Injera Crisps

December 20, 2013Final Proposal(Wendy Attuquayefio, Maggie Harding, Bangde Li, Qu Yanqi, Jacqueline Krampfl)

Executive SummaryThe Ethiopian flatbread injera is a staple in its respective country, traditionally made with tef flour, water, and a unique starter culture. A reverse innovation product derived from injera is a baked injera cracker (Injera Crisps), utilizing four different regionally-produced grains and the seed cake of the main oil seed of Ethiopia. The use of three additional grainsmaize, millet, and sorghumreduces the cost of the traditional product, and the nyger seed cake provides additional lysine and iron. The injera batter is baked on an industrial-scale roller and cut into small crackers. Subsequent drying in a food dehydrator to a constant low moisture content extends the shelf life of the product as compared to traditional injera. Packaging in sealed plastic bags in paperboard boxes protects the structural integrity and shelf life of the crackers. Given the essential presence of injera in Ethiopian cuisine, this injera cracker will provide a novel product to Ethiopian consumers while maintaining a familiar flavor.

Application DescriptionBy converting an indispensable Ethiopian flatbread into a snackable cracker, it provides a familiar flavor to Ethiopian consumers in addition to introducing a popular American product (crackers/chips) and the crunchy texture associated with crackers and chips. The target consumers are Ethiopian adults who are interested in a novel, nutritious snack or meal adjunct, but who dont necessarily want to try unique flavors. The product formulation for flour is given in Table 1 below:

Table 1: Formulation of Flours

FlourTefMaizeMilletSorghum

% of Formulation30302020

Lysine is known to be a deficient nutrient in the Ethiopian population7, as lysine is deficient in most cereal grains other than teff. Therefore, the teff content in the proposed formulation was held at 30%, due to its nutritional benefits. In order to reduce the cost of traditional injera, other cereal grains with lower lysine contents were used in this product formulation. However, maize has a similar lysine content to teff (0.265g/100g lysine in maize compared to 0.376g/100g in teff flour8), and is the cheapest of the four grains used (shown in Table 2: Flour Pricing, below), and thus was also used at 30% of the total. Therefore, although the final formulation is lower in lysine content than all-teff injera, the inclusion of maize flour increases lysine content compared to other cereal grains, and aids in cost reduction. The millet and sorghum added have low lysine contents (0.144 g/100g and 0.162g/100g, respectively8), but are both currently produced in Ethiopia and thus are readily available. Additionally, both millet and sorghum are cheaper grains than teff, and both have acceptability as ingredients in currently available multigrain injeras. Thus, the remaining 40% of the flour was split evenly between sorghum and millet, at 20% each. Iron is also known to be deficient in Ethiopian diets7. Whole nyger seed contains 58.4 mg/100g of iron, compared to 37.7 mg/100g in whole white teff1. Also, whole nyger seed has 0.945 g/100g lysine3, compared to 0.376 g/100g lysine in whole teff8. While only the seed cake (after the oil is pressed from the seeds) is used in this batter formulation, the seed cake contains about 30% protein11, and thus retains much of the iron. Other nutrient components of nyger seed do not have established levels, and thus the nutrition label for the proposed product includes only the four flours in the formulation. The nutrition content of the proposed multigrain injera flour formulation is compared to an all-teff formulation in Figure 1 below. Figure 1a: All-Teff InjeraFlour Nutrition Label (Label represents nutrients from flour only, without irsho)8,9Figure 1b: Proposed Multigrain InjeraFlour Nutrition Label (Label represents nutrients from flour only, without irsho)8,9

The current market price for teff, according to the FAO Food Price and Analysis Tool, is 13.59 Ethiopian Birr/kg. Maize, on the other hand, has a price of 6.40 Birr/kg. Sorghum and millet come in at 10.39 and 7.16 Birr/kg, respectively. Therefore, in order to lower the cost of traditional injera while maintaining the lysine nutritional benefit of teff, teff and maize have the highest percentages in the formulation, while sorghum and millet are lower, at 20% each. The nyger seed cake is a byproduct of nyger oil production, which is the main oilseed crop in Ethiopia3. By utilizing the seed cake, the multigrain injera cracker with nyger seed cake increases the value of current resources in Ethiopia.

Table 2: Flour Pricing4

Formulation PercentEthiopian Birr /kgEthiopian Birr/serving (30g)

