Damaged Starch in Flour Milling

CHOPIN Technologies: a KPM Analytics brand

Damaged Starch in Flour MillingDr. M. Hikmet Boyacioglu Cereal/Grain Scientist Applications Development SpecialistKPM [email protected]


What is damaged starch?

Structurally disruption/modification of starch granules in wheat and flour!

Starch damage, damaged starch, mechanically activated starch,mechanical starch modification

Wilson, et al., 2006

Small,

Round

(B-starch)

Large,

lenticular (A-starch)


Where does it comes from ?

➢ Pre-harvest sprouting (PHS) may result in extensivedamage to wheat starch granules???

➢ Significant changes occur in damaged starch contents inwheat during the after-ripening period, which stabilizedat around 60–90 days (Late maturity)???

Enzymatic!



There are two types of starch damage:

➢ Damaged starch comes from the wheat itself (as afunction of hardness) - genetic criteria -

The first is that which results in the starch granule being broken in two.Although the granule is clearly damaged, this type of damage results instarch that is not susceptible to attack by fungal α-amylase.



➢ Damaged starch also comes from the milling process -mechanical criteria -

The second more classic starch damage produced during milling results ingranules that have partially or completely lost their crystallinity and aresusceptible to fungal α-amylase.

Barrera, et al., 2013


Starch damage during milling

✓ Roller milling damages a small but significant number ofthe starch granules in the flour.

In general, the level of damage depends not only on the hardness of thewheat used but also on the settings of the milling rolls. Indeed, given aconstant wheat supply, flour with increasing water-absorptioncharacteristics can be produced by adjusting the roll settings such thatincreasing levels of starch damage are produced.

Hard

Soft


Impact of roll adjustments


10

15

20

25

30

0 0.02 0.04 0.06 0.08 0.1

Sta

rch

da

ma

ge

(U

CD

)

Roll gap (mm)

Starch damage = f (Roll gap)


Impact of roll adjustments


Damaged starch = f (Rolls pressure)

12

14

16

18

20

22

2 2,5 3 3,5 4

Pressure (bar)

Dam

ag

ed

Sta

rch

(U

CD

)

CHOPIN Technologies: a KPM Analytics brand PAGE 9


Analysis of flour streams

0

2

4

6

8

10

12

14

Bk1

Bk2

Bk3

Bk4

Red

1

Red

2

Red

3

Red

4

Red

5

Red

6

Red

7

Red

8

Red

9

Sta

rch

da

ma

ge

(%

)

Streams



Analysis of flour streams – Quantity of flour

0

2

4

6

8

10

12

14

16

Bk1

Bk2

Bk3

Bk4

Red

1

Red

2

Red

3

Red

4

Red

5

Red

6

Red

7

Red

8

Red

9

% F

lou

r p

rod

uc

ed

Streams

50+%



Analysis of flour streams – Most contributing fractions

0

20

40

60

80

100

120

0

2

4

6

8

10

12

14

16

Bk1

Bk2

Bk3

Bk4

Red

1

Red

2

Red

3

Red

4

Red

5

Red

6

Red

7

Red

8

Red

9

Da

ma

ge

d s

tarc

h X

flo

ur

qu

an

tity

Da

ma

ge

d s

tarc

h (

%)

Streams

Damaged starch

Flour produced

Damaged starchgiven by stream

Most

contributing

fractions


For any product, there is an optimum/moderate

level of starch damage!

Proteins (%)

Star

ch d

amag

e (U

CD

)

Why measure damages?


When starch damage occur at low levels (or at optimum/moderate levelsfor desired product) of the total wheat starch, they are considered to bebeneficial to flour performance;

because they are readily accessible to water and enzyme penetration andserve the dual function of increasing flour absorption and providingfermentable maltose for the yeast.



Protein absorbs 1.8 times its weight of water,

Pentosans: 10 times,

Native starch: 0.4 times,

➢ Damaged starch: 3 to 4 times!

Millers' objective• Produce the largest amount of flour from a lot of wheat (economic

profitability)

Produce flours according to the specifications of their customers (high hydration capacity flours for example for bread making flours)

Bakers' interest• Add max content of water (better yield and better profit)

Effects on water absorption

54

56

58

60

62

64

66

68

10.1 12.3 14.4 15.5

Starch damage (Audidier)

% a

bso

rpti

on

.

