1 FORMULATING DAIRY BASED PRODUCT Food Review Seminar: Update on Dairy Industry, Bogor June 2012 USING PRO-PREBIOTIC INGRIDIENTS Ir. Lilis Nuraida, MSc. Ph.D. SEAFAST Center and Departemen Teknologi Pangan dan Gizi Institut Pertanian Bogor Outline Definitions of Pro Pre and Syn biotic Definitions of Pro-Pre and Syn-biotic Application of Probiotic in Dairy Industry Pro- and Pre-biotic in Fermented Dairy Products Pro- and Pre-biotic in non fermented product Lilis Nuraida ‐ June 2012 Microencapsulation to improve viability of probiotic
Transcript
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FORMULATING DAIRY BASED PRODUCT
Food Review Seminar: Update on Dairy Industry, Bogor June 2012
USING PRO-PREBIOTIC INGRIDIENTS
Ir. Lilis Nuraida, MSc. Ph.D.SEAFAST Center and
Departemen Teknologi Pangan dan GiziInstitut Pertanian Bogor
Outline
Definitions of Pro Pre and Syn biotic Definitions of Pro-Pre and Syn-biotic Application of Probiotic in Dairy Industry Pro- and Pre-biotic in Fermented Dairy
Products Pro- and Pre-biotic in non fermented
product
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Microencapsulation to improve viability of probiotic
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Probiotic, Prebiotic and SynbioticTerm Definition
Probiotic = for life (G k)
Live microorganisms administered in d t t hi h f l(Greek) adequate amounts which confer a l
health benefits to the host FAO/WHO (2001)
Prebiotic Nondigestible food ingredient that beneficially affects the host by selectively stimulating the growth
d/ ti it f li it d
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and/or activity of one or a limited number of bacteria in the colon, and thus improves host health
Synbiotic A mixture of probiotic and prebiotic
Probiotic Market Probiotic foods
The largest share of the market, estimated $13.8 billion in 2008, should reach $17.0 billion in 2013, 4.2 percent growth.
Mostly in dairy products, with yogurts, kefir and cultured drinks representing the major categories of probiotic foods.
Y t d t t d f th l t h f l ti 36 6 t Yogurt products accounted for the largest share of sales, representing 36.6 percent.
properties are strain dependentEach strains has to be characterised
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Viability of probiotic bacteria Viability, physiological and metabolic activity of probiotic
bacteria in a food product at the point of sale are important consideration for their efficacy
They have to survive during shelf life of a food transit through
Probiotic bacteria should be present in a food to minimum concentration of 106 cfu/g or the daily intake should be about 109
cfu/g Fermented Milk and Lactic Acida Bacteria Beverages
Association Japan: minimum 107 cfu/ml to be present in dairy
They have to survive during shelf life of a food, transit through high acidic and alkaline conditions in the gastro-intestinal tract
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Association, Japan: minimum 10 cfu/ml to be present in dairy products
National Yoghurt Association, USA specifies 108 cfu/g at the time manufacture
Prebiotic effect of various oligosaccahrides
Carbohydrate Nondigestibility Fermentation Selectivity Prebiotic status
Inulin and oligofructose
Yes Yes Yes Yes
Galactooligosaccharides
Probable ? Yes Yes
Lactulose Probable ? Yes Yes
Isomaltoligosaccharides
Partly Yes Promising No
Lactosucrose NA NA Promising No
Xylooligosacchraides
NA NA Promising No
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des
Soybeanoligosaccharides
NA NA NA No
Glucooligosaccharides
NA NA NA No
Roberfroid, 2007
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Use of Prebiotics in food
Safety of ingredient is a must and good sensory properties desirable
Good prebiotics are stable under heat and Good prebiotics are stable under heat and when dried, can be stored at room T for months
A daily dose of 5-8g/d FOS or GOS has a prebiotic effect in adults
Doses higher than 20 g/day might induce
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Doses higher than 20 g/day might induce some side effects, such as increased flatulence or abdominal bloating.
