reduction 2020 technology update

Reduction 2020TechnologyUpdate

StefanTöpflDeutschesInstitutfürLebensmitteltechnike.V.

• Functionalization• Structure modification• Fermentation

Salt,fat and sugar reductionStrategies

Saltreduction

Example:Proteinfunctionalization bypressure

Reduction of salt content inarange of 1.2– 2.2%

Abb.1:Drip loss (%)of scalded sausage with varying salt content

• WHC– drip loss

èReducing salt contentresults inlower WHC

Lowsalt meat productsScalded sausage

Serotype 4b(3987/04)

p-T isokineticity diagrams for 5 log inactivation of 3 pathogenic strains of Listeria monocytogenes in “Black Forest Prosciutto” (Ham) after 15-240 s.

Serotype CLIP 74903Serotype CLIP 74902 1/2a

HighPressure ProcessingMicrobial inactivation

7

Oligomeric Structure

Monomere Structure

Intermediate, melted state

Unfolding

Aggregation

0,1 MPa 100 – 200 MPa > 700 MPa300 – 500 MPa

Pressure treatmentImpactonproteins

Abb.3:(1)Control,(2)HPP100MPa– Saltaddition prior to HPP,(3)HPP400MPa– Saltaddition prior to HPP,(4)HPP100MPa– Saltaddition afterHPP,(5)HPP400MPa– Saltadddition afterHPP,(6)Saltand phosphateaddition (0,06%)

• Saltcontent 1.8%• 100 MPa

• 400 Mpa

• No phosphate (except 6)

Nr.2und6

• Good structure• Good WHC

1 2 3 4 5 6

Lowsalt meat productsHPPconditioning

Ø Declarationwiththeclaim“reducedinsalt”ispossible

Cooked sausage Cooked ham

NaCl 1.26% 1 % 1.33 % 1.1%Phosphate 0.25 % 0.25 % 0.25% 0.25%KCl - 0.26% - 0.2%Processconditions

- - 100MPaaftertumbling

100MPaaftertumbling

Finalsaltreduction

30% 45 % 30 % 42%

Lowsalt meat productsResults

Fat reduction

Example:Replacing fatby lean meat

HighPressure ProcessingHPPstructure modification

HPP treatment of lean meat (e.g. turkey breast or thigh)

• 600 MPa 3 min at ambient temperature

• Freezing

• Use to replace fat or lard in meat products

Benefits

• Reduction of fat content < 10 %

• No use of plant based oils or other animal types

• „Clean-Label“ – no gums, thickeners or fibers

DIL– HighProSticks•Proteincontent >50%(dependent onmoisture removal)

•Fatcontent<10%•Fitness,bodybuilders,kids …

ExampleformulationTurkeythigh70%Turkeybreast(600MPa,3min)30%Curingsalt2,0%Dextrose0,25%Pepper0,2%Startercultures

HighPressure ProcessingHPPstructure modification

Fat reduction

Example:Reducing fat indispersesystems

Example of a high pressure gap

Stansted Fluid Power HydLok

• pressure up to 400 MPa

• 2 – stage pressure system

• 100 l/h continuous flow rate

• 15 kW power consumption

• 8 bar pneumatic air supply

HighPressure HomogenizationEquipment

Structuralmodification

• Particlesizereduction(Nanoparticles,nanosuspensions)

• Modificationofconstituents(proteins,starchetc.)

Foodpreservation

• Reductionofmicrobialload• Enzymeinactivation

control 100 MPa

200 MPa 300 MPa

HighPressure HomogenizationEquipment

1. Preparation

- Water 56 %

- Egg yolk (PLA2 modified)* 8 %

- Sugar 2 %

- Mustard 1 %

- Salt 1 %

2. Oil addition and acidification

- Slow oil addition 28 %- Vinegar 3 %

- Citric acid 1 %

3. Homogenisation

- Variation of pressure level (100-350 MPa)

HighPressure HomogenizationLowfat mayonnaise

0,1 mm

0,1 mm 0,1 mm

APV (18/5 MPa)

300 MPa200 MPa

100 MPa

0,1 mm

300 MPa200 MPa

100 MPa

Light microscopyConfocal laser scanning microscopy (CLSM)

APV (18/5 MPa)

