q uality attributes of functional extruded lentil-based snacks fortified with nutritional yeast
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3 rd International Conference & Exhibition on Nutrition & Food Science Track 6: Food Processing and Technology Valencia – September 23-25, 2014. Q uality Attributes of Functional Extruded Lentil-based Snacks Fortified with Nutritional Yeast. Jose De J. Berrios USDA-ARS-WRRC. - PowerPoint PPT PresentationTRANSCRIPT
Quality Attributes of Quality Attributes of Functional Extruded Functional Extruded Lentil-based Snacks Lentil-based Snacks
Fortified with Nutritional Fortified with Nutritional YeastYeast
Jose De J. BerriosJose De J. BerriosUSDA-ARS-WRRCUSDA-ARS-WRRC
3rd International Conference & Exhibition on Nutrition & Food Science
Track 6: Food Processing and TechnologyValencia – September 23-25, 2014
Nutritional & Health Value Nutritional & Health Value of Pulsesof PulsesNutrients Beneficial Effects
Protein
Body building and growth;; Hypocholesterolemic/Cholesterol lowering Prevention of CVDs; ↑ Satiety ↓ Obesity
Complex carbohydrate:
Oligosaccharides & Resistance Starch
Prebiotic effects; reduce Colorectal Cancer and Constipation; Hypocholesterolemic / Cholesterol lowering; Hypoglycemic effect/Blood Glu control α low GI (Diabetics)
Dietary Fiber: IDF/SDF
Hypocholesterolemic / Cholesterol lowering ; Prebiotics; Reduce colorectal cancer and CVDs; ↑ Satiety ↓ Obesity; maintain healthy intestinal tract & prevents constipation
Phytonutrients/AOX: anthocyanins,
polyphenols, tannins, carotenoids
Prevention of CVDs & different types of Cancer (including Lung Cancer); eye disease; enhance immune system
Vitamins/Folic acid & Minerals
Neural Tube Defect prevention (Spina Bifida); New Cell formation/Red Cell Development ; Healthy Bones; Blood Pressure regulation
“Gluten-free”
Prevents Celiac Disease/Gluten Intolerance
Yeast grown, from pure strains of Saccharomyces cerevisiae, on a
purified nutrient source specifically for its nutritional value.
Nutritional Yeast
• Excellent source of protein (essential and non-essential AA’s)
• Rich in Vitamins (B-complex; folic acid)
• High in Dietary Fibers (β-glucans)
• Naturally low in Fat and Sodium
Nutritional Yeast
• Product with No added Preservatives
• Kosher certified
• Not a Genetically Modified Organism (GMO)
Seed
PropagationFermenter
Add Air,
Molasses/Nutrients
Cream Storage Cooling Separator
Yeast is Drum
Dried
Cooling of Yeast
In Heat ExchangerPasteurization of
Yeast
Final Product-Packaged
Grinder
Nutritional Yeast Production
Lesaffre Yeast Corporation
Nutritional
Yeast(S. cerevisiae)
Protein/flavor
Forte: Cr/B Vits
Pro SCB: B Vits
Cell wall basic:
B-Glucan
SaFlavor+ :
Protein and DF
Nutritional
Yeast(S. cerevisiae)
Protein/flavor
Forte: Cr/B Vits
Pro SCB: B Vits
Cell wall basic:
B-Glucan
Nutritional Yeast
(SaFlavor+:
protein and TDF)
SaFlavor+ :
Protein and DF
• Whole Pulses – canned, micronized, split, flaked
• Products made with Whole Pulses– soups, chilis, refried beans, frozen entrees, snack mixes, roasted
and fried snacks (peas & lentils)
• Ground Pulses – Flours or powders (including naturally fermented flours)
• Products made with Ground Pulses– specialty bakery mixes, vegetarian foods (RTE frozen entrees,
vegi burgers), pasta & noodles, extruded-fried snacks, and dips
Available Products from Available Products from Legume PulsesLegume Pulses
Projected Value by 2014 Category (billion USD)
Savory Snack Industry: 61.5 (CAGR: 3.7%)
Breakfast Cereal Industry: 26.2 (CAGR: 3.1%)
Functional Foods: 90 (CAGR > 4%)
Gluten Free: 4.2 (CAGR > 5%)*
*: Faster growth - $4.2 bn - end of 2014 and $6.6 bn (CAGR > 20%) in 2017
Whole Grain and High Fiber food market - $27.6bn by 2017
High Protein-low Fat Food & Beverages - $40bn
Source: Datamonitor
Projected Value by 2014 Category (billion USD)
Savory Snack Industry: 61.5 (CAGR: 3.7%)
Breakfast Cereal Industry: 26.2 (CAGR: 3.1%)
Functional Foods: 90 (CAGR > 4%)
Gluten Free: 4.2 (CAGR > 5%)*
*: Faster growth - $4.2 bn - end of 2014 and $6.6 bn (CAGR > 20%) in 2017
Whole Grain and High Fiber food market - $27.6bn by 2017
High Protein-low Fat Food & Beverages - $40bn
Source: Datamonitor
Global Market (billion USD)
Food:• Breakfast cereals• Snack foods• Flat bread• TVP• Caseinate• Corn flakes• Chocolate
Feeds:• Pets• Cat food• Fish Feed• Your products…
• Calf fattening feed• Extruded corn• Extruded barley
• Extruded wheat• Debittered soya• Extruded soya
• Starch• Instant foods• Modified starches• Swelling starch• Instant flours• Filled tubes
Shapes:• Flakes• Rings• Stars• Tubes• Rods• Spheres• Granulates• Alphabet• Pictures
What Products are Made on an What Products are Made on an Extruder?Extruder?
