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Innovations for a better world. Current Challenges in the Supply of Pulse Ingredients Innovations for a better world. Aidin Milani Buhler Inc
Innovations for a better world.
Current Challenges in the
Supply of Pulse Ingredients
Innovations for a better world.
Aidin Milani
Buhler Inc
2
Aidin Milani
Sales & Development Manager
Pulses & Spices
Buhler Inc.
13105 12th Avenue North,
Plymouth, MN 55441-4509
www.buhlergroup.com
3
Pulses are part of the legume family.
LEGUMES
pulses
harvested
dry
low fat
content
oilseeds
soybean
peanut
vegetable
green beans
green peas
food feed other
70% 20% 10%
4
Pulses are staple food in many emerging regions.
1411
Africa
production (mio t / year)
consumption (mio t / year)
51
North America
7 7
Latin America
72
Europe
30
Oceania
33
27
Asia
18 18
India
source: FAOSTAT, 2011
export
exportimport
5
Pulses are staple food in several regions.
Africa
North
America
Latin
America
Europe
Oceania
South
Asia
traditional
market
new
market North
Asia
6
Consumers are setting the trends
The New Healthy
Consumers choosing
beyond dieting.
Clear
label
Natural
Organic
Free
from
Nutritious
Functional
+
Dietary Diversification
among All Ethnic
Groups and
Economics.
Shifting market
frontiers
Fastest spreading
megatrend in foods.
Consumers expecting to
see transparency and
traceability.
Ethical Living
+44%CAGR 2011-2016
food & beverage
launches featuring
ethical claims
+Snackification of
Everything +
+3%CAGR 2012-2017
snacks categories
volume WW (vs. <2%
rest of packaged food)
*Source: Innova Market Insights, Euromonitor, Mintel
7
Pulses production worldwide is about 78 million tons.
*Source: FAOSTAT.
Beans; 39%
Chickpeas; 17%
Peas; 28%
Lentils; 7%
Other; 9%
0
20
40
60
80
100
120
2010 2011 2012 2013 2014 2015 2016 2017
Global Pulses Production (million tons)
34%
Growth
2010-2017
8
Pulses – Different forms in different markets.
WHOLE PULSES
SPLIT PULSES
PULSE INGREDIENTS
Also consumed as
▪ Sprouted or Fermented
▪ Steamed or boiled
▪ Roasted or fried
▪ Canned or frozen
9
10
Differences in the structures of conventional and gluten free pasta
11
Improved protein profile of pulse-cereal pasta
12
baking / cold extrusion
crackers pasta
cookies bread
Pulse Flour Application
pulse flour
cooking extrusion
pet food
breakfast cereals snacks
meat analogs
13
Consistency
Particle
SizeMoisture
Protein
content
Starch
Damage
14
Textured Vegetable Protein
Dry textured products Wet textured products
15
Raw Material Requirements for Texturized proteins
Texture modifiers:
Acid / base
Salts
Sodium alginate,
sulfur
16
Variations in the entire supply chain
3
4
6
8
9
10
Pre-Cleaning & Storage1
2 Cleaning
Hulling
Splitting Optical Sorting
Pulse Flour
Sifting
Extruder
5
Grading
7Polishing
17
Protein Level Variation in Pulses
Yellow peas
746 Kernels
Average 21.7%
Stdv 2.5%
normal distribution
18
Protein variation in one field
Average 21.9%
S.D.
2.3%
Average 22.5%
Average 21.6%
Average 22.6%
Average 22.9%
S.D.
2.3%
S.D.
2.3%
S.D.
2.5%
S.D.
