Disruptive Ingredient Technologies: Characterizing Plant Proteins …€¦ · Disruptive Ingredient...

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Disruptive Ingredient Technologies:

Characterizing Plant Proteins to

Predict Optimal Food Matrix Use

May the 23rd 2017

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Table of contents

Why proteins are so important?

4 complementary ways to characterize protein

Main existing protein production processes

Disruptive technologies

How can IMPROVE support your projects?

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• Usages dominated by feed

• 50% of the world population is using less than 25 g of animal proteins/day

• 18% of the world population is using more than 60 g of animal proteins per day

Agricultural ressources usages

4

How do we utilize proteins?

World agro-production

2,3 2,4 2,83,3

9,8 9,8

milk fish Chicken porc beef sheep

Proteins conversion ratio

kg/kg

Production ProteinesMT MT

meat 296 59,2 eggs 69 5,5 milk 724 22,7 cheese 22 2,0 fish aquaculture 75 15,0 total 1 111 104 wild fish catch 75 15,0 TOTAL 119

Animal proteins production FAO 2013

plant origin Production ProteinesFAO 2013 MT MTSoya 260 98,8 Corn 883 88,3 Wheat 704 77,4 Rice 722 57,8 Oil seeds without Soya 203 50,8 Barley 134 17,4 Pulses 69 17,3 Legumes 1 044 10,4 Sugar cane 1 794 9,0 Fruits 608 6,1 Potato 374 3,7 Other roots 374 3,7 Nuts 13 3,3 Others 2 818 111,3 Total 10 000 555

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How do we utilize proteins?

World proteins balance:

• 56% from soy, 43% from wheat and less than 1% for pea, rice, potatoes, rape seeds

faba beans, lupine, sun flower, algae's, ….

Plant proteinsproduction =

555 Mt/y

Plant production = 10 000 Mt/y

Feed = 433 Mt/y of plant proteins

Food = 122 Mt/y of plant proteins

Only 2Mt/y are

proteins

ingredients*

Animal proteins

=

89 Mt/y

Average conversion ratio = 4,9

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Nutritional Functional

Organoleptic Claim & Labelling

4 complementary ways to characterize

protein

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Nutritional properties

0

50

100

150

200

250

300

350

400

450

0 50 100 150 200 250 300 350 400 450 500 550

Protein digestion speed

Time (min)

AA

blo

odco

ncen

trat

ion

(µm

ol/L

)

Young

Threshold of anabolism

Slow

fast

old

Essential AA balance

Unbalanced diet leading to AA oxidation

Well balanced diet leading to an optimal protein anabolism

0

20

40

60

80

100

120

140

mg Leu / g protein

0

20

40

60

80

100

120

140

mg Arg / g protein

Leucine is known to stimulate protein anabolism Arginine is known to reduce blood pressure

AA having messenger function

Protein digestibility: PDCAAS

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Functional properties

Solubility

Dispersibility

Viscosity

Gelling

Pro

tein

sol

ubili

ty % Soy

Rape seedWheat

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Functional properties

Emulsifying

Foaming

Binding (water or oil )

Texturizing

Heat Stability

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Flavor is a combination of

• Taste

• Non volatile compounds

• 8 (or more?) basic tastes: sweet, biter, sour, salty, pungent, metallic,

umami, astringent

• Aroma / Smell / Odor

• Volatile compounds

• More than 10 000 different aromas

Flavor is strongly influenced by

• Texture

• Smoothness, coarseness, hardness, thickness, slipperiness, viscosity…

• Trigeminal responses

• Heat of spices, cooling of menthol

• Astringency: a dry sensation in the mouth caused by interaction with

salivary protein and mucins � loss of lubrication

Organoleptic properties

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Plant proteins

• Often associated with off notes

• Astringency

• Bitterness

• Beany, hay, cardboard aroma

• 5 strategies to deal with off-notes

1. Selecting favorable raw material (variety selection, storage conditions...)

2. Prevent by processing (dehulling, enzymes deactivation, microbio

control …)

3. Eliminate by post processing (flash under vacuum,….)

4. Masking

5. Formulate

• What is perceived is most of the time a combination of aroma and

taste.

