Basic foods & feed
…
5 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Spirit of discovery. Continuous high investments in R&D.
4.2% of turnover invested in R&D
in CHF million
Industry Experts.
Customers.
Employees.
Suppliers.
State-of-the-art innovation management.
Bühler Innovation Board.
6 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Business Area Value Nutrition.
Our solutions
Innovative process solutions for the feed and food industries:
from feed for cattle and poultry to aqua feed and pet food, to pasta and
Asian noodles, to cereals and snacks as well as oilseeds.
VALUE NUTRITION
Key facts
Around 40% of the global pasta production takes place on Bühler machines. In addition,
35% of cereals, 30% of oilseeds, and 20% of feedstuff are processed with Bühler solutions.
The core technologies relate to the areas of extrusion, drying and flaking.
Our customers
International, regional and local feed & food producing companies
including feed mills but also flour and oil mills in 140 countries
all over the world.
7 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Agenda
1
2
3
4
6
Technological challenge
Process for production of gluten free pasta
Why is starch gelatinization important?
The role of amylose as “glue”
Raw material requirements
Market drivers
8 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Market drivers gluten-free pasta
1. Gluten free as dietetic product
2. Gluten free as alternative to
common pasta
- People suffering from celiac
disease don’t tolerate gluten
(0.01 to 0.5 % of the population)
- General tendency of consumers
towards “low allergen” and “gluten
free” nutrition
-Use of local non-wheat grains for pasta
-Use of cheaper non-wheat grains
-Transformation of low value by-products (e.g.
broken rice) into value added food product
like pasta
- Consumers looking for food diversity
9 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
What’s the challenges in producing pasta from gluten free raw material like rice and corn
Rice and maize contain proteins
(~7 to 12 %)….
…...but, the proteins are not able to
form a strong elastic network like
gluten
Therefore, for pasta from gluten free
raw material starch needs to be
gelatinized to act as “glue.
Note different microstructure of natural rice
and of rice pasta (protein is stained green).
50 µm
Natural rice
Rice pasta
10 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Starch gel of gelatinised starch builds
continuous phase
Continuous phase of protein
Wheat pasta Corn pasta
Wheat pasta and corn pasta are very different in terms of microstructure
11 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Conventional wheat pasta Gluten free pasta
Protein is the “glue” Protein (Gluten) network
provides framework
of pasta
Starch is a filler Starch granules are
embedded in protein
network
Starch is the “glue” Gelatinized starch
provides framework
of pasta
Small protein
patches (no relevance for
texture)
is embedded in
starch gel
Main difference between conventional wheat pasta and
gluten-free pasta
12 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
The Polymatik pasta press is perfectly suited for producing gluten free pasta
Nativ, gluten-free
raw material
Additive Poly-C-one®
c 0.5-1.0 % of flour
Press head
Mixer/Kneader
Vacuum
Steam
Press-
cylinder
Water
Mixing & Kneading in co-rotating twin-screw
extruder
Forced conveying in the twin-screw enables
„first-in first-out“
13 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Industrial short goods line for the production of gluten-free pasta
Industrial applications so far for rice and corn flours
E.g. Bühler short goods C-line for 1400 kg dried pasta/hour
14 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Industrial short goods line for the production of gluten-free pasta
Industrial applications so far for rice and corn flours
E.g. Bühler short goods C-line for 1400 kg dried pasta/hour
Dryer Zone B2 Cooler
Zone D1
Cartrapen
Pre-Dryer Zone B1 Polymatik-Press
Raw materials dosing systems
MSDA MSDF
Shaking predryer
Zone A1
15 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Industrial long goods line for the production of gluten-free pasta
Industrial applications so far for rice and corn flours
E.g. Bühler long goods C-line for 1200 kg dried pasta/hour
Polymatik®
Spreader
Pre dryer A
Dryer B
Stabilisation C 1 Moistening C 2
Cooler D
16 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
HT
drying
Moisture content [g/100 g wb]
Tem
pera
ture
[°C
]
Tg of starch
native
flour Extrusion
Mixing & Kneading
with H2O & steam
Tm
Melting
of starch
HT drying
HT drying
conventional
wheat pasta
gluten free
pasta
Comparison of extrusion conditions for wheat pasta and gluten free pasta in the state diagram of starch
17 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Heating in
presence of water
Melting, swelling &
amylose leaching
Native wheat starch
Upon processing of gluten free pasta the starch is gelatinized in the Polymatik press
After heating in excess water to 90°C
gelatinized
starch
native
starch
18 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
HT drying of gluten free pasta contributes to strengthening the amylose network structure.
Endo
Native rice flour with Poly C Starch is native and the amylose-lipid
complexes have low degree of perfection
Rice pasta after extrusion Starch is gelatinized and two forms
of amylose-lipid complexes exist
Rice after HT drying Further perfectioning of the amlyose-
lipid complexes has taken place
gelatinization
Melting of
amylose-lipid
complexes
Rice pasta will not fall apart
during cooking and presents
low levels of stickiness
19 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Suitable raw material for gluten-free pasta.
Flours and starches of gluten-free cereals
like rice or maize
Flours of pseudo-cereals like Amaranth,
Buckwheat, Millet or Quinoa
General requirements:
- Granulation of the flours
100 % < 250 µm
15 % < 125 µm
- Amylose content > 20 %
- Fat content < 1-1.5 %
- Ash content as low as possible (< 0.7 %)
- Note the special technical requirements for raw material handling for dietetic products
20 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Raw material requirements – Additives.
Additive Poly-C-one - Promotes starch (amylose) complexation and yields pasta with high
firmness, low cooking loss and low stickiness
- Acts as lubricant and reduces stickiness of pasta at the die during cutting.
- Poly-C-one is a specially designed emulsifier E471 (mono- and diglycerides of food fatty acids)
- Amount to be added 0.5% – 1% of flour quantity Additive Beta-Carotene
- Optional additive for rice or white maize flour to give pasta of yellow color
- Amount to be added 0.02% of flour quantity
Additive Curcumin
- Optional additive for rice or white maize flour to give pasta of yellow color
- Amount to be added 0.2 % of flour quantity
21 | © Bühler | Gluten free pasta production – basic technological aspects. | S. Hardtmann - U27186 | 2015
Target product qualities of gluten-free pasta processed by
Polymatik.
Quality-benchmark for gluten-
free pasta is wheat pasta
Good texture features of cooked
pasta
- bite > 0.8 N
High surface integrity of cooked pasta
- cooking loss < 5%
Gelatinization degree 50 - 70%
(enzymatic method)
Gluten content < 20 mg/kg dried pasta
Thank you!