Gluten-free Ingredients & Formulation Approaches
DILEK UZUNALIOGLU, PH.D.
MAY 2016
2016 B&CMA TECHNICAL CONFERENCE
• Gluten-free Bakery Market Overview
• Gluten-free Bakery Challenges
• Gluten-free Ingredients & Formulation Approaches
• Starches and Flours Used as Bulk Flours and Texturizers in Gluten-Free Formulations
• Use of Pulse Flours in Gluten-free Formulations
• Use of Gums in Gluten-free Formulations
Outline
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Gluten-free Bakery Market
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Source: Packaged Facts January 2015
*
Compound Annual Growth Rate 2010-2014 = 34%
Compound Annual Growth Rate 2014-2019= 19.2%Estimated
US Retail Sales of
Gluten-free Foods in Key
Categories, $ Sales
(in millions)
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The Consumer
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Source:1. Gluten-Free Foods and Beverages in the U.S., 4th Edition, October 17, 2012 2. NPD, March 6, 2013
Science-based problem-solvingfrom Ingredion Idea Labs
Gluten-free Formulation Challenges, Ingredients & Holistic Formulation Approach
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• Lack of viscosity or elasticity of the wheat-containing dough leading to difficulties in processibility and machinability
Processing
• Reduced volume, lack of an even cell structure• Dry, crumbly, grainy texture • Poor crust color and development• Grainy flavor
TextureTasteAppearance
• Shorter shelf-life/ Increased staling rates due to increased water mobility
Shelf-life
• Lack of protein, nutrients and fiber• Use of high levels of sugars and fats to mask the texture and flavor challenges
Nutritional Profile
Gluten-free Bakery Formulation Challenges
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Functionality of Ingredients Used
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Type Examples Usage Level Function
Native Flours and Starches Corn, Potato, Rice, Tapioca, Sorghum, Amaranth, Buckwheat, Quinoa, Soy, Millet, Teff, Bean, Pea, Nut
• 20-50% • Bulk/Backbone of the recipe
• Texture modifier: Body, elasticity & chewiness, crumb structure
Cook-up Native Functional or Modified Starches
Corn, Tapioca, Rice, Potato • 20-50% • Texture modifier: Body, elasticity & chewiness, crumb structure
• Freeze-Thaw Stability
Pre-gelatinized Native Functional or Modified Starches
Corn, Tapioca, Rice, Potato • 2-10% • Dough viscosity control
• Texture modifier
• Prevent staling
Proteins Whey Protein, Soy Protein, Zein, Egg White Powder, Pulse Proteins
• 2-5% • Build structure• Color development
Other Hydrocolloids/Gums
Xanthan Gum, Guar Gum, Cellulose Gum, Alginates, Konjac, Psyllium Husk
• -.5-3% • Dough viscosity control
• Texture modifier
• Prevent staling
• Freeze-thaw stability
Use combination of ingredient to match dough rheology and final product texture is key!
DIAL-IN®TechnologyThe shortest path to perfect texture and sweetness
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• Benchmarking wheat-containing and gluten-free products
• Identifying gaps using Descriptive Sensory Analysis
• Developing solutions to minimize the gaps
Gap Measured Using Descriptive Sensory Analysis
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Cohesiveness of Mass:The degree to which a chewed product forms a bolus/ball/holds together
Wheat-containing Benchmark
Wheat-containing Benchmark
Loose
LowHigh
Compact
Roughness of Mass:The amount of graininess as perceived on the surface of the product during its mastication
Gluten-free Market Samples
Gluten-free Market Samples
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Experimental Approach
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Process
• Dispersibility, Dough Rheology, Machinability, Handling
Descriptive Sensory Analysis
• Cohesiveness, Graininess, Dissolvability, Hardness, Denseness, Firmness, Springiness, Mouth CoatingFinal Product
Measurements
• Hardness via Texture Analyzer, Yield, Height, Moisture, Cost
Preliminary Screening
Optimization DOE
Final Optimal Composition
Texture Mapping
Grainy
C
2
M
Smooth
Dry
Crumbly
Grainy
Moist
Chewy
Cookie
2
Muffin
Muffin: Gluten-free Flour System
Commercial Cookie Benchmark: Gluten free
Commercial Muffin Benchmark: Gluten free
Cookie: Gluten-free Four System
Commercial Cookie Benchmark: Wheat containing
Commercial Muffin Benchmark: Wheat containing
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Desirable Nutrition ProfileChocolate Chip Cookie
140-180 Calories
7-9 g.
2-4 g.
20-24 g.
0-2 g.
15-20 g.
1-2 g.