Organoleptic properties

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Claim & Labelling

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Fractionation strategies: faba bean case

An

alysis Flour

Concentrate / Isolateby thermo coagulation -

pH precipitation -membrane filtration -

chromatography

ConcentrateFine fraction

by air classification

Seed

Dehulling

/ Milling

Dry

fractionationWet

fractionation

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Dry process: dehulling

Classification quality depend on the

processes parameters

Efficient impact

Inefficient

impact

Strong impact

Heavy Fraction

Light Fraction

Raw seeds

Dehuller

Gravity

classifier

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Dry process: milling

Impact Compression Shearing Abrasion Particle size

Coarse

> 500 µm

Fine

50 - 500 µm

Ultrafine

<50 µm

Hammer mill X Coarse

Knife mill X X Coarse

Pin mill X X Fine and Ultrafine

Impact mill X Ultrafine

Cylinder mill X X Coarse and Fine

Mortal and

millstone millX X X Coarse and Fine

Disk mill X X Coarse and Fine

Ball and bars

millX X X Fine and Ultrafine

Beater mill X X Coarse and Fine

Jet mill X Ultrafine

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Air classifyingStarch granule

Proteic body

Air classifying

↓Ultrafine milling

� Separate protein body from

starch granules

lower purity

higher yield

Higher purity (70%)

lower yield Fraction retained

8000 rpm

High purity

� 65% of protein

(DS)

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Faba bean Flour

Pin mill powder

↓Evaluation of the protein solubilizing at pH 9.5

Wet fractionation: Solubilisation step

Protein solubility vs. flour’s PSD

↓Compromise between energetic cost and

protein extraction yield

Maximum of solubility: pH 9 - 10

Minimum of solubility : pH 4

Maximum for a

d90<300 µm

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Thermo coagulation

Final Product

Protein concentrate

Step 4Concentration / Drying

Step 3 Isoelectric thermo coagulation +

centrifugation

Step 2

Decantation / Clarification

Step 1

Solubilisation

Raw material

Flour

Solid/Liquid ratio : 1/9

pH : 9,5 T° : 20°C

Time : 1h

Protein/DS: 32%

Cumulative yield: 100%

Faba bean flour

Protein/DS: 80%


Protein concentrate

Protein/DS: 72%


Extract

Removal : starch, insoluble

proteins, fibers…

Protein/DS: 80%


Coagulum

All centrifugation steps:

G force : 4000 g

Time : 15min

pH : 4,5 Temp : > 120°C

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pH precipitation

ProductProtein isolate

Step 5 Concentration / Drying

Step 4Cream washing + centrifugation

Step 3 Isoelectric precipitation + centrifugation

Step 2Decantation / Clarification

Step 1Solubilisation

Raw materialFlour


pH : 9,5 T° : 20°C

Time : 1h

Protein/DS: 32%


Faba bean flour

Protein/DS: 94%


Protein isolate

Protein/DS: 72%


Extract


proteins, fibers…

Protein/DS: 92%


Cream

Removal : salts, sugars, low

molecular weight proteins…

All centrifugation steps:

G force : 4000 g

Time : 15min

pH : 4,5

Time : 1h

4 volumes of water

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Membrane fractionation

ProductProtein concentrate


Step 4Diafiltration 50 kDa

Step 3 Ultrafiltration 50 kDa

Step 2Centrifugation


Raw materialFlour


pH : 9,5 T° : 20°C

Time : 1h

Protein/DS: 32%


Faba bean flour

Protein/DS: 89%


Protein isolate

Protein/DS: 72%


Extract


proteins, fibers…

Protein/DS: 85%


Retentate



G force : 4000 g

Time : 15min

CVF : 3,5

2 diavolumes

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Chromatographic fractionation

ProductPurified Protein


Step 4Chromatography

Step 3 Polishing

Step 2Centrifugation


Raw materialFlour


pH : 9,5 T° : 20°C

Time : 1h

Protein/DS: 32%


Faba bean flour

Protein/DS: >95%

Purified proteinPurified protein

Protein/DS: 72%


Extract


proteins, fibers…

Protein/DS: 85%


Clarified protein



G force : 4000 g

Time : 15min

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Dry processes

Helpful Harmful

Inte

rn

Strength Weakness

� clean label / organic compatible

� Preserves native nutritional value

� Preserves native functional properties

� Simple and robust processes

� Helps to reduce volume prior a wet process

� Efficient impact on some anti nutritional

factors reduction

� Low OPEX / CAPEX

� Limited protein purity

� Limited impact on some anti

nutritional factors reduction

Ex

tern

Opportunities Threats

� Part of almost every wet process

� May generate “new” products on the market

� Still room for optimization due to the actual

limited knowledge accumulated

� Need to well valorize all the co-

fractions

� Need specific attention on

mycotoxin or µbio contaminants

from raw material

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Thermo coagulation

Helpful Harmful

Inte

rn

Strength Weakness

� Compatible for food and feed market

� May reduce some anti nutritional factors

� Low risk in µbio contamination

� Simple process

� Good yield


� Limited functional properties

� Impact on digestibility

� Often limited to feed market

Ex

tern


� Adapting existing units to other raw material

to enlarge the production period

� Not responding to premium food

market expectations

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Isoelectric pH precipitation