0

2

4

6

8

10

12

14

16

18

20

Sta

bil

ity

Hydration Stability



Effects on dough processing

✓ Doughs produced with high mechanical starch modification levels may notbe fully developed at Peak time (optimum mixing time) and display asecond peak – Modify mixing time?

✓ Possibility of having a sticky dough probably because of weakenedprotein–filler interfacial interactions and larger voids within the proteinnetwork?

➢ Damaged starch increases initial water absorption andprevents optimum gluten formation during mixing!!!

Hackenberg, et al., 2019



Amylases preferentially attack damaged starch, not native starch.If starch damage in excess:

Effects on fermentation characteristics

SIMPLE SUGAR

• Intense yeast activity (too much of CO2), reduced gas-retention capacity

• Coloration possibly higher (Maillard reaction) and caramelization

WATER

• Bread shelf life

STARCH

DAMAGE



Effects on acrylamide formation in bread

Damaged starch content in wheat flour from the same cultivar showed astrong positive correlation with acrylamide formation in bread sincereducing sugar contents increased with increasing damaged starch contentin flour.

The mitigation of acrylamide formation in bread can be achieved by reducing damaged starch in flour and by fermentation of the dough.

Wand, et al., 2017

Eslamizad, et al., 2019



Effects on staling/shelf life of the bread

The content of damaged starch also influences the bread staling throughincreasing the retrogradation of the amylopectin and crumb firmness, andtherefore affects negatively the quality of the resulting fresh products andtheir shelf life.

Le´on, et al., 2006



If the level of damaged starch becomes too high, the doughrheology and baking performance are negatively affected.

Stickiness FermentationTexture

Color Cracks




Effects on cookies, biscuits

➢ An excess of starch damage causes:

▪ Broken cookies when packaging is opened!

▪ Cookie with too much/low color

▪ Non-standard/uniform size



Effects on noodles


For Chinese noodle making, the flour with excessive damaged starchcan absorb more water and reduce noodle cooking and eatingquality!

U.S. Wheat



Effects on wheat flour tortilla texture


As damaged starch increased, the flour tortillas become less stretchable,and firmness and rollability increase.

To make a tortilla with acceptable rollability, starch damage should notbe too high!

Mao and Flores, 2001

Wikipedia



Starch damage could not be increased indefinitely for at least two reasons:

✓ First, as water absorption increased with the increase in starch damage,the air-dough interface in gas cells became proportionally less stableduring baking, leading to a loss of volume and a coarse texture.

✓ Second, with too high a level of starch granule fragmentation, theavailable gluten can be insufficient to coat the surface of the starch,resulting in a loss of gas retention capacity, a lower loaf volume and abreakdown of cell structure.


“Proofed” Bread

Flat breads

Biscuits

Noodles, fideos (wheat flour)

“Durum” Wheat

• For breadmaking

• For pasta

Tortillas !!...

All concerned!



Measuring Starch Damage as a Mill Optimization Technique


Testing Objective

The objective of this project was to determine the optimal grinding

pressure for each reduction passage in the Hal Ross flour mill using the

amount of starch damage as the indicator.

Look at different grinding practices and their effect on flour starch

damage and quantity.

– Determine optimum grinding pressure on reduction rolls

Thiele, 2016




Data collection

Data was collected during a full day mill run with the same wheat (HRW)

• First collected a baseline ash curve after the mill warmed up with

reduction rolls set at an operator determined optimum setting.

• Then decreased the grinding pressure on all reduction rolls and

collected three ash curves on the soft grind.

• Next increased the grinding pressure on all reduction rolls and

collected three ash curves on the hard grind.

• Lastly, reset the mill to baseline settings and collected an additional

ash curve for the operator determined optimum setting.Thiele, 2016




Sample Set

The complete sample set consists of 16 individual flour streams

– 15 individual flour streams

• Collected at patent flour screw

– Straight grade flour sample

• Collected below rebolt sifter

Measuring Starch Damage

Amperometric measurement of iodine absorption.

– SDmatic rapid measurement of iodine absorption

Thiele, 2016




Conclusions

No significant gain in flour production from baseline to hard grind, just increased

amount of starch damage.

✓ The possibility to optimize midds rolls using a combination of flour release

and starch damage does exist.

✓ Starch damage and ash results were correlated, especially towards the tail

end of the mill, however, they don’t have a direct effect on one another.

