TFF Shortening Solutions

Greg J Grisanti CRC, CFSP Director of R&D Frisch’s Big Boy

Mitch Riavez C.M.B. National Account Manger STRATAS FOODS

Latest PHO Buzz & The FDA

• On 6/16/15 the FDA announced it had finalized its determination that partially hydrogenated oils (PHO’s) are not “generally recognized as safe - GRAS

• Removing GRAS status effectively eliminates the ability to use products containing the related ingredient or product

• The FDA has set a compliance period of 3 years (by June 2018) to either reformulate products without PHO’s and/or petition the FDA to permit specific uses of PHO’s

• The Grocery Manufacturers Association has filed a petition with the FDA arguing that “low level use” of PHO are just as safe as the naturally occurring trans-fat in foods such as meat, milk, dairy and other foods

Latest PHO Buzz & The FDA

• GMA estimates it could take “two or more years to complete” by which time many companies would have already made the switch

• Initially there was some debate on whether or not PHO emulsifiers were affected. The general consensus now is that eventually PHO based emulsifiers will in fact no longer be GRAS

• Nestle USA and General Mills, Inc. were both hit with class action lawsuits alleging that some of their food products contain trans fats when safer ingredients could have been used.

• In California where the General Mills legal action was filed, a judge ruled that “The FDA’s decision not to prohibit the sale of products containing PHO’s until 2018 indicates that it was not and is not unlawful under federal law to sell them before that time.”

• In addition, in a year-end Congress backed omnibus spending bill, language was included that declares PHO’s can’t be considered unsafe until at least 2018.

Fats & Oils Processing

Blend of Deodorized Oils

Melt and Add Emulsifiers Etc.

Votate/Plasticize

Package/Palletize/Temper/Store

Producing Solid Shortening

Added Nitrogen

Hydrogenation

o Maintain proper storage temperatures• Most shortenings – 65 to 75°F• Most margarines – 35 to 45°F• Palm not as tolerant to extreme temps as partially hydrogenated

soybean oil

o Avoid exposure to light (oxidation) notice how some beer companies bottle in dark glass!!! And some milk manufacturers use opaque plastic!!!

o Avoid exposure to strong smelling substances. Don’t store your margarine near the cheese and garlic!!!

Storage Is Key

PHO Replacements Palm / EIE Interesterified /Flex /High Oleic Oils

Palm Zero Trans Situation

Palm oil still represents a viable option today

• Kosher status is critical for bakery solutions• Palm oil has natural characteristics like partially

hydrogenated oils (ie. good creaming properties)• Pricing is similar to soybean oil• Availability is excellent….BUT… BUT !!!!!!!!!!!

Why Won’t Palm Act Like Traditional Shortening?

• Major building blocks of a functional shortening require specific fatty acids: Palm contains a narrow fatty acid profile…

• And not all palm is created equal !!! Low color palm? • Palm is functionally challenged / When its cold, palm is hard.

When is hot palm is soft.• This is not an issue in low fat content items. But with items

such as icings or laminated doughs (Danish & Puff Pastry) it can be a challenge.

What is EIE?

• Enzymatic interesterification (EIE) is the reaction that occurs when an enzyme is introduced into an oil. It changes the fatty acid.

• The EIE process adjusts the melting properties and improves the crystallization properties. This helps with functionality and plasticity in the shortenings. PHO performance without the trans.

• EIE fats and oils provide better health profiles than either palm oil or partially hydrogenated oil. And allows the use of domestic source oils.

What is Flex

• Flex processing is “better” than common palm or interesterified soy shortening options, since it delivers a crystal shape and size that mimics that of PHO.

• Crystal shape and size, plays a pivotal role in “boxing in” liquid oils to prevent instability and fat migration. This improves plasticity, temperature working ranges, and consistency.

• Flex technology improves both palm and inter-esterified soy shortenings by widening working ranges. However, it does not go as far as Golden Flex toward a drop in replacement.