Helpful Harmful

Inte

rn

Strength Weakness

� High purity


� Simple process

� Good yield

� Possible to fractionate protein based on

there solubility at different pH

� Limited OPEX / CAPEX

� Small negative impact on

functional properties

� May impact organoleptic properties

(if too much salts)

� High ash / low protein purity

� No possibility to sub fractionate

protein based on MW

Ex

tern


� Fit well in existing production lines

� When creating a new production line this

process can be the 1st step of the project

� It is possible to add new processing line to

enrich the product portfolio

� Specific attention on µbio

management � process step to be

defined in order to get a limited

negative impact on final product

quality

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Membrane fractionation

Helpful Harmful

Inte

rn

Strength Weakness

� High fractionation potential based on MW

� High protein purity

� High functional quality product


� Compatible with clean label / organic

� Possible low ash content

� Demanding process follow up

� Higher OPEX /CAPEX

Ex

tern


� Potential combination with enzyme

treatments

� Enrich protein portfolio based on one raw

material (like it was done with the dairy

protein fractionation)

� Specific attention on µbio

management � process step to be

defined in order to get a limited

negative impact on final product

quality

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Chromatographic separation

Helpful Harmful

Inte

rn

Strength Weakness

� High specificity

� Designed for highly functional protein

� Adapted for high added value market

� Can be used to remove “contaminants” like

anti nutritional factors, off flavors or

colorants

� Complex process

� Low yield

� High OPEX / CAPEX

Ex

tern


� May be well adapted for bio active protein or

peptides

� Risks in µbio contamination

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Disruptive technologies

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Electroseparation

Separator

Drum separators

Electrically charged screen

Freefall separator

Belt separator for fine particles

Particle charging

InductionCorona charging or

discharging Triboelectrification

Fiber/protein fractionation of sun flower meal *

* Barakat, et al. (2015)

Feed � 30,8% protein 21,2% lignin

F - � 5,1% protein 48,9% lignin

F + � 48,9% protein 7,5% lignin

Separation based on electrostatic properties

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Electroseparation

Helpful Harmful

Inte

rn

Strength Weakness

� Protein purity increase (alternative of air

classifying)

� Mature technology in the inorganic area

(coal or mines by-product refining)

� No consensus on design

� Not possible to reach an isolate purity

Ex

tern


� No real optimization performed so far

� Many possible protein applications

� Strong interest of many agro-industrial

actors

� Need a careful Ex proof management

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Powder functionalization

EnergyEnergy

Technology

Parameters to adjust

Product conditioning

Processes combination

Particles propertiesParticles

properties

Size

Shape

Specific surface

Powder properties

Powder properties

Fluidity

Dispersibility

Density

Moistening / drying

Swelling

Color

Powder production

process can be

designed for specific

applications

10 sec 3 H20 sec

= size

2 powders = composition

≠ shape

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Powder functionalization

Helpful Harmful

Inte

rn

Strength Weakness

� Possibility to optimize protein

solubilization

� Major impact on the powder

application

� Possibilities to simplified wet processes

� Characterization devices mainly used for

R&D development

Ex

tern


� Many possibilities to optimized powder-

handling cost

� Pedagogy required to explain the

possible benefit of such optimizing

� Actual choice are mainly established on

empirical knowledges

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Forward Osmosis

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Forward OsmosisHelpful Harmful

Inte

rn

Strength Weakness� No thermal impact on protein

� Unique way to concentrate protein

solution up to 50% DS

� No impact on organoleptic profile (color

or taste)

� Low energy usage in comparison with

classical evaporation

� Patented food grade osmotic liquid

� Membranes : already used for industrial

application (water recovery from waste)

� Can be easily combined with existing

process lines

� Linear scale-up with Modular/Extensible

system

� Limited pH range (3 to 8)

� Possible contamination of the osmotic

liquid with the feed

Ex

tern


� On going development on new

membranes with a wider pH spectrum

� Membrane fooling / life time

� Cross contamination between process

flow and osmotic liquid

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Electrostatic Spray Dry Systems

The Electrostatic effect forces thesolvent to migrate to the outersurface of the droplet while the activeor carrier remains at the center.

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Electrostatic Spray Dry SystemsHelpful Harmful

Inte

rn

Strength Weakness

� Make powder at low temperature (Ambient to

80ᴼC vs 180ᴼC)

� Control Powder Characteristics (vs adding Post

Processing Equipment)

� Insure near Perfect Encapsulation (vs having

active ingredient trapped on the surface of the

powder particle)

� Eliminating active ingredient loss, degradation,

or denaturalization

� Controlled Agglomeration using Pulse Width

Modulation (PWM®) of the electrostatic voltage

� Instant Hydration Properties

� Low Volatile Loss / No oxidation

� Need to work on recycled N2

� Limited to small production units (100 kg/h of

evaporation)

Ex

tern


� This can be the last process step of a complete

cold process line for protein production.

