Prosesseringsteknologi for økt utnyttelse

av korn og belgvekster.

Stefan SahlstrømAvd. Mat og Helse

Nofima.stefan.sahlstrom@nofima.no

Arbeidet med planteprotein til mat – skjer samarbeidsprosjektet

«FoodProFuture»

Nofima ansvarlig for Wp3. Prosessering

Finansiert av

BIONÆR

programmet,

Norges

Forskningsråd

Prosjekt 267858

Varighet:

01.4 2017 – 31.03. 21

Research partners:

NMBU, Nofima, NIBIO, Østfoldforskning,

NTNU, OsloMet, RISE (SE), LUKE (FI), VTT (FI), CSGA (F), UFT (Bul)

Industy partners:

AgriAnalyse, AM Nutrition, BAMA, Borregård, Gartnerhallen, Halogen, Hoff, Lantmannen Cerealia, Mills, NLR, Norsk Matraps, Orkla Foods Norge, Skala

Fokus i «FoodProFuture» er belgvekster og

korn.

Norges miljø- og biovitenskapelige universitet 3

Belgvekster/legumes:

Gule erter og åker-

bønner (faba beans)Høy proteinkonsentrasjon i frø

20 -35 /% protein

Kornarter:

Bygg og havreProduktive, lette å dyrke

10 – 14% protein

Bidrar mye til verdens

proteinforsyning

Pseudocerealer:Eksempel: Bokhvete, quinoa,

amarant, chia, ..

Middels høy proteinkonsentrasjon

Høyt innhold av mineraler og

vitaminer

Potet:Protein utgjør 5-8%

av tørrstoffet

Gunstig AA

sammensetning

Fettproduserende

vekster:Viktig for produksjon av matolje

Har også høyt proteininnhold

4

1. Overview of FoodProFutureWP3 – Processing technologies and model foods

Raw-materials

(pulses/cereals)

• Peas (var. Ingrid)

• Faba beans (var. Kontuand Vertigo)

• Oat

• Barley

• Etc…

Tørr fraksjonering –maling og sikting

Dry-Fractionation

• High-protein fractions

Characterization

• Solid-state analysis (morphology, particle size)

• Composition (protein, starch, fiber contents, …)

• Techno-Functional properties

• (…)

Development of model food products

• Extrusion technology

• Baking

• Homogenization

AIM of WP3: Protein-rich ingredients and model food products based on dry fractionation combined with other sustainable processing technologies

5

2. Dry fractionation – PrincipleNon-chemical sustainable production of protein concentrates from pulses and cereals

Dry-fractionation

Air-classification

Milling

Wet-fractionation(conventional)

Dry-fractionation(non-chemical)

Water addition Yes No

Use of enzymes & chemicals Yes No

Functionality Modified Native

Side-streams High Minimal

Drying step Yes No

Separation ofparticlesbased on

densities and sizes

Milling Air classification

Reduce PS and detach

starchgranules and

protein bodies

Pelgrom et al., 2013:- Starch granules ( 22 µm)- Protein bodies (1-3 µm)- Whole cells or part of cells (>40 µm)

2 steps

Wheel

6

2. Dry fractionation – Configuration / Set-up

Dry-fractionation

Air-classification

Milling

Feedvessel

Classifierwheel

Coarse particles(Starchconcentrate)

Fine particles(Protein concentrate)

Filters

Pin mill

Rotating pin discs

Impact against the grinding pins

Feed rate

Speed of rotors

Principle of centrifugal

counterflowHigh-speed

deflector wheel

Flour

Air flowrate

Speed of wheel

Non-chemical sustainable production of protein concentrates from pulses and cereals

Transportedby air flow

@ Nofima

Saldanha do Carmo et al., 2020, Is dehulling of peas and faba beans necessary prior to dry fractionation for the production of protein- and starch-rich fractions? Impact on physical properties, chemical composition and techno-functional properties, JFE, 278

7

2. Dry fractionationProduction of protein concentrates from yellow peas and faba beans

Raw-materials

Yellow peas (Var. Ingrid)

Faba beans (Var. Kontu)

Crushing and milling

Air-classification

FINE fraction (protein-enriched)

COARSE fraction(starch-enriched)

Cell wall

(fiber)

Starch

granuleProtein

bodies

Yellow peas flour

Protein content

20.4 - 21.3

Starch content

49.3 - 53.1

Dietary fiber

7.5 - 14.6

Faba bean flour

Protein content

30.1 - 34.1

Starch content

38.2 - 43.4

Dietary fiber

7.1 - 15.7

Yellow

peas

Fine fraction

Protein content

44.0 - 46.2

Starch content

10.5 - 12.4

Dietary fiber

17.0 - 17.8

Faba

beans

Fine fraction

Protein content

60.0 - 60.9

Starch content

7.92 - 14.9

Dietary fiber

10.0 - 10.3

Yellow

peas

Coarse fraction

Protein content

8.7 - 8.9

Starch content

63.7 - 72.5

Dietary fiber

4.6 - 16.1

Faba

beans

Coarse fraction

Protein content

21.5 - 25.5

Starch content

50.9 - 56.0

Dietary fiber

6.4 - 14.9

Values are in % dm

8

2. Dry fractionation

Raw-materials

Faba beans

Crushing and milling

Air-classification

FINE fraction(protein-enriched)

COARSE fraction(starch-enriched)

0

20

40

60

80

100

0 5000 10000 15000 20000

%l

rpm

Vertigo 2017 Utbytte og proteininnhold vs ATP

hastighet

Utbytte fin fraksjon (%) Protein (N*6,25 %) Fin fraksjon

Åkerbønner forskjell mellom år

0

20

40

60

80

100

0 2000 4000 6000 8000 10000 12000 14000 16000

%

rpm

Vertigo 2018Utbytte og proteininnhold vs ATP hastighet

Utbytte fin fraksjon (%) Protein (N*6,25 %) Fin fraksjon

Høyere proteininnhold i proteinfraksjon 2018 enn 2017, henholdvis 78% og 62 %. Samme utbytte ca 20 %.

