Milling technology for cereals - Food Fortification Initiative · Milling process oSuccession of 3...
Transcript of Milling technology for cereals - Food Fortification Initiative · Milling process oSuccession of 3...
Milling technology for cereals
QA/QC on flour fortification, Kampala, 24-05-2016
DR. F IL IP VAN BOCKSTAELE
FA C U LT Y O F B I O S C I E N C E E N G I N E E R I N G
L A B O R ATO R Y O F C E R E A L T E C H N O LO GY
Cereals
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Cereal grains
oCeres
oWhat are cereals?•Grass family (Gramineae)
•One seeded fruits◦ Caryopsis = kernel = grain
◦ Germ
◦ Endosperm
◦ Bran: seed coat and fruit coat
◦ Developes in glume (chaff, husk)
•Easy to grow, high yield, stable, storage
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Cereal grains
12/04/2016 4CEREAL TECHNOLOGY
Cereals in the world
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844
672 651
12356 29 13 12 2
1021
741 728
14468
28 17 15 2
Corn Rice (paddy) Wheat Barley Sorghum Millet Triticale Rye Buckwheat
2010
2014
o Annual production of major cereals in 2010/2014 (source: faostat.fao.org)
(Mill
ion
ton
nes
)
Nutritional importance of cereals
•Macronutrients:◦ Carbohydrates (50-80%)
◦ Staple food◦ Digestable: starch◦ Undigestable: dietary fiber
◦ Proteins (8-15%)◦ Lipids (1.5-7%)
•Micronutrients:◦ Vitamins◦ Minerals (1-2.5%)
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Dewettinck, K., Van Bockstaele F., Kühne, B., Van de Walle, D., Courtens, T. and Gellynck, X. (2008). Nutritional value of bread: influence of processing, food interaction and consumer perception. Jounal of Cereal Science, 48, 243-257.
Wheat
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Wheat grain
Source: Principles of cereal science and technology
GERM (3%)
BRAN (17%)Incl. aleuronlayer
ENDOSPERM (80%)
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Wheat producing countries
52
110
76
EU13025
58
13
19
(source: faostat.fao.org) Million tons (average 2005-2010) 9
WheatoUnique
-> wheat gluten proteins
-> breadmaking quality
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Wheat classificationoWheat class system depends on country
oWheat type•Triticum aestivum (>90%)
•Triticum durum (±5%)
oCriteria (USA)•Kernel texture: hard ↔ soft
•Bran color: red ↔ white
•Growth habit: spring ↔ winter
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Maize
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Corn/MaizeoMost produced grain
oHighest yielding cereal (world average)• Maize: 4.3 tonnes/hectare
• Paddy rice: 3.8 tonnes/hectare
• Wheat: 2.7 tonnes/hectare
oAnimal feed
oHuman food: tortillas, porridge
oStarch production: wet milling
http://www.baobab.net
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Maize grain
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MaizeTYPES
Dent
Soft
Waxy
Popcorn
Sweet
White
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Corn producing countries
309159
49
(source: faostat.fao.org) Million tons (average 2005-2010)24/05/2016 17MILLING TECHNOLOGY FOR CEREALS
Cereal milling
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From cereal to flouroMilling:
•Separation of bran/germ from endosperm•Size reduction of endosperm -> flour
oProcessing steps involved•Reception and pre-cleaning•Cleaning•Conditioning•Milling•Sieving•Blending
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ReceptionoReception
• intake of cereals
• quality control!: IN -> OUT
• different factors
•pre-cleaning◦ magnet
◦ sieve cleaner
◦ aspiration
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Factors affecting milling yield, end use qualityo hectoliter weight
o Impurities
o Immature kernels
o Preharvest sprouting
o Insect damage
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Courtesy: Marieke Dhooge
Sitophilus (weevil)
Factors affecting food safety: mouldsFUSARIUM SPP.
Mycotoxins!