Investigate the use of extrusion technology to develop ready-to-eat healthy expanded snack-type products from lentil flours fortified with Nutritional Yeast
Evaluate the sensorial, physico-chemical and nutritional attributes of the developed extrudates
Sensory Evaluation Ranking Test (BIB Design)
Proximate Analysis Standard AOAC methods (1990)
IVPD Multienzyme solution (Hsu et al. 1977)
Water Activity Aw meter Aqua Lab CX-2 (Decagon, Inc.)
Expansion Ratio πrext2/ πrdie2: Cross-sectional (CS) area of extrudate/CS area of die opening
Bulk Density Bead displacement method(Berrios et al, 2010)
SME (kJ/kg) Net Mechanical Energy Consumption/TotalFeed Rate
Statistical Analysis Response Surface Methodology (RSM)ANOVA – Fisher’s LSD(MINITAB, v16)
MATERIALS
& METHODS
Formulation:Continuous
Mixer
Twin ScrewExtruder
Raw Materials
FormulationMix
Hammer Mill
PinMill
Formulation & Formulation & ExtrusionExtrusionProcessingProcessing
Formulation & Formulation & ExtrusionExtrusionProcessingProcessing
SRCL Nutr. Yeast
Protein 26.63 51.29
Total DF 6.17 22-26
IDF 5.17 4-7
SDF 1.00 18-22
Lipids (Fat) 0.79 1.06
MATERIALS
& METHODS
Texture ModifiersH2O
Starches
LentilFlour
Nutr. Yeast
Emulsifying agentsFlavoring agents
Fibers
Extrudate Rods
Cooling/Drying/Cutting
In Vitro Protein Digestibility (Hsu et al. 1977)
In Vitro Protein Digestibility (Hsu et al. 1977)
1.6mg/ml Trypsin3.1 mg/ml Chymotrypsin1.3 mg/ml Peptidase
pH Meter
Multienzyme Solution:6.0 mg/ml total
5 mLpH 8.0
4oC
y=210.464–18.103xy=IVPD (%)x=pH value of the protein suspension after 10 minutes digestion
50 mLProtein
Suspension6.25 mg/ml
pH 8.037oC
Sensory Evaluation ResultsSensory Evaluation Results
Formulation Overall Liking
Formula Ctrl 3.475b
12%, 140C 5.500a
12%, 160C 5.500a
Increase (%) in nutritional value due to NY fortification
Increase (%) in nutritional value due to NY fortification
Nutrients Formula Ctrl
12%, 140C
% increase
Protein 22.1b 25a 13.12
Ash 1.92b 4.27a 122.40
Fat 0.37b 0.64a 72.97
IVPD
70
75
80
85
90
95
Casein Formula ctrl 12%,140c
Per
cen
t
Raw IVPD
Ext IVPD
IVPDIVPD
97.32%
100.00%
90.37%
87.92%
92.63%
Increase (%) in nutritional value & Digestibility due to NY fortificationIncrease (%) in nutritional value & Digestibility due to NY fortification
Nutrients Formula Ctrl
12%, 140C
% increase
Protein 22.1b 25a 13.12
Ash 1.92b 4.27a 122.40
Fat 0.37b 0.64a 72.97
IVPD 83.40b 88.60a 6.24
Effect of NY fortification on extrudate Physico-chemical
parameters
Effect of NY fortification on extrudate Physico-chemical
parameters
ER BD (g/cc) Aw
Formula Ctrl, 140C
15.43a 0.0688b 0.3330b
12%, 140C 9.23b 0.1298a 0.3927a
♦ Sensory evaluation test demonstrated that the Lentil-based extruded snacks containing up to 12% NY, had good acceptability by the tasters
♦ Nutritional components: protein, ash (minerals), fat, and dietary fiber of the extruded snacks increased as the concentration of NY increased in the lentil-based formulations
♦ Effect of Yeast fortification on some physico-chemical parameters:
● Degree of expansion of the extrudates was considered appropriated for
expanded snacks
● Bulk density was inversely related to expansion ratio and directly related with
higher yeast concentration
● SME required to process the extrudates was favored by higher Yeast
concentration
● Water activity of the extrudates was very low and similar to those of
dehydrated foods (Aw 0.4)
♦ Expanded extruded snack-type foods, made from pulse-based formulations fortified with NY, would generate economic advantages for pulse’ producers and food processors & provide consumers with highly nutritious, healthy, safe, and convenient food alternatives
♦ Fortification with 12% NY significantly increased the IVPD of the extruded snack
Acknowledgement
Mr. James PanChemist, Extrusion ProgramProcessed Foods Research Unit
Mr. Matthew TomSystems EngineerExtrusion ProgramProcessed Foods Research
Adeline Cheong, Ph.D.Senior Manager – Business Development