� Reduction/Elimination of Emissions

� Energy Savings

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Dynamic Cross Flow Filter

Turbulent flow is not made bypumping liquids but by rotatingceramic discs.

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Dynamic Cross Flow Filter

Helpful Harmful

Inte

rn

Strength Weakness

� Very low energy usage (5 times less than

a classical tangential filtration unit)

� Can work at high viscosity

� Can work a low transmembrane

pressure (TMP)

� Can achieve very high VCF

� Can use ceramic membranes (robust

and easy to clean)

� Discharging of high viscous material can

be difficult

� Limited cut off available (7 nm, 30 nm,

60 nm, 200 nm, 500 nm, 2000 nm).

� Dead volumes to be optimized

Ex

tern


• Side streams valorization (Can be used

to reclaim high value liquid)

• Can replace RVF working with filter aids

2017-05-24 RENIX INC

Downcomer

Riser

Separator

Dynamic Seal

Dynamic Seal

Process Feed

Raffinate Outlet

Eluent

Eluate Outlet

SorptionDesorption

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C.F.I.X.

Uninterrupted Resin Regeneration

Continuous Flow of All Fluids

No Sequencing

Fluidized Bed ChromatographyRENIX Inc.

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Fluidized bed Chromatography

Helpful HarmfulIn

tern

Strength Weakness� Can work with suspended solids

� Continuous operation / resin

regeneration

� High Resin Use Efficiency

� Low Breakthrough Risk

� No risk of channeling

� Resin leaving the bed are always

saturated

� 30% chemical usage reduction

� No Valve / Pump Sequencing,

� Reduced Maintenance


� Work need to be done on resin density

vs product density

Ex

tern


� Protein recovery can be done in one or

multiple stages

� Development of new resins adapted to

targeted molecules

� Sanitization needs to be under perfect

control

� Hydraulic flows need to be perfectly

adjusted

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LABIOCRAC process: whole seed cracking

Precipitation process with

PROTEXTRA® natural

flocculent

LABIOCRAC process also

targets the valorization

of the hulls and/or brans

through several

fractionation and

precipitation steps:

pectin, pentosans, etc.

https://youtu.be/GNkwf_ZLfRE

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Labiocrac process

Helpful HarmfulIn

tern

Strength Weakness� Profitable process due to side stream

valorization (six components, including

albumin°

� Globulin quality > 85% /DS. Low lipids,

low salts, neutral taste.

� No need of membrane filtration to

fractionate albumin and globulin.

� Low cost process due to water recycling

� Process compatible with existing wet

process

� Not industrialized yet. Reproducible at

pilot scale.

Ex

tern


� Formulation of new food products

made possible by the combination of

different recovered components. For

example: Protein bars without sugar.

� Not industrialized yet. Reproducible at

pilot scale.

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Salt or chemical reduction

Reducing the pH by CO2

addition rather than by acid

addition

Conventional or Bipolar

electrodialysis

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Bioactive

Milk

isolate

Functional

WPC WPI

SPCFunctional

Wheat

gluten

Eges,

Gelatin

NaCas

Solublewheat alb

& glob CSL SWP

Insoluble

CGM CG VWG

0-20% 20-40% 40-60% 60-80% 80-100%

Proteins concentration %

Proteins matrix

Pro

pert

ies

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How we can help you ?

IMPROVE is a private R&D center, services provider of technical and

scientific expertise fully dedicated to alternative proteins valorization.

IMPROVE is a fast growing company working in confidential

contractual research for food and feed innovation, Intellectual

Property is 100% for customers.

IMPROVE offers the best of 23 brains and diversified technologies

with 1200m² of laboratories, pilot facilities (from 100 g up to few tons

of raw material).

IMPROVE is your incubator for food and feed innovation based on our

expertise in proteins processing and our network : academic partners

like INRA, Universities, technological platforms and engineering

schools.

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A large range of raw material

If you are interested in alternative proteins you

should come to us to see how we can support

your projects on:

• Pulses

• Cereals

• Oilseeds

• Algae's

• Roots

• Leaves

• Coproducts

• Microorganisms

• Alternative animal sources

• …

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IMPROVE can help you to make

Alternative Protein strong!

Thanks

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Disruptive Ingredient Technologies: Characterizing Plant Proteins …€¦ · Disruptive Ingredient...

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