Ways to help reduce Wastage in the Dairy Food Chain

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Ways to help reduce Wastage

in the Dairy Food Chain

Stephen Bullin – Business Manager for Sub Saharan Africa

[email protected]

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Wastage

FreshQ®

Keep IT

Extended Shelf Life Yoghurt - ESL

Bio Safe for cheese





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Be profitable Large value potential in scrap reduction in production, distribution & consumption

3

Global Food Losses and Food Waste (2011); Food and Agriculture Organization of the United Nations

http://www.fao.org/save-food/info-resources/en/

Loss and waste of food is a global concern with significant impact on economics and social welfare

180 175 160 160 180

110

200

100 120

80

5

30

15

20

Europe NorthAmerica &Oceania

IndustrializedAsia

Sub-SaharanAfrica

North Africa,West &

Central Asia

South &Southeast

Asia

Latin America

Per Capita loss and waste of food (KG/year)

Supply Chain Waste Consumer Waste

4





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Shelf life is pushed to the limit

Complaint

YES

NO

Re-purchase

YES

NO

Spread word

YES

NO

Source: CH internal survey

5

Product spoilage before end of shelf life can be a silent

brand killer…

Consumers will stop buying and spread the word, but not

necessarily file a complaint!

6

All Natural and Clean Label is a major global trend !

6





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Wastage

FreshQ®

Keep IT


Bio Safe for cheese





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Benefits of FreshQ®

Better quality during shelf life

Quality defects is the silent killer..

Potential Shelf life extension

Optimize “open” shelf life

Consumer experience

Natural alternative to preservatives

Clean label





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Mode of Action: What is known from literature

9

LAB have potential for being effective in

combating food borne yeast and mold

Fungi-static effect

A moderate level of antifungal activity is a

relative common property of LAB

Isolates with higher activity than

average can be found with reasonable

frequency

Adequate screening/ application assay

Majority of isolates with high antifungal

activity belong to the genus lactobacilli

Three mechanisms involved in antifungal

efficacy

Antifungal activity mechanisms and

interactions are complex and difficult to

elucidate

Competition for nutrients and space

Cell interaction

Cell communication

Production of antagonist compounds

Peptides, H2O2, diacetyl, benzoic

acid Phenyl-lactic

acid…

Yield of organic acid

Lactate, Acetate





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FreshQ® 2 and 4 inhibit yeast Example: Debaryomyces hansenii (50 cfu/g) in yogurt stored at 7ºC/45ºF





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Number of days until first mold growth is visible (average of two cups):

Still no growth

on day 51

FreshQ® 2 and 4 increase time to visible mold Example: FreshQ® 2 in Greek yogurt 1,5% fat

Challenge test with high contamination level: 1000 spores/spot!

Penicillium commune

Aspergillus versicolor

P. palitans

P. crustosum

P. paneum

P. palitans

P. paneum

P. roqueforti





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Reference

FreshQ® 2

7ºC/45ºF 12ºC/54ºF 22ºC/72ºF

FreshQ® 4

FreshQ® 2 & 4 work over a broad temperature range Challenge test with P. crustosum added at 1000 spores/cup and stored 36 days

FreshQ® as replacement of sorbate in yoghurt

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The antifungal efficacy of FreshQ® versus sorbate in Yogurt FreshQ® generally has comparable antifungal effect to potassium sorbate levels in the range 0.2 – 0.4 % (w/v)

Yoghurts made with different levels of potassium sorbate (PS), with FreshQ® (100U/T) or

without (Reference) and spiked with different molds (approx. 500 spores/cup) followed by

60 days storage at 7C

Reference FreshQ® 2 0.1% PS 0.2% PS 0.4% PS

P. crustosum

P. discolor

14





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Wastage

FreshQ®

Keep IT


Bio Safe for cheese





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FD-DVS KeepIT 1.0

Primary benefit is low post-acidification at elevated storage

temperatures which translates into better quality within

shelf-life or even extended shelf-life.

Culture provides good gel structure, low ropiness and

medium flavor in set yogurt

Fermentation:

Milk: 1.5% fat & 4% protein

Inoculation: 500U/2500L

Temperature: 43ºC

16





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Post acidification at elevated temperatures

17





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Wastage

FreshQ®

Keep IT


Bio Safe for cheese





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What is Extended Shelf-Life Yoghurt?

Extended Shelf-Life (ESL) Yoghurt is simply stirred Yoghurt that undergoes a

thermisation stage after fermentation

Products are packaged into clean packaging and are stable at ambient

temperatures

The products can be plain and unsweetened but in most cases are

sweetened and flavoured

Differ from UHT Yoghurt drinks in that they have thicker texture and

equivalent protein levels of a fresh, stirred Yoghurt

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Long Shelf Life & Convenience

Distribution

Cool Chain integrity less

important

Export

Wider geography

Reduction of

Y & M

Enzymes

Bacteria

Contaminants

Post Acidification

Why go the ESL route ?