WHEAT BASED
Ingredients True %
Native Functional Flour 19.25
Butter, Soft 17.49
Light Brown Sugar 11.65
Medium Invert Sugar 9.00
Cane Juice 3.66
Eggs 8.38
White Rice Flour 4.00
Corn Starch 3.20
Vanilla 0.40
Salt 0.35
Baking Soda 0.28
Xanthan Gum 0.13
Semi Sweet Chocolate Chips 22.21
Total 100.00
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Science-based problem-solvingfrom Ingredion Idea Labs
Key Starches and Flours Used in Gluten-free Formulations
Every Starch is Different
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SOURCE TYPEDIAMETER
(µm)SHAPE
AMYLOSE
CONTENT
IODINE
STAINSEM
Corn Cereal 5 – 26Round,
polygonal22 – 28 Blue
Waxy Corn Cereal 5 – 26Round,
polygonal< 1 Red-violet
Tapioca Root 5 – 25Truncated,
oval17 – 22 Blue
Potato Root 15 – 100Oval,
spherical23 Blue
Wheat Cereal 2 – 35Round,
lenticular17 – 27 Blue
Rice Cereal 3 – 8Polygonal,
angular16 – 17 Blue
Sago Pith 15 – 65Oval,
truncated26 Blue
High Amylose
CornCereal 3 – 24
Round,
elongated50 – 90 Blue So
urces: Ingredion, John F Robyt, C.W. Wong and al
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Waxy Maize
Wheat
Tapioca
Potato
Maize
36 g starch, anhydrous
starch + H2O = 490 g
rapid heating to 50°C, then 1,5 °C/min
to 95°C, maintain 20 min
cooling to 30°C -1,5°C/min
Brabender
10 20 30 40 50 60 70 80 90
minutes
2600
2400
1600
1400
1200
1000
800
600
400
200
95° C 95 + 20 minutes 30° C
[BU]
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Comparative Viscosity Profile
Key Gluten-free Starches and Flours
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Ingredient Functionality
Rice Flour • Mild taste small granule size, smooth texture• Very digestible and no allergenic• Gives body, but turns quite dense when used on its own
Corn Starch • Typical maize flavor, creamy to yellow color• Gives a light crumb structure• Good setting properties but fast staling
Tapioca Starch / Tapioca Flour
• Adds some elasticity, chewiness (prevents from crumbling)
• Gives good moisture, lightness, fine crumb structure
Potato Starch / Potato Flour
• High water absorption, gives moisture to the end product
• Quite bland in taste at low levels• Recipe concentration effect / Good cost in use
Corn
Tapioca
Potato
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Science-based problem-solvingfrom Ingredion Idea Labs
Enhancing the Nutrition & Texture: Pulse Flours & Proteins
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What is a Pulse? Legumes
Soybeans
Peanuts
PulsesDried Beans, Dried Peas, Chickpeas, Lentils
Fresh Peas
Fresh Beans
Chickpeas
Dried Beans
Lentils
Dried Peas
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Plant Fixing NitrogenLower Energy Requirement
Increased Water Use Efficiency
Source: Hoekstra and Chapagain, Globalization of Water, U. of Twente, Waterfootprint.org National Geographic, April 2010
• 43 gallons of water required to
produce one pound of pulses
• 1,857 gallons of water required to
produce one pound of beef
1,857Gallons/ lbs
43Gallons/
lbs
Pulses
756Gallons/
lbs
469Gallons/
lbs
• Pulses Use Less Non-Renewable
Energy Relative to Other Crops
• 70% of the non-renewable energy
used in cropping systems in
western Canada is attributable to
fertilizers
Source: (Zentner et al. 2004)
• Pulses produce their own fertilizer
by fixing nitrogen
Sustainable Agriculture
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• The United Nations declared 2016 as the International Year of Pulses (IYP).
• The IYP 2016 aims to increase the public awareness of the nutritional benefits of pulses as part of sustainable food production and towards food security and nutrition.
2016 is the International Year of Pulses
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Source: http://www.fao.org/pulses-2016/en/
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Media Coverage
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Highlights:
• 600+ Online Media Channels have covered IYP.
• The Social Media campaign has generated 145M impressions on Twitter, 2.5M impressions on Instagram and has reached 14.3M consumers on Facebook.
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Pulse Ingredients
Pulse Ingredients
• Pulse Protein Concentrates• 55-60% protein d.b.• Pulse Flours• 10-25% protein d.b.• Derived from• peas• faba beans• lentils• chickpeas
Functionality
• Emulsification
• Texture• Gelation
• Water-holding• Adhesion• Film Forming
Value Propositions
• Enhance textureand provide moist mouthfeel• Good synergy with other gluten-freeflours• Proteinenhancement
• Soy proteins replacement
Labelling & Nutritional
• Natural
• Non-GMO• Gluten-free & Grain-free
• Hypoallergenic• High Protein, High Lysine
• High Dietary Fiber• Low Glycemic Index
• High in Micronutrients
Peas Lentils ChickpeasFaba Beans
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Production of Pulse Ingredients
Minimum 20% Protein d.b.