Application of Probiotic in Dairy Industry
Fermented products: Yoghurt and fermented milk drinkYoghurt and fermented milk drink Cheeses
Non-fermented products: Ice cream and milk based dessert Powdered milk for infant Butter, Mayonnaise, Fat spread
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The choice of probiotic microoganism for production of starter culture
Posses health beneficial effect to human Tolerance to acidity and bile salts The ability of the probiotic
microorganism to grow in the medium to increase the cell number
The robustness of microoganism to
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The robustness of microoganism to withstand the freezing or drying of starter culture
Several aspect must be considered during the production of probiotic fermented milk drink
Many probiotic strain grow slowly in non-supplemented milk due to limited proteolytic activity
S l t d ith h d li d t i h Supplemented with hydrolised protein, whey derivatives, or amino acid
The production condition are often unsuitable for their growth Optimum temperature for probiotic isolated from
human is 37oC Conventional yoghurt fermentation done at 42oC
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The metabolites of probiotics may be undesirable due to formation off flavor Bifidobacteria produce acetic acid and lactic acid in
the proportion 3:2 which give vinegar like taste
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Yoghurt and fermented milk drink
Conventional yoghurt is fermented by L. bulgaricus subsp delbruekii and S thermophilussubsp delbruekii and S. thermophilus
not very resistant to the bile released into the small intestinenot maintained alive in the gastrointestinaltract in very high numbers
Bio‐yoghurt is yoghurt contain live probiotic microoganisme, i.e. Lactobacillus acidophillus and
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strains of Bifidobacterium the presence of which may provide beneficial health effect (Laurent‐Hattingh and Viljoen, 2001).
Incorporation of probiotic into fermented milk
Add the probiotic microorganisms together with the starter culture (as Direct to Vat Innoculation/DVIstarter culture (as Direct to Vat Innoculation/DVI culture) Probiotics do not usually grow markedly during mixed
fermentation
The probiotic microorgnisms may be grown in one batch of milk to achieve a high viable count, another batch of milk is fermented with traditional starter
lt
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culture. The two batches are then mixed together
Probiotic microorganism(s) may be used as starter culture, the fermentation may be longer
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Yoghurt fermentation
Homogenized milkTS 12%
Incubation at 43.3, to reach pH 4.8
Prebiotic
Heating and cooling
Addition starterculture
Cooling, agitating,
Packaged in small container
Cooling and Holding
Set yoghurt
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Packed in cups
Bulk container
small containerOr cup
y g
ProbioticStirred yoghurt
Factors affecting L. acidophillus and Bifidobacteria in bio-yoghurt
Yoghurt acidity
Most strain of bifidobacteria are sensitive to pH below 4.6
The product should be maintain at pH above 4.6
L. acidophillus is more resistant
Strains
The bifidobacteria should be able to grow in milk. Some lack of proteolytic activity
Co-culture and species interaction
H2O2 produced by L. bulgaricus is detrimental to L. acidophillus
Synergistic growth between L. acidophillus and Bifidobacterium
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Dissolved oxygen
Bifidobacteria is strictly anaerob
Storage condition
Low temperature restrict the growth of Lactobacillus and so over-acidification
Bifidobacteria less tolerant to low temperature storage
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Improvement of survival L. acidophillus and Bifdobacteria in bio-yoghurt...................1
Prevention over acidification:
Applying heat shock before addition of probiotic culture
Lowering storage temperatur to 3 4oC Lowering storage temperatur to 3-4oC
Improving buffering capacity by the addition of whey protein concentrate
Modification of incubation temperature
Incubation temperature of 37oC favours the growth of bifidobacteria
Rate of innoculation
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Some probiotic bacteria grow poorly in milk use a large innoculum size or concentrated inoculum
Selection of starter culture
Improvement of survival L. acidophillus and Bifidobacteria in bio-yoghurt...................2
Two-stage fermentation
Acid and hydrogen peroxyde produce by yoghurt starter culture may b d t i t l t bi ti lt ddi bi ti b t i ftbe detrimental to probiotic culture adding probiotic bacteria after fermentation or adding yoghurt starter culture at later stage
Addition of growth promoting substances
Supplementation of casitone, casein hydrolysate, fructose, whey protein concentrate improved viability of L. acidophillus
Cystein, acid hydrolysate and tryptone improved viability of bifidobacteria
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Microencapsulation
Type of packaging container
Bifidobacteria is anaerobic, while lactobacilli is microaerophilic
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Effect prebiotic on bio-yoghurt
Addition of oligosaccharides potentially enhance viability bifidobacteria: Use of lactulose in fermented milk improved quality of
f t d ki ilk b L id hil L hfermented skim milk by L. acidophilus, L. rhamnosus, Lactobacillus bulgaricus and Bifidobacterium lactis in co-culture with Streptococcus thermophilus.
Increased the counts of all probiotics, with particular concern to B. lactis (bifidogenic effect)
Inulin addition to co-cultures and cocktail:
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Enhanced products firmness, Increase in microbial growth induced by metabolic
interactions among lactic acid bacteria and partial inulinmetabolization.
(Oliviera et al., 2011)
Probiotic Cheeses Natural cheese has proven to be a good carrier for
probiotic cultures.
Studies have suggested that consuming probiotics in a cheese matrix is favorable for the viability of probioticsy pthrough the digestive tract.
Desirable properties of probiotic bacteria to be incorporated to cheese:
Must survive the entire shelf-life of cheese.