Tef3013.590.1228

Sorghum2010.390.0626

Maize306.400.0578

Millet207.160.0431

Total----0.2864

Table 3: Nutrient components of nyger seed12

ComponentNiger Seed

Moisture (g/100g)2.8

Protein (g/100g)30.0

Fat (g/100g)34.4

Ash9.9

Crude Fiber (g/100g)9.0

Starch (g/100g)6.1

P (mg/100g)801

Ca (mg/100g)587

Mg (mg/100g)323

Fe (mg/100g)30.0

Zn (mg/100g)6.6

Mn (mg/100g)8.5

Cu (mg/100g)5.7

Cr (mg/100g)0.4

Tannins (mg/100g)158

Nicotinic acid (mg/100g)0.57

Riboflavin (mg/100g)0.22

With the relatively recent design of an industrial machine to bake injera, it is now more economically feasible to produce an injera product for Ethiopian markets. Additionally, the low water activity of the product compared to traditional injera causes the product to be a functional innovation. The recipe for the injera batter is a 1:2 ratio of flour to water. The nyger seed cake was added (5g/100mL) post-fermentation, immediately prior to baking. Traditional injera is baked on a mitad, or round griddle, for 2-3 minutes. This proposal utilizes an industrial baking machine with a continuous roller oven. Once the rectangular sheets of injera are baked, they are cut into 4 cm x 4 cm squares, then placed in a food dehydrator in a single layer at 100C for 90 minutes to dry the crackers to a constant moisture content of approximately 5% (aw of approximately 0.3)6.

Results Table 4: Moisture content of injera crisps with and without nyger seed press cake addition

SampleReplicatesWeight%MoistureMeanStd. dev.

Thin cracker without nyger (~5mm)11.0335.234.880.40

21.0094.96

31.0354.45

Thick cracker without nyger (~8mm)11.0337.957.802.01

21.0165.72

31.0289.74

Thick cracker with nyger(~9mm)11.0199.1413.136.71

21.0220.88

31.0359.37

Table 5: pH values of injera crackers with or without nyger seed press cake addition

SampleReplicatespHMeanStd. dev.

cracker without nyger13.944.020.11

24.09

cracker with nyger14.304.350.06

24.39

Moisture content was measured with a moisture analyzer. According to the results, the thin crackers had a lower moisture content than the thicker crackers. Within the same dehydration time, thickness is one key factor that can prevent a moisture decrease in the crackers. Therefore, the thickness of Injera Crisps was determined to be 5 mm, which is a sufficient thickness to allow a low moisture content of 5%, while maintaining the desired sensory properties of the cracker.Sourness is another key factor in the product, which was measured by pH. Results show that the pH of the cracker with nyger was an average of 4.35. This pH indicates a high sourness, but is not as sour as the crackers without nyger, at a pH of 4.02. The sourness of injera is one of its key attributes in Ethiopia, so maintaining a sour flavor is highly significant in consumer acceptance.

PackagingThe main consideration for biscuits or crackers as far as packaging materials are concerned is that they must be adequately protected from moisture in the atmosphere because they are hygrosvopic and become soft when moisture is absorbed. Crackers also must be screened from strong light and atmospheric oxygen, which will promote fat rancidity and result in unpleasant flavors. Oxidative rancidity is particularly rapid when the biscuits have picked up moisture contributing to the general condition of staleness. Lastly, packaging must also protect the crackers from breakage and physical damage. In addition the materials that make the immediate pack around the biscuits must be easily heat sealable, have good grease resistance, have good puncture resistance, and maintain low odor, especially after printing6. The solution to these concerns is a plastic, heat sealable bag inside a thin paperboard box. Plastic packaging in general is lightweight and strong. Modern plastic food packagingsuch as heat-sealed plastic pouches and wrapshelps keep food fresh and protects it from contamination, while using minimal resources, creating less waste, and producing fewer CO2 emissions than alternative materials. Plastics make packaging more efficient, which ultimately conserves resources10. By placing the plastic package inside a paperboard box, the physical integrity of the crackers can be maintained during transport and storage.

Competitive framework A Patent and Trademark search was conducted in order to determine potential competitors. The search was done with The United States Patent and Trademark Office14. The terms multigrain and Injera; Injera and crackers; multigrain and Enjera; Ethiopian and flatbread; dried and flatbread were all searched with no comparable results to be found, showing no known competitors for the product.

Quality AssuranceThe moisture content of the injera cracker is extremely low due to the drying process. Thus neither bacteria nor mold growth is likely and the shelf life of the cracker is naturally extended6.The roller oven used for baking injera must be properly cleaned and sanitized in order to prevent contamination with residue from previously baked product or with microorganisms. Likewise, the containers and utensils used to mix the injera batter must also be properly cleaned and sanitized prior to use. The stored flours need to be sealed and in a dry storage area to prevent absorption of moisture and subsequent spoilage of the flour. Proper storage of the crackers, preventing moisture absorption, is imperative to the microbial and textural shelf life of the product.

SafetyInjera manufacture presents a slight safety concern with the use of an industrial sized roller oven, reaching temperatures of up to 210C13. Care must be taken to ensure proper precautions are observed when operating the machine to prevent burn injuries. The drying stage of manufacture is a safety concern due to the heat from the oven.Microbiologically, the starter culture used for injera, irsho, can be easily contaminated. Thus all containers and utensils need to be sanitized and cleaned properly during manufacture to inhibit the growth of molds in the batter. The temperature of the fermentation needs to be held between 23-27C in order to promote growth of the Irsho and prevent growth of other organisms. The injera must be dried into cracker form within two days of baking the batter, before molds grow and spoil the injera13. The dried crackers, due to their low water activity, are at low risk of microbial contamination6.