Coarse & Medium
Pulse Flour
55-85% fiberMinimum 10% protein
d.b.55-60% proteins d.b
High Starch Pulse Flour
Pulse ProteinPulse Bran
Pulse Seeds
Dehulling Spliting
Minimunm 20% Protein d.b.
FinePulse Flour
11 22
33 44
Sieving
Pulse Hulls
Milling &Air classificationMilling
Milling
Pulse Splits
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• “C-type” crystallization pattern (a mix of “A” and “B” types)
• High amylose content (~30-35 % amylose)
• High degree of retrogradation
• High thermal stability
• Relatively high resistance to shear thinning
• Moderate swelling power
• High gelatinization temperature (>60oC)
• High gel elasticity
Pulse Starch
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Soft candies
SEM image of Faba bean starch
SEM image of yellow pea starch
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Extruded Snacks Noodles
Nutritional Quality
• 9 Essential amino acids - cannot be made by the body, must come from food.
– Histidine
– Isoleucine
– Leucine
– Phenylalanine
– Threonine
– Valine
Impact of Pulse Protein Amino Acids Composition on Product Formulation
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Deficient in pulse protein
Functionality/Product Property
• E.g. Tendency of Browning (at neutral pH, with reducing sugars)– High Lysine content
– Lysine is a substrate of Maillard reaction
No pulseWith Pulse– Methionine
– Tryptophan
ε-amino group
– Lysine Abundant in pulse protein
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Pulse Flour has similar/higher protein content as wheat flour, but…
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14.5812.1
9.5
5.9
02468
10121416
Yellow PeaFlour V-6000
Wheat Flour(All Purpose)
Corn Flour Rice Flour
Protein (% d.m.)
HOMECRAFT® Pulse Flour*
* This one has higher starch content, lower protein content
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• Pulse protein v.s. Wheat protein
…but very different protein composition
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PulsesProteinfractions
Wheat
10 – 30% Albumin 5 – 15%
40 – 80% Globulin 5 – 10%
10% Glutelin 30 – 50%
0 – 5% Prolamin 30 – 50%
≈ 80% soluble protein
≈ 80% insoluble protein
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Wheat Gluten Formation
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Not a one-to-one replacement for wheat flour if gluten formation is requiredEducated guess: ☺ Soup☺ Batters & Breadings☺ Cake, cracker, cookies
� Bread, seitan http://www.perten.com/Products/Glutomatic/About-gluten/
(Baumann 2015)-Buhler Group
• Wheat proteins is high in Cysteine content
– Disulfide bond formation
• Pulse protein is low in Cysteine content
– Limited disulfide bond formation
Starch
Protein
Kneading
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• Market drivers
– Health, clean label and taste driving growth in the snack segment
– New ingredients for gluten and high protein snack applications
• What Pulse Flour, Protein and Fibers can do
– Controlled Expansion
– Differentiated Texture
– High Protein
– High Dietary Fiber
– Low Fat, Differentiated Texture without frying
– Unique Taste, Aroma and Flavor
Extruded Crisps
All in Gluten-free,
Non-GMO
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Extruded Crisps with Pulse Ingredients
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Extruded Crisp A Extruded Crisp B
Faba Bean Concentrate (min 60% protein in d.b.)
96.5%
Sugar 2.5%
Salt 1.0%
Faba Bean Flour (min 10% protein in d.b.)
60.5%
Faba Bean Concentrate (min 60% protein in d.b.)
25.5%
Pea Fiber 80 10.5%
Sugar 2..5%
Salt 1.0%Texture: Dense, hard and crunchy., loose and gritty bolus Texture: Airy, crispy.
dissolves quickly, low toothpacking.
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Pulse Ingredients in Gluten-free Bakery
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Crackers & Biscuits
Protein enrichment ��������
Improved browning ��������
Improved smoothness ����
Improved bite ����
Differentiation (taste, color) ����
���� Pulse flours ���� Pulse Proteins
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Gluten Free Hummus CrackerPre-gelatinized Tapioca Flour provides a crunchy texture while helping with dough handling and sheeting.
Chickpea Flour and GF Flour System (tapioca flour, rice flour) are gluten-free flours used in the formula to replace wheat flour.
Globe® Glucose Syrup, Non-GMO ingredient primarily contributes to sweetness and binding.