Must not produce metabolites that are detrimental to the quality of cheese
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Should not interfere with the normal activity of other essential microorganisms in the cheese
Should be compatible and not produce antimicrobial compounds
Should be able to grow on starter culture media
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Introduction of probiotic microorganism into cheeses
Introduce as adjunct cultures together with lactic starter cultures
Risk of losing large numbe rof cells to whey or domination of lactic starter cultures
Addition of microencapsulated probiotic
Protected the probiotic from degradation duirng teh aging period
Addition of dried probiotic cultures during salting of curd on semi-hard and hard cheese
Addition of freeze dried culture to mtrix of Cheddar cheese following cheddaring and salting
Addition of fermented cream dressing in cotage cheese
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Cream dressing is added for flavour and texture development
Two stage fermentation:
Fermentation with probiotic bacteria for 2 h followed by fermentation with starter culture
The lactic starter culture grow faster than probiotic bacteria
Standardized milk
Starter culture
Whey draining
CheddaringProbiotic
Rennet
Curd Cutting
Milling
SaltingProbiotic
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Cooking Hooping and Pressing
The manufacturing stage of Cheddar Cheese (Tamime et al., 2007)
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Ice cream and frozen milk based dessert
The ice cream matrix might be a good vehicle for probiotic culture due to its composition (milk protein, fat, lactose and other compounds)other compounds)
During manufacturing ice cream, freezing involves vigorously agitating to incorporate air Detrimental to probiotic bacteria: Lactobacilli are microaerophilic, bifidobacteria are
anaerobic Freeze stress must be considered with respect to viability
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Freeze stress must be considered with respect to viability during manufacture and extended storageImpact of probiotic bacteria on flavor should be considered as ice cream is not fermented product
Incorporating probiotic into ice cream
Direct, i.e. blend the ice cream mix and probiotic cells prior to freezing
Involve fermentation of the milk for proliferation of probiotic bacteria prior to blending with ice cream mix frozen yoghurt ice creamprior to blending with ice cream mix frozen yoghurt ice cream
Protection of the probiotic cells againts freeze damage is important (use cryoprotectant)
Fermented frozen dessertPro or synbiotic ice cream
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Problems during processing ice-cream containing probiotic culturesStep Problem Solutions
Formulation with fruit
l /j i
•High acidity of the final product may lead to decreased probiotic survival
•S i di t h i hibit
•Preferably, use of fruit pulp/juices with a lower natural acidity
•Ch k f i hibit ti it f th pulp/juice •Some ingredients may have inhibitory activity against probiotic strains
•Check for inhibitory activity of the food ingredients to be used against the probiotic strains to be employed
Fermentation Probiotic bacteria show some loss in viability at low pH values
•Control of the pH during the fermentative process
•Increased inoculum concentration•Selection of strains tolerant to low pH values
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Beating Oxygen represents a factor of toxicity for probiotic bacteria
Selection of oxygen-tolerant strains
Storage Stress induced by freezing reduces the viability of probiotic bacteria by at least 1 log cycle
•Increased inoculum concentration•Avoid temperature oscillations during storage of the product
Cruz et al., 2009
Stability of the probiotic cultures during ice-cream storage
Probiotic cultures wee capable maintaining their stability in frozen food productsstability in frozen food products
Addition of prebiotic (inulin and oligofructose) : Higher overrun for the ice-cream mix with inulin Less changes in melting properties Firmer during storage Increase probiotic survival during storage of the ice-
t i i li f t
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cream containing oligofructose
Improvement stability: the use of microencapsulation of cultures and the supplementation with prebiotics
Cruz et al., (2009)
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Application of probiotic in powdered/dried dairy products
Liquid materials + liquid ingredient
Spray drying
Dry base
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Powdered dairy product
Mixing Dry ingredient
Dried encapsulated
probiotic
Microencapsulation: a process whereby the cells are retained within
Microencapsulation Technique to improved viability
Protection againts adverse conditions in the product
whereby the cells are retained within the encapsulating membrane
Improving viability, survival during freezing, stability during storage
Entrapment in gelatin, calcium alginat, xanthan-gellan or vegetable gums
E l t d ll b d i d t
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Encapsulated cells can be dried to produce cell powder/granule (freeze drying, spray drying, fluidized bed drying)
Protection againts deleterious conditions in the upper GI tract
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Technique for microencapsulation
Atomization:Spray drying Spray drying
Spray Chilling
Extrusion Technique
Emulsion Technique
Freeze Drying
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Technique for microencapsulation Atomization
Spray drying is a commonly used method of encapsulation in the food industry:
controlled by means of the product feed gas flow and temperature controlled by means of the product feed,gas flow and temperature
