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PHO Free Toolbox for Fats and Oils Steve Robbins
PHO Free Toolbox for Fats and OilsSteve Robbins
• What is the function of fat in cooking and baking?
• Tenderizes
• Imparts flavor
• Aeration
• Provides and defines structure
• Heat transfer medium
• Affects color
• Holds water
• Performance Requirements
• Functionality
• Nutrition
• Cost
Functionality and Performance
Evolution of Available Fats and Oils
Partially
Hydrogenated
Fats and Oils
First
Generation
Zero Trans
Second
GenerationZero Trans
Blended Oils
Interesterified
Oils
Vegetable Oils with
Modified Fatty Acid
Profiles
• Vegetable Oils with Modified Fatty Acid Profiles
• High Oleic (Omega-9) oils
• Omega-3 oils (Stearidonic, EPA, DHA)
• Low saturated fat
• High stearic oils
• Interesterification
• Soy/Fully Hydro Soy
• Simple Blending
• Hardstocks
• Liquid Oils
First Generation Zero Trans Oils
Fatty Acid Profile and Oxidative Stability
• Blending of one or more hard fats with liquid oil to obtain the desired solid fat content and nutrition.
• Selection of the hard fats is important to provide structure and hold in the liquid oil.
• Palm Oil
• Lauric Fats
• Fully hydrogenated oils
• High stability liquid oils can be used in combination with conventional oils to gain the right balance of stability and nutrition.
Narine et al. U.S. Patent 8,431,177, 2013Orthoefer et al. U.S. Publication 20140030411, 2014
Simple Blending
• Palm oil is challenging to process
• Mouthfeel
• Texture
• Palm fractions can be blended with liquid oils to:
• Tailor the solid fat content to a specific application
• Provide desired mouthfeel
• Meet specific nutritional targets
• Improve overall functionality
Palm Oil Blends
• Fibers
• Emulsifiers
• Emulsions
Higgins. U.S. Patent 8,394,445, 2013Ervin et al. U.S. Publication 0053251, 2012
Fat Replacement
• Can be used to create a functional shortening that has no hydrogenated oils and no palm oil.
• Mono and diglycerides effectively bind water and oil.
• Good for:
• Pie dough
• Cookie dough
• Tortillas
• Mono and diglycerides do not effectively trap air.
• Not good for:
• Icings
Fat Replacement – Mono and Diglycerides
• Product lines in this category have expanded and improved
• High oleic oils offer potential for both higher stability IE oils, as well as increased solid fat content.
• Multiple hard fats allows for improved manipulation of the SFC curve.
Interesterification
Dry
Ingredients
Shortening
(melted)
Step 1Shortening
added to dry
ingredients
Step 2
Mixture is
cooled
Step 3Material is
packaged at
ambient
temperature
Case Study – The Application
• Control – Partially hydrogenated soybean oil
• Shortening 1 – Interesterified soybean oil (~30% fully hydrogenated soybean oil, ~70% liquid soybean oil)
• Shortening 2 – Palm based shortening (~90% palm and palm stearin, 10% soybean oil)
• Shortening 3 – Hardfat mix (70% Palm, palm stearin,
palm kernel oil, 30% canola)
Case Study – The Shortenings
0
5
10
15
20
25
1.0 2.3 3.7 5.0 6.3 7.7 9.0 10.3 11.7 13.0 14.3 15.7 17.0 18.3 19.7 21.0
Solid F
at
Conte
nt
(%)
Time (min)
Crystallization of Shortenings @ 20 Celsius
Control Interesterified Palm Hardfat Blend
Step 3
Material is packaged at ambient temperature
0
10
20
30
40
50
60
1.0 2.3 3.7 5.0 6.3 7.7 9.0 10.3 11.7 13.0 14.3 15.7 17.0 18.3 19.7 21.0
Solid F
at
Conte
nt
(%)
Time (min)
Crystallization of Shortenings @ 0 Celsius
Control Interesterified Palm Hardfat Blend
Step 2
Mixture is cooled
0
2
4
6
8
10
12
14
16
1.0 3.7 6.3 9.0 11.7 14.3 17.0 19.7 22.3 25.0 27.7 30.3 33.0 35.7 38.3 41.0 43.7 46.3 49.0
Solid F
at
Conte
nt
(%)
Time (min)
Crystallization of Shortenings @ 30 Celsius
Control Interesterified Palm Hardfat Blend
Step 1
Shortening add to other ingredients
Product/Oil Type Saturated
Fat
Mono-
unsaturated
Fat
Poly-
unsaturated
Fat
Trans
Fat
OSI
(hours)
Control (Partially
Hydrogenated Soybean) 29 41 5 24 48
Interesterified Soybean 40 8 41 1 6
Palm + Soybean 52 35 12 <1 16
Hardfat Blend (Palm,
Palm Kernel, Canola)
48 38 13 <1 14
Hardfat Blend 2 (Palm,
Palm Kernel, High Oleic
Canola)
48 43 8 <1 28
Fatty Acid Profile and Shelf Life Considerations
Blended OilsInteresterified
Oils
Vegetable Oils with
Modified Fatty Acid
Profiles
Interesterified
Palm Blended
with Canola
High Oleic Soybean
Interesterified with
Hydrogenated
Soybean
High Stability
Blended Frying
Shortenings
Second Generation Zero Trans Oils
• Improved Nutrition
• Zero Trans Fat
• Higher levels of monounsaturated and polyunsaturated fat
• Improved Quality
• Better formulation, better processing, better handling
• Continuing Challenges
• Drop in Solutions? Procedural Changes?
