Gluten-free Ingredients & Formulation Approaches · Removing gluten results in formulation...

Gluten-free Ingredients & Formulation Approaches

DILEK UZUNALIOGLU, PH.D. BUSINESS SCIENTIST, TEAM LEADER, GLOBAL APPLICATIONS,

INGREDION INCORPORATED

OCT 2016

IBIE INTERNATIONAL BAKING INDUSTRY EXPOSITION

http://www.ibie2016.com/

http://www.ibie2016.com/

• Gluten-free Bakery Challenges

• Gluten-free Ingredients

– Flours, Starches, Gums

• Holistic Formulation Approach to Gluten-free Formulation

• Enhancing the Nutrition and Texture: Pulse Flours and Proteins

Outline

2Copyright® 2016 by Ingredion Incorporated

Science-based problem-solvingfrom Ingredion Idea Labs

Gluten-free Formulation Challenges, Ingredients & Holistic Formulation Approach

4

• 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

Texture

Taste

Appearance

• Shorter shelf-life/ Increased staling rates due to increased water mobilityShelf-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

Copyright® 2016 by Ingredion Incorporated

5

Functionality of Ingredients Used


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 ingredients to match dough rheology

and final product texture is key!


Key Starches and Flours Used in Gluten-free Formulations

Key Gluten-free Starches and Flours

7

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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Gums Used in Gluten-free Formulations

• 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

Copyright® 2016 by Ingredion Incorporated 9

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

ArabicEmulsification and film formation

LBG

Batter 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


Gum No Gum

Gum No Gum


Holistic Formulation Approach to Gluten-free Formulation

DIAL-IN® TechnologyThe shortest path to perfect texture and sweetness


• 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


Experimental Approach


Process

• Dispersibility, Dough Rheology,

Machinability, Handling

Descriptive Sensory Analysis

• Cohesiveness, Graininess,

Dissolvability, Hardness,

Denseness, Firmness, Springiness,

Mouth Coating

Final 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


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 %

Gluten-fee Flour System (Tapioca

Flour, Rice 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



Enhancing the Texture & Ambient Shef-life

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Procedure

•Dissolve the syrup into lukewarm water (77°F), add yeast and psyllium husk to

hydrate for 1.5 minutes.

•Premix the dry ingredients.

•Add dry ingredients to water solution.

•Add oil on top of dry ingredients, mix for 2 min on slow to obtain firm dough.

•Grease bread loaf pans; weigh dough at 520g; mould and place in the baking pans.

•Proof for 60 min at 95°F (35°C)/85% RH.

•Bake at 400°F (204°C), one steam injection at beginning of bake, for 30 - 33 minutes.

Ingredients Bakers %

Modified tapioca, potato & corn starch 100.00

Psyllium HUSK 5.84

Granulated Sugar 8.27

Egg White Powder 3.74

Salt 2.04

HPMC K4M 4.06

High Fructose Corn Syrup 5.09

Canola Oil 12.19

Water 100.00

Yeast, Instant 1.63


Gluten-free Bread

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Modified

Solution

Clean Label

Solution

Retail Gluten-

FreeRetail Wheat

Containing

Modified tapioca, potato & corn

starch


Gluten-free Bread

20

Ingredion gluten-free

samples scored closely

to wheat breads

Peak

Forc

e A

vera

ge (

g)

Retail GF Breads

Retail Wheat Breads

Clean Label

Solution

Modified Solution

Modified Solution

Native Solutions

Modified tapioca, potato

& corn starch solution

breads stored in

ambient conditions

extended shelf-life up

to 21 days

Peak

Forc

e A

vera

ge (

g)


Gluten-free Bread Improved Ambient Shelf-life


Enhancing the Nutrition & Texture: Pulse Flours & Proteins

What are Pulses?

22

Pulses are the dried

seeds of plants in the

legume family. They

include:

• Peas

• Beans

• Lentils

• Chickpeas


Food Protein Fat Starch & Sugar Fiber

Tapioca Flour 0.2 0.0 87.8 0.9

Whole Corn Flour 8.0 7.0 62.0 8.0

Whole Rice Flour 5.6 1.4 77.7 2.4

Whole Soy Flour 35.0 20.0 25.6 9.6

Whole Wheat Flour 13.2 2.5 61.3 10.0

Dry Pea 23.7 1.3 45.5 16.6

Lentil 26.3 1.1 45.0 13.6

Chickpea 24.4 5.9 41.1 8.7

Dry Bean 24.5 1.5 41.5 22.5

Pulses Composition vs. Other Grains

Exceptional Nutritional

Value

• High in Protein (High in Lysine), Dietary Fiber, Micro nutrients (Iron, Zinc, Selenium, -Carotene)

• Low-Glycemic Index (GI=40-55)


