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)

Beer

Cheese

Spirits

Sourdough

Root beer

Bread

Brewer’s Yeast

(S. cerevisiae)

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

The Food PyramidThe Food Pyramid

• 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

Main IngredientsLentil (Lens culinaris)

Nutritional Yeast: (Sacharomyces cerevisiae)

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

32mm TS Extruder50+ kg/h capacity 1,200 rpm

MATERIALS

& METHODS

Extruder

140 and 160C

500 rpm

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

MATERIALS

& METHODS

Sensory EvaluationSensory Evaluation: 7-point hedonic scale -Overall liking

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

SMESME

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

My working team My working team

WRRC

Nutrients SRCL Nutr. Yeast

Protein 22.10 51.29

Total DF 6.17 22-26

IDF 5.17 4-7

SDF 1.00 18-22

Lipids (Fat) 0.79 1.06

ER