• Maintaining functionality
• Clean Label?
Nutritional Goals and Challenges
Common Challenges
of PHO Free BakingAlex Milligan
October 9, 2016
Do not share without Stratas' written permission
1. Stability
Trans fats are more resistant to oxidation
than cis unsaturated fatty acids
2. Performance
Highly functional & robust!
Trans fats provide a very broad plasticity
range
3. Economics
Inexpensive process on low cost
commodity soybean oil provides better
stability vs. today’s higher priced enhance
trait (IP) oils
Why is replacing trans so hard?
Trans Fatty Acids
Commercial Fats and Oils Options
1961 1985
1994
2003
2006
Meat Fat Bad! Tropical Oils Bad! Notice to Label Trans
Trans Label
Compliance
2013
PHO GRAS
Revocation
Proposed
Trans consumption goes from
4.6 g / day to about 1.0 g / day
2014
Meat Fat & Tropical
Oils Good?
PHO GRAS
Revocation
Notice
2015
Trans consumption goes from less
than 1.0 g / day to 4.6 g / day
1984
PHO Fat Good!Margarine better
than Butter
As time goes on, nutrition science has increased in precision and
accuracy, and the variability in findings decreases.
2009
Petition to
Outlaw PHO
Trans Fat Bad!Butter better than
Margarine
PHO Landscape
PHO Migration:
Finding the Right Fit
Generation 1: Conventional solutions using palm blends, interesterified
soy
Palm and IE Soy Shortenings
Generation 2: Solutions that clearly improve the working range,
consistency and plasticity of conventional solutions
Flex Processed Palm and IE Soy Shortenings
Generation 3: Solutions with the marriage of Flex technology,
interesterification, and a high oleic fatty acid matrix that gives you full
PHO functionality without the PHO
Apex Shortening processed with Golden Flex Technology
PHO Free Solutions
Stratas Foods
PHO Free Solutions
Generation 1: Palm and IE Soy
Conventional Palm Commodity product
Variable quality
Sustainability
IE Soy ShorteningsEnzymatic IE Soy
Interesterification: rearrangement of
fatty acids on the glycerol backbone.
IE modifies the crystallization and
melting characteristics without
changing the fatty acid composition.
Enzymatic Interesterification:
positional selective IE which cleaves
and reattaches fatty acids using an
enzyme catalyst
Common workhorses which can be good options
Potential drawbacks compared to PHO or the improvements
Stratas has developed with the Flex technology.
Generation 1: Palm and IE Soy Shortenings
0
10
20
30
40
50
60
10°C 21.1°c 26.7°C 33.3°C 40.0°C
PHO
Palm
Palm Shortening Has:
• Lower SFC’s than PHO
• Increased waxiness if additional
saturates are added to raise the
SFC’s
• Palm lacks fatty acid complexity
and crystal morphology needed
for stability, plasticity, and
working range
C16:0 = 11%
C18:1 Trans = 31%
C16:0 = 44%
C18:1 Cis = 40%
Generation 1: Palm Shortening
SFC Slope and FAC Composition Drives Functionality
SFC Comparison: Typical PHO vs. Palm Shortening
Temperature °C
Solid
Fat C
onte
nt %
0
10
20
30
40
50
60
10.0°C 21.1°C 26.7°C 33.3°0 40.0°C
Temperature °C
PHO
IE
C16:0 = 11%
C18:1 Cis = 15%
C16:0 = 11%
C18:1 Trans = 31%
IE Soy Shortening has:
• Lower SFC values at start
and higher at end than PHO
• Directionally similar oil
binding to PHO
• Shortening texture softer
than PHO
• Likely requires adjustment
to your process
Generation 1: IE Soy Shortenings
SFC Slope and FAC Composition Drives Functionality
Solid
Fat C
onte
nt %
SFC Comparison: Typical PHO vs. IE Soy Shortening
Stratas Foods
PHO Free Solutions
Generation 2: Flex Processed Palm
Stratas’ Flex processing is a physical processing technology
that directly replicates crystal morphology of a PHO
Palm oil with Flex
Processing: small, tight
crystals (stable)
Palm oil: Large,
needle like
crystals (unstable)
Why is Flex better?