Ingredients Percent (%)
Chickpea Flour 25.48
GF Flour System (Tapioca Flour, Rice Flour 25.48
Pregel Tapioca Flour 7.39
Monocalcium Phosphate 0.76
Baking Soda 0.76
Salt 0.81
Buttermilk Powder 2.15
Dill, Freeze Dried 0.35
Vinegar Powder 0.71
Garlic Powder 0.27
Onion powder 0.27
Parsley, Freeze Dried 0.16
Granulated Sugar 1.40
Pepper, Ground Black 0.11
Palm Shortening 7.90
Water 23.76
Globe® 63 DE Glucose Syrup, Non-GMO 2.24
Total: 100.00
1. Preheat convection oven to 375°F. 2. Combine dill, parsley, water, and HFCS in bowl allowing herbs to hydrate for 30 minutes.3. Combine remaining dry ingredients in mixing bowl with paddle at speed 1 for 90 seconds.4. Add shortening and continue mixing for 90 seconds.5. Slowly add the hydrated herb mixture to bowl and mix with paddle for 1 minute. 6. Switch to dough hook and continue mixing at speed 1 for another 3 minutes. 7. Sheet dough to about 1.5 mm thickness. Cut and dock with cracker cutter.8. Place crackers on perforated sheet tray and bake for 3-6 minutes depending on thickness.9. Remove crackers and let cool on sheet tray. 10. If applying a topical seasoning or salt, coat the crackers evenly with it before they cool.
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Gluten Free Snack Crackers
1. Preheat oven to 295°F2. Sift dry ingredients together. Place dry ingredients in Hobart mixer bowl with sugars and butter 3. Mix at speed 1 with paddle until mixture resembles coarse sand4. Add water, vanilla extract, and syrup to bowl. Mix at speed 1 until a cohesive dough forms5. Wrap dough in plastic wrap and chill in refrigerator for ~10 minutes or until ~ 70°F6. Sheet dough out to 3 ~ 3.5mm thickness. Cut shapes and place on baking sheet 7. Bake 23-28 minutes depending on cookie size and oven. If using convection oven cut baking time to 6-14 minutes 8. Let cookies cool on sheet
Ingredients Percent (%)
Faba Bean Flour 35.47
Faba Bean Protein 5.07
Pregel Tapioca Flour 2.57
Pregel Corn Starch 2.57
Shortening 10.29
Granulated Sugar 8.38
Brown Sugar 7.09
Salt 0.80
Baking Powder 0.40
Baking Soda 0.40
Xanthan Gum 0.40
Vanilla Extract 1.03
Globe® 63DE Corn Syrup 4.03
Globe® 42DE Corn Syrup 4.05
Non-fat Dry Milk Powder 2.03
Ground Cinnamon 0.85
Water 14.56
Total: 100.00
Faba Ben Flour is gluten-free faba bean flour used in the formula to replace wheat flour.
Faba Bean Protein used in the formula to increase the protein content.
Pre-gelatinized Tapioca Flour provides a crunchy texture while helping with dough handling and sheeting.
Pre-gelatinized Corn Starch provides expansion and a crunchy texture.
GLOBE® 42 DE Glucose Syrup and GLOBE® 63 DE Glucose Syrup ingredients primarily contribute to sweetness.
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• Gums provide viscosity, elasticity and produce favorable textural attributes that are lost when gluten is removed
• Gums work synergistically with ingredients such as starches and other gums to produce various textural attributes
–Change in rheology
–Gel Formation
– Viscosity
– Film forming
Gums
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Use of Gums in Gluten-free Formulations
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Product Functionality
XanthanBatter viscosity and cohesive texture
GuarBatter viscosity, freeze/thaw stability and moisture retention
CMCCell structure and moisture retention
HPMCStructure and set during baking due to thermal gelling characteristics
Gum Arabic
Emulsification and film formation
LBGBatter viscosity, cohesive texture, cell structure and freeze/thaw stability
A combination of Corn Starch, Gum Arabic, Xanthan gum and Guar gum provides volume, uniform cell structure, suspension and moisture retention
A combination of Potato Starch, Tapioca Starch and Guar gum provides a soft crumb structure, volume and moisture retention
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Gum No Gum
Gum No Gum
Key Takeaways
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More consumers than ever switching to gluten-free diet
Gluten is essential component of taste and texture of food products through its unique functional properties
Removing gluten results in formulation challenges to build back the texture and eating experience
A holistic formulation approach with key functional ingredients are shown to replace gluten without compromising the eating quality, processing and shelf-life
Science-based problem-solvingfrom Ingredion Idea Labs
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Thank You & Questions?
Dilek Uzunalioglu, Ph.D., Business [email protected]
908-685-5294
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