Table 6: HAACP Plan

HAZARD DESCRIPTIONCONTROL MEASURESCRITICAL LIMITSMONITORING PROCEDURESCORRECTIVE ACTIONS

Flour Intake

Foreign bodies in final productApproved supplier and instruments (griddle, bucket, scoop)Instruments contact no damaged or contaminated goods

Certificate of analysis with every delivery;Daily checkReject out of specification deliveries.Stop using damaged instruments

Moist flourApproved supplier and its packaging

Storage;Sealing packageCertificate of moisture analysis;Random challenge testingKeep storage environment dry;Seal unpacked package

Survival of microorganismsPurchased from approved supplierCompliance with specificationCertificate of analysis;Random challenge testingReject out of specification deliveries

Water Intake

Survival of microorganismsRoutine microbiological checksCompliance with specificationCertificate of analysis;Random challenge testingWater board inform of contamination;Stop use of suspect water

Starter Culture (Irsho) Intake

MicrobiologicalApproved supplier compliance with specification;Check each deliveryMaintain temperature below 4C;Feeding in timeCertificate of conformity each delivery;Bubbles on surfaceReject out of specification deliveries;Start with new starter culture

Instruments

ContaminationCheck after each use

Residues left after processingCertificate of analysis before processingStop using;Run cleaning and sanitization

Process Flow Diagram

Processing Description1. Mix 30% tef, 30% maize, 20% millet and 20% sorghum flour with twice as much water in a sanitized bucket using a sanitized spatula.2. Add starter culture, Irsho, which is 20% of total flour weight into bucket. Stir with sanitized spatula.3. Ferment the mixture (batter) for 72 hours at ambient temperature (approximate 25C)4. Check pH after fermentation, if pH of batter is below 3.5, it is ready for second fermentation. If pH is above 3.5, continue fermentation.5. Prepare absit from 10% of the batter mixed with three times as much water; cook on the stove (approximately 120C) until bubbles are formed.6. Cool the absit down to ambient temperature and add it back to the batter. Ferment for 2 to 4 hours more (second fermentation).7. Check the batter after second fermentation: if it is bubbling on the surface, it is ready to bake. If it is not bubbling, continue fermentation until it bubbles.8. Stir the bubbling batter and pour it on a heated griddle in a thin layer. Temperature of griddle should be around 210C.9. Bake for 2 to 3 minutes until eyes are formed on the surface.10. Remove and cut it into 4cm X 4cm square size.11. Place cut injera onto the tray in a single layer and transfer them into a dehydrator.12. Dry injera for 4 to 5 hours at 100C. 13. Analyze moisture content of the crackers: if moisture content is below 5%, package it. If moisture content is above 5%, continue drying.

References1. Abebe Y, Bogale A, Hambidge KM, Stoecker BJ, Bailey K, Gibson RS. 2007. Phytate, zinc, iron and calcium content of selected raw and prepared foods consumed in rural Sidama, Southern Ethiopia, and implications for bioavailability. Journal of Food Composition and Analysis. 20(3-4): 161-168.

2. Ethnic FoodsUSJanuary 2013. 2013. London: Mintel.

3. Eklund A, Agren G. 1970. Some chemical and biological properties of a protein concentrate from nigerseed. Quality of Plant Material and Vegetation. XIX (4): 313-332.

4. GIEWS Food Price Data and Analysis Tool. 2013. Rome: FAO.

5. General Considerations for Preservation of Fruits and Vegetables. 2003. Technical Manual. Rome: FAO.

6. Manley D. 2000. Technology of Biscuits, Crackers, and Cookies. 3rd edition. Cambridge, UK:Woodhead Publishing

7. Nutrition Country Profiles. 2010. Federal Democratic Republic of Ethiopia. Rome: FAO.

8. NutritionValue.org. Teff; Maize; Millet; Sorghum. 2013.

9. Online Labels. 2013. Free Nutrition Label Generator.

10. Plastic Packaging. 2013. American Chemistry Council. Washington, DC: ACC.

11. Ramadan MF. 2011. Functional Properties, Nutritional Value, and Industrial Applications of Niger Oilseeds. Critical Reviews in Food Science and Nutrition. 52(1): 1-8.

12. Rao, P. U. (1994). Nutrient Composition of Some Less-Familiar Oil Seeds. Food Chemistry, 50(4), 379-382.

13. Strobel S. 2012: Optimization of Teff Fermentation by Lactobacillus coryniformis Starter Culture and Investigation of Sorghum and Buckwheat as Substitute Components in Injera Batter, Honors Thesis.

14. US Patent and Trademark Office. 2013. US Department of Commerce. Washington, DC: USDOC.

Figures

Figure 2: Injera Crisps

Figure 3: Traditional Injera

Figure 4: Industrial Use Injera Continuous Roller Oven