• Flex delivers a crystal shape and size that
mimics that of PHO
• Crystal shape and size also plays a pivotal role in
“boxing in” liquid oils to prevent instability and
fat migration. This improves plasticity,
temperature working ranges, and consistency
• Flex technology improves both palm and IE soy
shortenings by widening working ranges and
improving plasticity
Generation 2: Flex Palm
Typical – 1.5 min mix time Flex – 1.5 min mix time
Generation 2: Flex Palm
Pie Crust Dough
Shortening lumps visible in
finished dough
More homogeneous distribution
of shortening
Typical Palm Flex Palm
Generation 2: Flex Palm
Pie Crust Dough
Flex Palm
Mi
Ma
Firmness Comparison: Flex Palm vs.
Time
Fo
rce
Functiona
Flex Palm Sets Sooner and Stays Stable Longer
Generation 2: Flex Palm
Firmness Comparison
Stratas Foods
PHO Free Solutions
Generation 2: Flex Processed IE Soy
ABC’s of IE Flex
Issue: IE Soy shortenings have inconsistent plasticity and firmness and have
been known to be soft in the package
Solution: As with Flex Palm, Stratas has utilized Functional crystallization
technology to make Flex EIE shortening look, feel and work more like PHO
shortening.
Attributes:
• Typical plasticity and firmness in the cube
• More consistent plasticity and firmness throughout the pallet
Benefits:
• Wider workable range in application usage
• Expanded product applications potential!
Challenges:
• Customer acceptance
Observation: IE control process yields soft and inconsistent shortening
Solution: Application of Flex technology improves cube consistency and firmness.
Generation 1: Non-Flex EIE soy
Soft and oiling out
(cube 1)
Firmer
(cube 2, same lot)
Generation 2: Flex EIE soy
Flex processing delivers a consistent, firm IE
shortening, lot to lot and cube to cube
Generation 1 vs 2:
EIE Soy Performance Improvement
Stratas Foods
PHO Free Solutions
APEX – the next generation
Apex Shortening Processed with Golden Flex Technology
• Combines Flex technology with the structural benefits of adding high oleic soybean oil to the
interesterification process
• This unique and proprietary combination increases the benefits from uniform, functional
crystallization allowing for the delivery of a true drop-in replacement for PHO
• Our newest development utilizes ground breaking crystallization technology applied to
domestic fats to deliver the full functionality of “PHO without the PHO”
• We are asking customers interested to confirm sample requests in order to potentially get
involved in this exciting new product line
• Cost is higher, but high oleic soybean oil trend is for ample supply and lower prices long term
Generation 3: Apex Shortening
• Solid Fat Content of Interesterified (IE) Soy is raised to directly match
PHO’s
• The resulting matrix offers a “drop in” non PHO solution, superior to
common approaches currently used in the market
– Palm lacks the fatty acid complexity and beta prime form for achieving
wide plasticity and creaminess
– Conventional IE soy can be weak, lacking the structure needed for
firmer shortening applications
– Conventional hard fat and liquid oil blends deliver inferior structure
and stability, and often lead to fat migration
Apex: How does it work?
0
10
20
30
40
50
60
10.0 °C 21.1°C 26.7°C 33.3°C 40.0°C
Solid
Fat
Conte
nt
%
Temperature °C
Solid Fat Content: PHO vs. Apex IE HOSOY
PHO Apex IE HOSOYC16:0 = 11%
C18:1 Trans = 31%
C16:0 = 11%
C18:1 Cis = 50%
SFC values comparable to PHO from start to
finish!
• Enables nearly identical oil binding to PHO
• Comparable working range to PHO!
Generation 3: Apex IE High Oleic Soybean Oil
Aligns Directly with PHOs
Partial
Hydrogenated
Generation 1:
IE Soy
Generation 2:
Flex Palm
Generation 3:
Apex
Technology PHO IE COMMODITY FLEX PALM IE FLEX HOSOY
MDP °C 48 54 40 49
SFC@ 10.0°C 54 28 50 45
SFC@ 21.1°C 30 23 24 34
SFC@ 26.7°C 21 15 23
SFC@ 33.3°C 13 14 8 14
SFC@ 40.0°C 8 11 4 8
Predicted OSI > 20 HOURS < 10 HOURS > 20 HOURS > 20 HOURS
Saturated Fat (%) 26 43 49 40
Trans Fat (%) 31 < 3.5 < 3.5 < 3.5
Key Hurdle GRAS Revocation Stability SustainabilityAdvance contracting
required
All-Purpose Shortening Attributes Comparison
Generation 3: Apex
Aligns Directly with PHOs
Generation 3: Apex Shortening
Delivers the functionality of a PHO
Apex delivers full functionality over the same working range as PHO,
something that palm cannot match due to palm’s limited plasticity and stability
Dramatic improvement to operational functionality and quality performance
Wider shortening working range
More consistent cube to cube
Reduced down time, clumping, oiling out, tearing of doughs
Increased shelf life potential
• Greater protection of finished product desired form, to optimize desired
organoleptic properties
Basically, what we all loved about
PHO is delivered by Apex!