HighPressure HomogenizationLowfat mayonnaise

Flow rate: 360 l/h

Max. Pressure: 3800 bar (380 MPa)

Input Power: 56 kW

UHPHequipmentDILdevelopment

High pressure pump

Valves:

1st Stage und 2nd Stage

Fat reduction

Example:Reducing fat uptake duringfrying

PEFtreatment influences the structure of potatoes

Pulsed Electric FieldsStructure impact onfat uptake

Pulsed Electric FieldProcessingCutting improvement

22

Productquality

• Texturesofteningandsmoothercut

• Higheryield(lessbreakage),Longerfries

• Reducedoiluptake(upto10%)

• Possibilitytodevelopnewcutsandshapes(e.g.Latticecut)

Processing

• Energyandwatersavings

• Increasedknifedurability(upto60%)

PEF

Oilcontent

5.7% 5.1%

Pulsed Electric FieldProcessingBenefits for FrenchFriesProcessors

23

Productquality:• Reducedfat→smoothercut→countercurrentmasstransfer

• Crisperchip

PEF

OilcontentFryingtime:– 25%

Fastermoisturerelease→shorterfryingtime

0

2

4

6

8

10

12

14

16

160 180 200 220

Moisture%

Fryingtimeat175°C[s]

untreated PEF

Fryingtime:– 25%

0

2

4

6

8

10

12

14

16

160 180 200 220

Moisture%

Fryingtimeat175°C[s]

untreated PEF

1%

Fryingtime:– 25% 38.3% 25.5%

Pulsed Electric FieldProcessingPotato Snacks

-33 %

Equipment design

Sugarreduction

Example:Replacing sucrose by othersugars /sugar alcohols

SugarremovalBakery products

Pleasure Project, Le Bail, 2015

Dough rheology:Nativeegg(55%)foamed with Saccharoseor Fructose(45%)with addition of 25%wheat flour and 0,5%salt

SugarreplacementBakery products


DSC:Nativeegg(55%)foamed with Saccharoseor Fructose(45%)with additionof 25%wheat flour and 0,5%salt

Globuar proteins

native

Heat

Shear

unfolded denaturéd

60 – 70°C > 80°C

Stable due to

molecular interactions

Stabilized by covalent

bonds (-S-S-)

poss.

reversible

Instable, potential for

interactions and reactions

SugarreplacementProteindenaturation

Fructose SaccharoseSugar alcohol

Xylit


Colour (Melanoidins)

Volatiles, roasted and bitter flavours

Saccharose: non-reducing sugar

Maillard Reaction

Non-enzymatic

reaction of

sugars and

amino acids

SaccharoseFructose

!

SugarreplacementBrowning

Sugar alcohols

à No reducing sugar

à no Maillard-Reaction?!

Water removal during baking: 2

à increased reactivity

à dehydration

à Maillard-Reaktion

Slow reaction with complex

reaction paths

Sugar alcohol

Xylit

Xylit

SugarreplacementBrowning

25°C 35°C 45°C 55°C

65°C 75°C 85°C 95°C

Dough with Saccharose

SugarreplacementBaking

25°C 35°C 45°C 55°C

65°C 75°C 85°C 95°C

Dough with Fructose


Dough with

Fructose

25°C 95°C

Dough with

Saccharose


Sugarreduction

Example:Reducing sugar byfermentation

SugarreplacementEnzymatic hydrolysis

Pleasure Project, Le Bail, 2015

SugarremovalFruit products

In purees up to 30 % reduction reached, no significant change in fruit ingredients.

Pleasure Project, Lötzbeyer, 2015



Biotechnological approach for sugar reduction processes, other reaction

pathways e.g. gluconic acids possible as well

Structure design

Example:Snackand highmoistureextrusion

Extrusion

65 % protein concentrate (soy, pea, dairy, algae…)

35 % waterFat free impingement or mold baking

Targeted processing allows structure modification and functionalityenhancement:

• Pressure induced protein unfolding can increase water binding capacity andallow partialreplacement of salt

• Reduction of lipid droplet size by ultra highpressure homogenization allowsviscosity increase and reduction fat content

• Structure modification of planttissue results incutting improvement andlower fat uptake

• Sugarreduction can be achieved by replacement or fermentation

• Extrusionallows designof low fat carbohydrate and protein based structures

Conclusions

reduction 2020 technology update

Science