2.4%
> 1000 kernels
19
There is also a variation in one plant
nod 1
nod 2
farthest to
peduncle
nearest to
peduncle
proximal
distal
1120
670
335
150
212
150
132
Div.1
B1 B2 B3
750 710 670 600
710 670 600 560
670 600 560 530
C1B C1A
S1
C4
S3
FLOUR 1
FLOUR 2
Su
ctio
n p
ne
um
atic lift
Cyclone
Airlock
Plansifter
Purifier
Fluted
Rolls
Detacher
Smooth
Rolls
S2
1180 1000 950 850
1000 950 850 800
950 850 800 710
C3C2
20
1120
670
335
150
212
150
132
Div.1
B1 B2 B3
750 710 670 600
710 670 600 560
670 600 560 530
C1B C1A
S1
C4
S3
FLOUR 1
FLOUR 2
Su
ctio
n p
ne
um
atic lift
Cyclone
Airlock
Plansifter
Purifier
Fluted
Rolls
Detacher
Smooth
Rolls
S2
1180 1000 950 850
1000 950 850 800
950 850 800 710
C3C2
Managing inconsistencies in Milling
21
1120
670
335
150
212
150
132
Div.1
B1 B2 B3
750 710 670 600
710 670 600 560
670 600 560 530
C1B C1A
S1
C4
S3
FLOUR 1
FLOUR 2
Su
ctio
n p
ne
um
atic lift
Cyclone
Airlock
Plansifter
Purifier
Fluted
Rolls
Detacher
Smooth
Rolls
S2
1180 1000 950 850
1000 950 850 800
950 850 800 710
C3C2
Managing inconsistencies in Milling
22
1120
670
335
150
212
150
132
Div.1
B1 B2 B3
750 710 670 600
710 670 600 560
670 600 560 530
C1B C1A
S1
C4
S3
FLOUR 1
FLOUR 2
Su
ctio
n p
ne
um
atic lift
Cyclone
Airlock
Plansifter
Purifier
Fluted
Rolls
Detacher
Smooth
Rolls
S2
1180 1000 950 850
1000 950 850 800
950 850 800 710
C3C2
Managing inconsistencies in Milling
23
Managing inconsistencies in Milling
1120
670
335
150
212
150
132
Div.1
B1 B2 B3
750 710 670 600
710 670 600 560
670 600 560 530
C1B C1A
S1
C4
S3
FLOUR 1
FLOUR 2
Su
ctio
n p
ne
um
atic lift
Cyclone
Airlock
Plansifter
Purifier
Fluted
Rolls
Detacher
Smooth
Rolls
S2
1180 1000 950 850
1000 950 850 800
950 850 800 710
C3C2
Silo Silo Silo
24
25
Selection of milling technology depends on the requirements.
Roller Mill
Narrow particle size
distribution
Particle Size
Hammer Mill
Wide particle size
distribusion
particle size (mm)0.1 1 10
100%
particle size (mm)0.1 1 10
100%
Flexible Range of
Flours
Limited Range of
Flours
Fat Content
Starch Damage
Viscosity
Fiber Content
Sifting
26
Selection of milling technology depends on the requirements.
Roller Mill
Narrow particle size
distribution
Particle Size
100 m
Hammer Mill
Wide particle size
distribusion
particle size (mm)0.1 1 10
100%
particle size (mm)0.1 1 10
100%
particles < 100 m
Pin Mill
Pulse Fractions
air classification
particle size (m)1 10 100
100%
SiftingSifting
Flexible Range of
Flours
Limited Range of
Flours
27
Pin Mills
28
Pulverizer
29
Selection of milling technology depends on the requirements.
Roller Mill
Narrow particle size
distribution
Particle Size
100 m
Hammer Mill
Wide particle size
distribusion
particle size (mm)0.1 1 10
100%
particle size (mm)0.1 1 10
100%
particles < 100 m
Pin Mill
Pulse Fractions
air classification
particle size (m)1 10 100
100%
SiftingSifting
Flexible Range of
Flours
Limited Range of
Flours
30
Composition of pulses
2 mm
seed husk
(11%)
cotyledons
(87%)
embryo axis
(2%)
Composition (based on DW)
• CARBOHYDRATE 68%• starch 42%
• oligosaccharides 10%
• fibers 16%
• PROTEIN 24%
• FAT 3%
• MINERALS 3%
• ANTINUTRIENTS 2%
31
De-Hulling = Removal of seed husk without splitting
100 m
seed husk
• Reduction of antinutrients & indigestible fibers
• Higher bioavailability of micronutrients
• Improves sensory properties (appearance, texture)
• Improves convenience (cooking quality)
32
De-Hulling & Pitting
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PULSROLLTM
Pulse De-Huller.Specifically designed for Pulses to provide gentle handling
and higher yield and quality
34
Inconsistencies in De-hulling
35
Pulse processing overview
splitting
starch/protein/fiber
ingredients
whole
seedssplitsflour
cleaning
germination
hulling
raw material
hulls
milling
12%
impurities3%
grading
polishing
fractionation
brokens12%
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Ingredients are applied to make ready-to-eat products
starch/protein/fiber
ingredientsflour
application
in products
Extruded Products
Pasta
Baked Good…
hulls brokens
byproduct
valorization
37
… exploiting the full value of pulses!
customer
requirements
key
properties
convenienttasty
healthy
structures
process
39
Buhler’s
Food Application Center
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Thank You
