quality attributes of functional extruded lentil-based snacks fortified with nutritional yeast jose...
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Quality Attributes of Quality Attributes of Functional Extruded Functional Extruded Lentil-based Snacks Lentil-based Snacks
Fortified with Nutritional Fortified with Nutritional YeastYeast
Jose De J. BerriosJose De J. BerriosUSDA-ARS-WRRCUSDA-ARS-WRRC
3rd International Conference & Exhibition on Nutrition & Food Science
Track 6: Food Processing and TechnologyValencia – September 23-25, 2014
Nutritional & Health Value Nutritional & Health Value of Pulsesof PulsesNutrients Beneficial Effects
Protein
Body building and growth;; Hypocholesterolemic/Cholesterol lowering Prevention of CVDs; ↑ Satiety ↓ Obesity
Complex carbohydrate:
Oligosaccharides & Resistance Starch
Prebiotic effects; reduce Colorectal Cancer and Constipation; Hypocholesterolemic / Cholesterol lowering; Hypoglycemic effect/Blood Glu control α low GI (Diabetics)
Dietary Fiber: IDF/SDF
Hypocholesterolemic / Cholesterol lowering ; Prebiotics; Reduce colorectal cancer and CVDs; ↑ Satiety ↓ Obesity; maintain healthy intestinal tract & prevents constipation
Phytonutrients/AOX: anthocyanins,
polyphenols, tannins, carotenoids
Prevention of CVDs & different types of Cancer (including Lung Cancer); eye disease; enhance immune system
Vitamins/Folic acid & Minerals
Neural Tube Defect prevention (Spina Bifida); New Cell formation/Red Cell Development ; Healthy Bones; Blood Pressure regulation
“Gluten-free”
Prevents Celiac Disease/Gluten Intolerance
Yeast grown, from pure strains of Saccharomyces cerevisiae, on a
purified nutrient source specifically for its nutritional value.
Nutritional Yeast
• Excellent source of protein (essential and non-essential AA’s)
• Rich in Vitamins (B-complex; folic acid)
• High in Dietary Fibers (β-glucans)
• Naturally low in Fat and Sodium
Nutritional Yeast
• Product with No added Preservatives
• Kosher certified
• Not a Genetically Modified Organism (GMO)
Beer
Cheese
Spirits
Sourdough
Root beer
Bread
Brewer’s Yeast
(S. cerevisiae)
Seed
PropagationFermenter
Add Air,
Molasses/Nutrients
Cream Storage Cooling Separator
Yeast is Drum
Dried
Cooling of Yeast
In Heat ExchangerPasteurization of
Yeast
Final Product-Packaged
Grinder
Nutritional Yeast Production
Lesaffre Yeast Corporation
Nutritional
Yeast(S. cerevisiae)
Protein/flavor
Forte: Cr/B Vits
Pro SCB: B Vits
Cell wall basic:
B-Glucan
SaFlavor+ :
Protein and DF
Nutritional
Yeast(S. cerevisiae)
Protein/flavor
Forte: Cr/B Vits
Pro SCB: B Vits
Cell wall basic:
B-Glucan
Nutritional Yeast
(SaFlavor+:
protein and TDF)
SaFlavor+ :
Protein and DF
The Food PyramidThe Food Pyramid
• Whole Pulses – canned, micronized, split, flaked
• Products made with Whole Pulses– soups, chilis, refried beans, frozen entrees, snack mixes, roasted
and fried snacks (peas & lentils)
• Ground Pulses – Flours or powders (including naturally fermented flours)
• Products made with Ground Pulses– specialty bakery mixes, vegetarian foods (RTE frozen entrees,
vegi burgers), pasta & noodles, extruded-fried snacks, and dips
Available Products from Available Products from Legume PulsesLegume Pulses
Projected Value by 2014 Category (billion USD)
Savory Snack Industry: 61.5 (CAGR: 3.7%)
Breakfast Cereal Industry: 26.2 (CAGR: 3.1%)
Functional Foods: 90 (CAGR > 4%)
Gluten Free: 4.2 (CAGR > 5%)*
*: Faster growth - $4.2 bn - end of 2014 and $6.6 bn (CAGR > 20%) in 2017
Whole Grain and High Fiber food market - $27.6bn by 2017
High Protein-low Fat Food & Beverages - $40bn
Source: Datamonitor
Projected Value by 2014 Category (billion USD)
Savory Snack Industry: 61.5 (CAGR: 3.7%)
Breakfast Cereal Industry: 26.2 (CAGR: 3.1%)
Functional Foods: 90 (CAGR > 4%)
Gluten Free: 4.2 (CAGR > 5%)*
*: Faster growth - $4.2 bn - end of 2014 and $6.6 bn (CAGR > 20%) in 2017
Whole Grain and High Fiber food market - $27.6bn by 2017
High Protein-low Fat Food & Beverages - $40bn
Source: Datamonitor
Global Market (billion USD)
Food:• Breakfast cereals• Snack foods• Flat bread• TVP• Caseinate• Corn flakes• Chocolate
Feeds:• Pets• Cat food• Fish Feed• Your products…
• Calf fattening feed• Extruded corn• Extruded barley
• Extruded wheat• Debittered soya• Extruded soya
• Starch• Instant foods• Modified starches• Swelling starch• Instant flours• Filled tubes
Shapes:• Flakes• Rings• Stars• Tubes• Rods• Spheres• Granulates• Alphabet• Pictures
What Products are Made on an What Products are Made on an Extruder?Extruder?