Palm oil with Flex Processing: small, tight crystals (stable)

Palm oil: large, needle like crystals (unstable)

A process that directs crystal shape more like that of a PHO product

• High oleic soybean oil combined with FLEX technology delivers a shortening with PHO characteristics

• Higher oleic content in the soybean oil provides the fatty acids needed for plasticity and stability

• Flex technology provides proper crystal shape, wider temperature working range, and more consistency cube-to-cube

• This new IE product offers current palm users the opportunity to raise their performance back to what they enjoyed with PHO products.

PHO shortening functionality without the PHO’s

What is Golden Flex?

What are High Oleic Oils?

What is “high oleic” oil? High oleic oil is any oil that is high in monounsaturated fats. Olive and

canola oil are naturally high in monounsaturated fat, but they are also high in polyunsaturated fats which mean they are not very shelf-stable.

Scientists have developed sunflower, soy (and other) oils that are bred to be high in monounsaturated fats and low in polyunsaturated fats.

Why do food companies use high oleic oil? In the past, food companies used hydrogenated oils (trans fats) to keep

food shelf-stable and preserve flavor. They switched to high oleic oils or palm kernel oil to make their food last longer for customers.

These oils are often used in packaged baked goods (packaged cakes, cookies, etc.), as spray coating for cereal, crackers and dried fruit; and in non-dairy

creamers as well as many types of frying.Is it healthy? High oleic oil is high in unsaturated fat, low in saturated fat, and has no

trans fats. High oleic oil has been shown to lower LDL cholesterol (the bad kind) without lowering HDL cholesterol (the good kind).

Application Review Pie Crust Dough

Typical – Finished Dough Flex – Finished Dough

Shortening lumps

visible in finished dough

More homogeneous distribution of

shortening

Big Boys Pie Dough

• When we were converting from PHOs to lard we realized some of the benefits of PHOs, one being the crust’s ability to withstand the rigors of automated manufacturing. Pecan pie filling is very dense and sticky, and must be held at a higher temperature when injected into the crust. Between its heaviness and its heat, the filling hits the crust and breaks it up. This creates holes on the bottom, with crust pieces rising to the top. Pecan pie was no longer a second-tier conversion. It was moved to the third prong.

• Mitch Riavez, a Certified Master Baker with Stratas Foods, was assisting with some other conversion projects, I discussed the pecan pie predicament. Mitch has many years in the business and has seen it all. He recommended a simple solution: freeze the crusts for about a half hour before filling them. We are in the process of evaluating this approach and believe the problem will be solved without requiring any additional ingredients.

Sweetex Flex: will work as a 1 to 1 drop-in Big Boys is doing it now.

Nutex: will work as a 1 to 1 drop-in / Use your own formula/ Replace plasticized shortening and mix the same way you always have.

Scratch Chocolate cake formulas - Comparison pictures belowScratch Yellow cake formulas - Comparison pictures below

1 To 1 Drop-In replacements

17

That’s what Bakers like to hear…

Finished Piped Icing

Control FlexShortening

Lumps

Removing all PHOs from formulations and recipes

• The first prong was the low-hanging fruit…the fried foods. It was fairly easy to replace the frying oil, and in some instances make minor adjustments to breadings and batters.

• Next came our pies, which we knew would be somewhat challenging, but not as difficult as our cakes. The answer was lard. We tried it and it worked. Well, it worked for all the pies except pecan.

• Next came the cakes: Mitch ran the Sweetex Flex as a 1 to 1 drop-in. In blind testing the new formula was chosen, and said to be more moist.

• We are in the process of converting the final menu items, one item at a time. From the start we worked very closely with Stratas, as Mitch and his team have the expertise for a smooth and flawless transition. They spend days with us in the production facility, trying different fats and oils with other ingredient and manufacturing modifications. It’s perfectly acceptable for culinary professionals to tap into the knowledge of their suppliers. Throughout this process I recall Mitch saying to me many times, “I think I can help you with this one, too.”

Frischs Big Boy Fudge Cake

Don’t miss out on dessert from the Big Boy