22

Technical Commercial

Process Line

23

Wide Aperture Plate

Heat Exchanger

Tubular Heat

Exchanger

24

Heat Treatment

75°C for 15 seconds is sufficient to eliminate both S. thermophilus

& Lb. bulgaricus

Heat treatment up to 80°C / 30s does not influence concentration

of volatiles* compared to reference yoghurt

* Acetaldehyde, Acetone, Ethanol, Diacetyl, Acetoin

Heat-treatment ST (cfu/g) LB (cfu/g)

75 °C/15s 0 0

85 °C/15s 0 0

95 °C/15s 0 0

85 °C/ 300s 0 0

Reference (2 bar PTU) 6.3 x 108 4.7 x 108





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Base Formulation

Base formulation is crucial to product quality, but unlike fresh stirred

Yoghurt goes beyond milk protein alone

Pectin is utilised to protect the coagulated milk protein during post

thermisation stage and prevent syneresis

Starch is necessary due to high-shear in process

Gelatine can be used although we see a trend away from this ingredient

Gellan Gum is effective for smoothness and viscosity

Culture selection is also an important consideration

26

Recipe Optimisation

27

For a sweetened recipe, the

following formulation has proven

effective :

2.8 % Milk protein

6.0 % Sugar

1.50 % Modified Starch

0.15 % LM Pectin

0.03 % Gellan Gum

0.02 % YoFlex YF-L901

Milkbase Mod.

Starch

(%)

Pectin

(%)

Gellan

Gum (%)

A 1.50 0.30 -

B 1.50 0.15 0.03

C 1.75 0.15 -

Effect of Strike pH

28

Lower cut pH gives

improvement in both texture

& appearance

Yoghurt heat-treated at 80°C/15s

From left to right; cut pH 4.60, 4.50, 4.40

Culture Selection

29

As with any Yoghurt, the culture used will impact upon the flavour,

texture, acidity and fermentation time

Due to heat-treatment post-acidification is not a consideration

ESL yoghurts tend to have a mild flavour profile

A culture is required which will drop to pH 4.3

Any contribution to texture from EPS can be beneficial as product

relies on hydrocolloids for stability

The ideal culture therefore needs to impart:

Acidification to pH 4.2 Moderate to high EPS Mild flavour profile

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30

Culture selection - YoFlex® Range

Yoghurt flavor intensity

Viscosity (mouth thickness)

Low

Very mild Very strong Medium

Extra high

High

YC - X 11

YC - 183

YC - 190

YC - X 16

YC - 180

YC - 280

YF - 203

YF - L800

YF - 202

YC - 470

YC - 471 YC - 370

YC - 380

YC - 381

YF - LX700 YF - LX701

YF - L702

YF - L703

YF - L811

YC - X 11

YC - 183

YC - 190

YC - X 16

YC - 180

YC - 280

YF - 203

YF - L800

YF - 202

YC - 470

YC - 471 YC - 370

YC - 380

YC - 381

YF - LX700 YF - LX701

YF - L702

YF - L703

YF - L811

YF L812 -

YF L901 -

YF L902 -

YF L705 -

YF L706 - Very high

YF L903 - YF L904 -

Advance 1.0

Advance 2.0

Mild 1.0 Classic 1.0 -

Premium 1.0

YF-3331

Part of range most

relevant to PPY





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Wastage

FreshQ®

Keep IT


Bio Safe for cheese

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32

New BioSafe culture range

for natural ripened cheese





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Late blowing

Late blowing is a serious defect associated with mainly brine salted semi-

hard and hard cheeses

Caused by Clostridium spp. particularly C. tyrobutyricum

2 Lactate butyrate + 2 H2 + 2 C02

If no measures are taken to inhibit clostridia growth, it is recommended to

have <10 spore per 100 ml cheese milk (<1 spore/g cheese).

33





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Removal of spores from milk

Bactofugation (98%)

Micro filtration (99,9%)

Prevention of growths by additives

Nitrate

15g/100 l milk sufficient to prevent <10.000 spores/l

High heat treatment (82°C/20 s) inactivate xanthine oxidoreductase

which convert nitrate to nitrite and prevent use of nitrate

Lysozyme

Ways to prevent late blowing

Gel

Curd

Ripened cheese

Milk

Consumer

BioSafe for inhibition of clostridia Potentially in combination with bactofugation

if clostridia level in milk is high

34





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BioSafe challenge test example

Control* + BS-10 50 spores + BS-10

50 spores 25 spores

*Control means no clostridia spores added,

so only the natural content in the milk.





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Nisin levels obtained in cheese trials

36

Continental customer trial Germany

Dosage: 45U/10.000 l

Edam customer trial Poland

Continental pilot plant trials (DK)

Vat no. Culture Nisin (mg/kg)

3 BS-20 2,0

10 BS-20 1,4

17 BS-20 1,6

23 BS-30 2,9

30 BS-30 3,1

37 BS-30 2,0

63 BS-10 3,0

77 BS-10 1,0

Vat no. Culture Nisin (mg/kg)

6 BS-20 0,42

12 BS-20 1,04

18 BS-30 1,54

25 BS-30 2,62

BS-10 BS-20 BS-30

Nisin (mg/kg) after brine 8,0 6,5 7,6

Nisin (mg/kg) two weeks

3,9 1,2 0,7

Nisin (mg/kg) 6 weeks

3,1 0,5 1,0





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BioSafe mode of action

Concentrated strains of Lactococcus lactis subsp. lactis

Metabolic activity results in production of nisin during the cheese process

Nisin is a known bacteriocin that inhibits gram+ anaerobic spore formers

Sold as F-DVS BioSafe BS-10, BS-20 and BS-30 in 10x65 unit bags

Dosage recommendation: 20-25 U per 5.000 l milk

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Spore

Germination

Vegetative

growth

Sporulation

NOTE: Nisin kill bacteria via pore

formation in cell-wall following

binding with Lipid II in different

pathogen, like listeria and clostridia.

Similar to lysozymes, nisin mode of

action also target vegetative cells

and has no effect on their spores.

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38

Ways to help reduce Wastage in the Dairy Food Chain

Economy & Finance

Transcript of Ways to help reduce Wastage in the Dairy Food Chain