Investigate the use of extrusion technology to develop ready-to-eat healthy expanded snack-type products from lentil flours fortified with Nutritional Yeast
Evaluate the sensorial, physico-chemical and nutritional attributes of the developed extrudates
Main IngredientsLentil (Lens culinaris)
Nutritional Yeast: (Sacharomyces cerevisiae)
Sensory Evaluation Ranking Test (BIB Design)
Proximate Analysis Standard AOAC methods (1990)
IVPD Multienzyme solution (Hsu et al. 1977)
Water Activity Aw meter Aqua Lab CX-2 (Decagon, Inc.)
Expansion Ratio πrext2/ πrdie2: Cross-sectional (CS) area of extrudate/CS area of die opening
Bulk Density Bead displacement method(Berrios et al, 2010)
SME (kJ/kg) Net Mechanical Energy Consumption/TotalFeed Rate
Statistical Analysis Response Surface Methodology (RSM)ANOVA – Fisher’s LSD(MINITAB, v16)
MATERIALS
& METHODS
32mm TS Extruder50+ kg/h capacity 1,200 rpm
MATERIALS
& METHODS
Extruder
140 and 160C
500 rpm
Formulation:Continuous
Mixer
Twin ScrewExtruder
Raw Materials
FormulationMix
Hammer Mill
PinMill
Formulation & Formulation & ExtrusionExtrusionProcessingProcessing
Formulation & Formulation & ExtrusionExtrusionProcessingProcessing
SRCL Nutr. Yeast
Protein 26.63 51.29
Total DF 6.17 22-26
IDF 5.17 4-7
SDF 1.00 18-22
Lipids (Fat) 0.79 1.06
MATERIALS
& METHODS
Texture ModifiersH2O
Starches
LentilFlour
Nutr. Yeast
Emulsifying agentsFlavoring agents
Fibers
Extrudate Rods
Cooling/Drying/Cutting
MATERIALS
& METHODS
Sensory EvaluationSensory Evaluation: 7-point hedonic scale -Overall liking
In Vitro Protein Digestibility (Hsu et al. 1977)
In Vitro Protein Digestibility (Hsu et al. 1977)
1.6mg/ml Trypsin3.1 mg/ml Chymotrypsin1.3 mg/ml Peptidase
pH Meter
Multienzyme Solution:6.0 mg/ml total
5 mLpH 8.0
4oC
y=210.464–18.103xy=IVPD (%)x=pH value of the protein suspension after 10 minutes digestion
50 mLProtein
Suspension6.25 mg/ml
pH 8.037oC
Sensory Evaluation ResultsSensory Evaluation Results
Formulation Overall Liking
Formula Ctrl 3.475b
12%, 140C 5.500a
12%, 160C 5.500a
Increase (%) in nutritional value due to NY fortification
Increase (%) in nutritional value due to NY fortification
Nutrients Formula Ctrl
12%, 140C
% increase
Protein 22.1b 25a 13.12
Ash 1.92b 4.27a 122.40
Fat 0.37b 0.64a 72.97
IVPD
70
75
80
85
90
95
Casein Formula ctrl 12%,140c
Per
cen
t
Raw IVPD
Ext IVPD
IVPDIVPD
97.32%
100.00%
90.37%
87.92%
92.63%
Increase (%) in nutritional value & Digestibility due to NY fortificationIncrease (%) in nutritional value & Digestibility due to NY fortification
Nutrients Formula Ctrl
12%, 140C
% increase
Protein 22.1b 25a 13.12
Ash 1.92b 4.27a 122.40
Fat 0.37b 0.64a 72.97
IVPD 83.40b 88.60a 6.24
SMESME
Effect of NY fortification on extrudate Physico-chemical
parameters
Effect of NY fortification on extrudate Physico-chemical
parameters
ER BD (g/cc) Aw
Formula Ctrl, 140C
15.43a 0.0688b 0.3330b
12%, 140C 9.23b 0.1298a 0.3927a
♦ Sensory evaluation test demonstrated that the Lentil-based extruded snacks containing up to 12% NY, had good acceptability by the tasters
♦ Nutritional components: protein, ash (minerals), fat, and dietary fiber of the extruded snacks increased as the concentration of NY increased in the lentil-based formulations
♦ Effect of Yeast fortification on some physico-chemical parameters:
● Degree of expansion of the extrudates was considered appropriated for
expanded snacks
● Bulk density was inversely related to expansion ratio and directly related with
higher yeast concentration
● SME required to process the extrudates was favored by higher Yeast
concentration
● Water activity of the extrudates was very low and similar to those of
dehydrated foods (Aw 0.4)
♦ Expanded extruded snack-type foods, made from pulse-based formulations fortified with NY, would generate economic advantages for pulse’ producers and food processors & provide consumers with highly nutritious, healthy, safe, and convenient food alternatives
♦ Fortification with 12% NY significantly increased the IVPD of the extruded snack
Acknowledgement
Mr. James PanChemist, Extrusion ProgramProcessed Foods Research Unit
Mr. Matthew TomSystems EngineerExtrusion ProgramProcessed Foods Research
Adeline Cheong, Ph.D.Senior Manager – Business Development
My working team My working team
WRRC
Nutrients SRCL Nutr. Yeast
Protein 22.10 51.29
Total DF 6.17 22-26
IDF 5.17 4-7
SDF 1.00 18-22
Lipids (Fat) 0.79 1.06
ER