✓ Measuring starch damage on reduction rolls could ensure a more consistent

grind between shifts and help monitor excess grinding pressure.

✓ Next steps would be to measure energy usage compared to flour released

and starch damage to determine savings.Thiele, 2016


TO ACT ACCORDINGLY!

If I do not have enough starch damage?

I can:

✓ Set the mill differently✓ Choose a harder type of

wheat...✓ Both of them...

If I have too much starch damage?

I can:

✓ Take care of amylases content✓ Add gluten to increase rheological

properties✓ Set the mill differently✓ Change wheat for a softer one…


In every case, we see the necessity for measuring the damaged starch in the flour !!!


How measure damages?

In view of the importance of damaged starch to the flourand baking industries, many methods have beendeveloped to quantify its presence:

Colorimetric

Polarimetric

Spectrophotometric

Enzymatic

Amperometric


Damaged starch determination methods

AACC Approved Methods of Analysis, 11th Edition

Starch

AACC Method 76-30.02Determination of Damaged Starch

ObjectiveThis method determines the percentage of starch granules in flour or starch preparations that is susceptible to hydrolysis by fungal alpha-amylase. Percent starch damage is defined as g starch subject to enzymatic hydrolysis per 100 g sample on a 14% moisture basis.



Starch

AACC Method 76-31.01Determination of Damaged Starch -- Spectrophotometric Method

ObjectiveIn this method, damaged starch granules are hydrated; this is followed by hydrolysis to maltosaccharides and limit dextrins by fungal alpha-amylase. Amyloglucosidase is then used to convert dextrins to glucose, which is specifically determined spectrophotometrically after glucose oxidase/peroxidase treatment. Damaged starch is calculated as a percentage of flour weight on "as is" basis. This method is applicable to wheat flour and starch.





Starch

AACC Method 76-33.01Damaged Starch -- Amperometric Method by SDmatic

ObjectiveThis method measures the kinetics of iodine absorption in a liquid suspension, using an amperometric probe. Results are given in an iodine absorption index percentage (AI%). An indication of the speed of iodine absorption in seconds is also reported as “Vabs”. The method is specific to white flour obtained from Triticum aestivum coming from either laboratory or industrial milling, but it can also be used on wholemeal flour.


The SDmaticby CHOPIN Technologies

The SDmatic CHOPIN provides a simple, precise and fast (less than10 min) measurement of starch damage in flour!

CHOPIN SDmatic


AACC Method 76-33.01Damaged Starch -- Amperometric Method by SDmatic

CHOPIN SDmatic


CHOPIN SDmatic

Tactil screen

Spoon

Heatingof the sample

Electrode of measurement

Cleaning accessories

Reaction bowlSDmatic

- Composition -


Prepare the solution

Place the reaction bowl in the SDmatic and lower the arm

Put the flour (1g) in the spoon. Put the spoon in the SDmatic

Start the test

Test:

CHOPIN SDmatic

1

3

2

4


The element brings the solution to 35°C and produces iodine

The probe measures the residual current

The flour is introduced and the iodine binds to it

Results are displayed

Test:

CHOPIN SDmatic

5

7

6

8


Principle: The amperometric method measures the amount of iodineabsorbed by the starch granules in a solution at a temperature of 35°C(Medcalf and Gilles, 1965).

0: start of measuring cycle

1: heating to 35°C

2 & 3: production of iodine (100s for 1g)

4: measure the exact current

5: introduction of the flour

6: 180 seconds after, the probe measures the residual current (Ir).

CHOPIN SDmatic


CHOPIN SDmatic

0

20

40

60

80

100

120

140

0 50 100 150 200 250 300 350 400 450 500

Low damage

High damage

At the end of the test, the SDmatic measures the residual current/iodine absorption in a diluted flour suspension!

– More damaged starch, more fixed iodine.

– The residual current decrease.


CONCLUSION

Damaged Starch

is influenced by the

hardness of wheat kernel

depends on wheat

preparation and milling

process

can improve the quality of

flour

in excess may affect the quality

of the final product

interacts with alpha amylase


Application examples

• Blending flours

• Anticipate overload

• Optimize rolls life

• Avoid lower yield

= Cost reduction

CONCLUSION


• Fully automated analysis, enzyme-free, using 1 gram of flour

Easy

• Results in less than 10 minutes

Fast

• Reproducible and standardized measurement

Reliable

CONCLUSION

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Damaged Starch in Flour Milling

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