Pulse Ingredients Benefits

Functionality

• Emulsification

• Texture

• Gelation

• Water-holding

• Adhesion

• Film Forming

Value Propositions

• Enhance texture and provide moist mouthfeel

• Good synergy with other gluten-free flours

• Protein enhancement

Labelling & Nutritional

• High Protein, High Lysine

• Natural

• High Dietary Fiber

• Gluten-free & Grain-free

• Low Glycemic Index

• High in Micronutrients

Peas Lentils ChickpeasFaba Beans


25


Modified Tapioca, Potato, Corn Starch 60.00

Native Functional Rice Flour 40.00

Flaxseed Meal 5.00

Psyllium HUSK 6.25

Egg White Powder 3.74

HPMC 2.00

Salt 2.04

Sugar 5.09

Yeast, Instant 1.63

Bread Crust Flavor 1.17

Olive Oil 12.19

Water 97.00


Modified Tapioca, Potato, Corn Starch 60.00

Chickpea Flour (min 20% protein in d.b.) 20.00

Flaxseed Meal 5.00

Psyllium HUSK 6.25

HPMC 2.00

Salt 2.04

Sugar 5.09

Yeast, Instant 1.63

Bread Crust Flavor 1.17

Olive Oil 12.19

Water 99.98

• More open cell structure

• Balances chewiness, with crispy crust

• Remove egg whites in the formula:

formula cost reduction

• Texture impact-delivers Chewy texture

• Open cell structure

Gluten-free Pizza: Navigating Texture


Gluten-free Tortilla

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Modified tapioca, potato,

corn starch mimics the

functionality of wheat flour

Chickpea flour is a gluten-free,

pulse-based flour, provides

moistness, color

Pregelatinized modified

tapioca starch is a cold water

swelling modified food starch

derived from tapioca helping with

dough stability during processing

Faba bean protein

concentrate helps with dough

handling, adds color, improves

elasticity

Ingredients Percent %

Modified tapioca, potato, corn starch 37.10

Chickpea Flour (min 20% protein in

d.b.)

14.00

Pregelatinized Modified Tapioca

Starch

6.00

Water 30.00

Vegetable oil 8.52

Faba Bean Protein (60% protein in

d.b.)

1.69

Salt 0.69

Sugar 0.92

Glycerine 1.00

Xanthan gum 0.08

Total 100.00



Gluten Free Hummus Cracker

GF Flour System

(tapioca flour, rice flour)

is gluten-free flour used in

the formula to replace

wheat flour

Chickpea Flour is gluten-

free flours used in the

formula to replace wheat

flour, and provides softness

and flakiness to the product

Pre-gelatinized Tapioca

Flour provides a crunchy

texture while helping with

dough handling and sheeting

Ingredients Percent (%)

Chickpea Flour (min 20% protein in d.b.) 25.48

GF Flour System (Tapioca Flour, Rice

Flour)25.48

PregelTapioca 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

63 DE Glucose Syrup, Non-GMO 2.24

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Key Takeaways


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


2929

Thank You & Questions?

Dilek Uzunalioglu, Ph.D., Business [email protected]

908-685-5294


mailto:[email protected]

Guide for the Gluten-free Baker, Make-up Processing Solutions

Cesar Zelaya

Director of Bakery Technology

Handtmann Inc.

October 10th, 2016

Questions??

• Does your bakery needs to automate?

• Benefits:

• Cost Savings, Product Quality, Process Flexibility, Increased Capabilities

Questions??

• What level of automation fits your needs?

Agenda

• Objective

• Products to Automate

• Equipment Considerations

• Product and Process

• Engineering and Facilities

• Production Systems

• Conclusions and Review

• Questions ???

Objective

• To present a practical approach toautomate your gluten-free production,considering key factors related to theproduct, process and equipment involved.

Products to Automate

• High Demand Items/ Long Production Times• Sandwich Breads, Hot-Dog and Hamburger

Buns

• Labor Intensive SKU’s• Bagels, Pizza, Pies

• Product Quality and Consistency Issues• Bagels, Healthy Bars, Cookies


• Product with Similar Processing Requirements• Sandwich Breads and Pound Cakes

• Muffins and Buns

• Bagels and Pizza


• Consider Increasing Scope Based on Production Capabilities• Coextrusion

Equipment Selection:Product and Process• Most bakery equipment in the market was

not designed to handle gluten free• Consider Alternative Technologies

Vacuum Filler

Equipment Selection:Product and Process• Processing challenges to handle your

specific dough or batter formulations (absorption, sugar content)

• Quality attributes: crust and crumb structure, symmetry, volume, height, shelf life

Equipment Selection:Product and Process• Gentle handling of inclusions and particle

definition in your product (chocolate chips, blueberries)

• Accurate scaling 1-2% standard deviation depending on formulation

• Consistency and handmade look

Equipment Selection: Engineering and Facility

• Ability to increase capacity in the future

• Integration into existing production line

• Flexibility to produce multiple products in the same line, quick changeovers

• If you produce gluten and gluten free in the same facility and clean-ability of the equipment

• Equipment mobility if being used in different production areas or for sanitation purposes

• Consider leasing and trade-in options

Production Systems

• Single and Multi-line Solutions

Production Systems

• Depositing System with Different Valves

Conclusions and Review

• Automating your gluten-free production process will bring Cost Savings, Product Quality, and Flexibility to your process and increase capabilities

• When you Automate your Process consider:• Selecting SKU’s with high demand and those that

bring the most savings (labor, processing times)• Focus on product quality and plan to expand your

scope of supply based on equipment capabilities• When selecting equipment considering your existing

layout, look for flexibility, addition of new products, and sanitation features

• Discuss financial options such as leasing and trade-in

Thank you!

Cesar ZelayaHandtmann, Inc. Director of Bakery Technology

(847) 808-1100(847) [email protected]

28690 N Ballard Dr. Lake Forest, IL 60045USA

mailto:[email protected]

Gluten-free Ingredients & Formulation Approaches · Removing gluten results in formulation...

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