6-Stratas Foods Manufacturing/Distribution
6-Distribution Centers
12-Contract Manufacturing Locations (not including refineries)
Quincy-SF8Decatur-SF1
Fresno-SF3
Valdosta-SF2
1-Corporate Support Center & Pilot Plant
Parke Warehouses – Decatur, IL-SG4
Midwest Controlled “CAVES”- Quincy, IL-QY1
Osburn Hessey - Edwardsville, IL-SU7
Sherway Warehouse-Brampton, ON-SU9
Sherway Warehouse-Mississauga,ON-40-SW6
Dallas-SX1
Houston-SX2CRC-Cross Road Centers Houston, TX SX8
Memphis-SF9
Stratas Foods Supply Chain
Thank you for your kind attention!
Availability and Functionality of U.S.-Grown PHO Replacements
• Domestic solution for the food industry to the trans fat ban
– High oleic soybean and interesterified soybean oil
• United Soybean Board committed $60 million over five years
Soybeans Provide a U.S.-Grown Solution
Oilseed Production in North America
Available Acreage
SUNFLOWER1.4 MIL. ACRES
SAFFLOWERCANOLA
SOYBEAN80 MIL. ACRES
170,000 MIL. ACRES20 MIL. ACRES
Launch of High Oleic Soybean Oil
2012
More processors and refiners added
2014-2015
Today
2016
Acreage expansion continues
2018
Ultimate goal
2026
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026
High Oleic Soybean Oil Production
Years
Bil
lio
ns
of
Lb
s.
High oleic soybeans are on pace to be America’s fourth
largest row crop in acreage within the
next decade.
Fry Oil Performance
High oleic soybean oil > Commodity soybean oil SIGNIFICANT
High oleic sunflower oil ≥ High oleic soybean oil SLIGHT
High oleic soybean oil > High oleic canola oil MODERATE
Functionality TestingDeep Frying - High Oleic Soybean Oil
Sensory Test Results from Well-seasoned Oil
High oleic soybean oil > High oleic canola oil SIGNIFICANT
High oleic soybean oil > Commodity soybean oil SIGNIFICANT
Blending High Oleic Soybean Oil
• Blending high oleic soybean oil with another oil, such as corn oil and cottonseed oil, will: – Extend Oxidative Stability Index (fry life/shelf life of oil) – Extend deep frying oil life – Decrease polymerization
• Blending high oleic soybean oil with another relatively high-priced, high-stability oil (such as peanut oil) could extend supply and reduce cost, without affecting performance
• High oleic soybean oil is an excellent blending component due to its high stability and low flavor contributions
• Enzymatic interesterification (EIE) is an alternative process to partial hydrogenation that produces similar end products to partial hydrogenation
• Interesterifing high oleic soybean oil with fully hydrogenated conventional soybean oil best replicates the properties and functionality of PHO with zero trans fats
Interesterified (IE) High Oleic Soybean Oil
Functionality TestingDeep Frying Results -Interesterified high oleic soybean oil
• IE high oleic soybean oil produced similar texture, spread and height, and “star” shape of inner doughnut circle as partially hydrogenated frying shortening
• Doughnuts prepared with IE high oleic soybean oil shortening produced less oil weeping than all other products
• Results suggest IE high oleic soybean oil performed most similar to partially hydrogenated soybean oil
Functionality TestingWhite Cake Results
• Palm had the biggest difference in side to dome height ratio
• IE high oleic soybean oil produced a texture most similar to that of palm-based shortening, while IE soybean oil and IE high oleic canola oil produced cake with a harder texture
Functionality TestingButtercream Icing Results
• Specific gravity were all very similar
• Viscosity all came in lower
• Overall performance of IE high oleic soybean oil was the closest to that of PHO
This study is still under way and will be completed later this fall.
U.S.-Grown Soy-based PHO Alternatives
01,0002,0003,0004,0005,0006,0007,0008,0009,000
10,000
Bil
lio
ns
of
Lb
s.
Years
High oleic soybean oil:
Highly functional in multiple edible applications
Familiar soybean oil flavor profile
High Oleic Soybean Production
Secure and short supply chain
Backed by industry commitment