9

2. Dry fractionation

Raw-materials

Faba beans

Crushing and milling

Air-classification

FINE fraction(protein-enriched)

COARSE fraction(starch-enriched)

Bygg forskjell mellom sorter

Litt høyere proteininnhold i proteinfraksjon fra Arild enn RGT planet, henholdsvis 28% og 22 %. Samme utbytte ca 15 %.

0,0

10,0

20,0

30,0

40,0

50,0

60,0

70,0

80,0

90,0

0 5000 10000 15000 20000 25000

%

rpm

RGT Planet Utbytte og proteininnhold vs ATP hastighet

Utbytte fin fraksjon

Protein fin fraksjon (%)

0,0

10,0

20,0

30,0

40,0

50,0

60,0

70,0

80,0

90,0

0 5000 10000 15000 20000 25000

%

rpm

Arild Utbytte og proteininnhold vs ATP hastighet

Utbytte fin fraksjon

Protein fin fraksjon (%)

10

3. Extrusion TechnologyPrinciple and set-up

Raw material feeding

Compressive and shearing forces

Increasing heat transferDie headExtrudate

(≠ shapes)

Barrel

Drive

Screw

T, P

Die

Final product properties

Raw-material is fed into the extruder barrel, transported by one or two screws,mixed, heated and cooked in the screw section (Gelatinization / Denaturation)

The die section shapes andforms the final extrudate

Extrudere (lat.) = to press / drive outThe food extruder is considered a high-temperature short time (HTST) bioreactorthat transforms a variety of raw ingredients into modified intermediate andfinished products(J. M. Harper, 1979/1981)

* In the case of a twin-screw extruder, the screwconfiguration can be buildby the operator

Unit operationsMixingDough

formingCompression

Gelatinization/Denaturation

PressurizingShapingExpansion

11

4. Model Food Products by Extrusion Technology

Enriched-fractions obtained by milling and air-classification are being incorporated into innovative model food productswith improved health, sensorial and functional properties mostly through extrusion technology

@ Nofima

12

4.1 Pasta products

Tnozzle = 90°C

Durum-wheat-based

Different shapes of pasta fortified with pea protein (PP) obtained by extrusion (low temperature, no pressure)

100 (w %) durum wheat

(DW)

85 % DW15% Pea Protein (PP)

60% DW40% PP

No expansion

Simple screwconfiguration

13

4.2 Snacks

100 % w/w corn starch (CS)

Corn starch-based

Corn snacks fortified with peaprotein (PP), obtained by extrusion(high pressure, high temperature)

Incre

asing

pro

tein

con

ten

t

85:15 % w/w CS:PP

60:40 % w/w CS:PP

High expansion

Low expansion

There is no expansion at higherprotein levels

Screw configuration with more shearing elements

14

4.2 Healthier SnacksBackground and Aim

Explore the production of an expanded healthy snack entirely based on pea- and oat-rich fractions by Extrusion Technology

Ready-to-eat healthy snack

(Extrusion Technology)

Oatfiber

Pea starch

Pea protein

Snacks normally existing on the market are mostly based on corn or rice starch withlow nutritional quality due to their high energy density and poorness in nutrients

Pea and oat ingredients seems to be perfect candidates to produce healthier snacks,high in fiber and with an interesting nutrient profile

Balanced amino acid profile

Existing studies are based on milled flours and not enriched fractions

15

4.2 Healtier SnacksProcess optimization

Saldanha do Carmo et al., LWT (2019)

-glucan was not degraded by extrusion

expansion

16

4.3 Meat analogues by Dry texturizationLow-moisture extrusion cooking (LME)

100 % w/w soy protein concentrate (SPC)0% w/w pea fiber (PF)0% w/w oat fiber (OF)

80:20 % w/w SPC:PF 80:20 % w/w SPC:OF

Soaking

GrindingFormulation of

meat-freeproduct

Soy protein concentrate + Pea fiber and Oat fiber= Protein concentrate

TVP

17

4.4 Meat analogues by Wet texturizationHigh-moisture extrusion cooking (HME)

Cooling section will allow the fast cooling of the cookedprotein and directional shear in order to build a laminarstructure. The anisotropic layers form a meat-like textureand a bite-feel

With a high moisturecontent and no moistureloss throught cooling down,no re-hydration is required

Non-expanded fibrousproduct

= Protein concentrate

18

4.4 Meat analogues by Wet texturizationHigh-moisture extrusion cooking (HME)

Soy protein

100 % w/w Soy protein

80:20 % w/w Soyprotein:Fiber

source (Pea fiber)

Pea protein

fraction

100 % w/w Pea protein

Bean protein fraction

100% w/w Bean protein

63.5% dm protein3.5% dm starch

10% dm NSP

55% dm protein6% dm starch13% dm NSP

67% dm protein

55% dm protein

19

5. Take home message

Model Food

Products

Dry-fractionation

ExtrusionTechnology

Baking

Bread and energy bar

Pasta,

breakfast

cereal and

snacks

Meat analogues

Liquid foodsSoups, smoothies

etc.

Ingredienser med høyt proteininnhold og modellmat produkter kan produseres ved hjelp av bærekraftige og løsemiddelfrie teknologier som tørrfraksjonering og ekstruderingsteknologi

Proteinene i proteinfraksjon som fås ved bruk av tørrfraksjonering er ikke rene men beholder sin struktur og funksjonalitet

20

Takk for oppmerksamheten