ERGOT
•Claviceps purpurea
•Toxic alkaloids
•Difficult to separate
•0.05% limit
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Wheat grain quality controloFast analysis before grain intake:
•Moisture content
•Protein content
•Hectoliter weight
•%Impurities
•Amylase activity -> Hagberg falling number
•Gluten quality -> sedimentation value of Zeleny
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Storageo Storage
• possible: low moisture content
• BUT living substance which can decay
o Control• temperature
• grain condition
• oxygen supply
• moisture content grain
◦ safe value ~ cereal (13-15%)
◦ drying if necessary
• pest and mould control
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Blending and cleaningoBlending
• wheat mix of uniform quality• directly in storage bin• just before milling process (other tempering conditions)
oCleaning• remove impurities
◦ undesired seeds, infested kernels, shrunken and broken kernels, otherforeign material
• prevent contamination of mill products + damage of equipment
• separation based on differences in size, shape, specific gravity, behaviour in air currents, magnetic properties
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Cleaning
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SIEVE SEPARATOR
ASPIRATOR
DISC SEPARATOR
SCOURER
MAGNET
ConditioningoConditioning = adjustment of moisture content
•not too dry
◦ bran should become elastic to avoid splintering andcontamination of flour
◦ better separation of endosperm-bran
◦ less power required to grind to flour
•not too wet
◦ Endosperm too soft, no creation of sharp particles
◦ No efficient sieving
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ConditioningoTempering
•controlled addition of water (and heat)
•intensive mixing to ensure uniform distribution
•resting for a period of time (3-36 h) ◦ optimal distribution in different parts of kernel
◦ reduce hydration differences
•25°C, 15-20% moisture content◦ Soft wheat: 15 – 16.5%
◦ Hard wheat: 17 - 18%
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Milling: goals
o remove bran andgerm
o flour with specificparticle sizedistribution
o extract as muchwhite flour as possible
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Milling o Milling process
• multi-stage process• size reduction, separation (sieving) and purification
operations• different materials at different stages BUT no
fraction completely pure
o Milling efficiency•flour extraction degree•pureness of the fractions
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Milling processoSuccession of 3 systems:
•breaking◦ breaks up grain in large pieces◦ removing endosperm from bran◦ as little flour and bran powder as possible
•coarse reduction (scratching or sizing)◦ removing small pieces of bran and embryo from endosperm ◦ smaller particles endosperm
• fine reduction◦ grinding endosperm into flour◦ minimum in crushed germ and bran powder◦ optimum in damaged starch granules
Siev
ing
in b
etw
een
ste
ps
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MILLING TECHNOLOGY FOR CEREALS
Roller milling
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Roller milling: break systemo 4-5 breaks, corrugated rolls
• first break opens kernel
• subsequent breaks: scraping endosperm fromthe bran
• gradually smaller but more corrugations
• differential from 2.5 to 1
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Roller milling: reductionsystemoGradual decrease of particle size into flour
o Roller mill with smooth rolls, • differential 1.25 to 1• high shear pressure, lower shear forces
oCoarse reduction: 3-5 stages• removing small pieces of bran and embryo from endosperm
• smaller particles endosperm
• no severe grinding: no bran in flour
oFine reduction: 6-10 stages• grinding endosperm into flour
• minimum in crushed germ and bran powder
• optimum in damaged starch granules
o Material to purifiers, final reduction, flour
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Hammer millo impact milling
o screen determinesthe particle size
o requires dehullingwhen applied for‘white’ flour/meal
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Sieving
Plansifter Purifier
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Sieving: plansifteroSieving stage follows each set of rolls
• different mill fractions
• directed to:◦ Next break rolls
◦ Reduction rolls
◦ Purifier
◦ Finished product
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SievingoPurifiers
• separation of pure endosperm and endosperm with different amounts of bran
• vibrating motion of sieves: heavier endosperm close to sieve, brannier material on top
• air currents fluidise and stratify according tosize, specific gravity and shape
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Milling: end products
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100 µm
100 µm
Wheat flour Maize meal
Milling and flour/meal qualityoParticle size
oBran content -> ash content
oColor
oStarch damage
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Source: principles of cereal science and technology, Hoseney
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Courtesy: Philip Randall
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Milling technology for cereals
QA/QC on flour fortification, Kampala, 24-05-2016
DR. F IL IP VAN BOCKSTAELE
FA C U LT Y O F B I O S C I E N C E E N G I N E E R I N G
L A B O R ATO R Y O F C E R E A L T E C H N O LO GY