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From Gluten-free to Whole Grain: Formulating On-trend Products
Heather MaskusProject Manager, Canadian International Grains Institute
May 4th, 20162016 Protein Trends & Technologies Seminar
• Created in 1972
• Independent organization
• Funding: Farmers, Government
of Canada (AAFC) and industry
partners
• Mission: Creating profitable
opportunities for Canadian field
crops; wheat, pulses, barley
What is Cigi?
2016 International Year of Pulses
Opportunities for Pulse Ingredients
Canadian Pulses
5Black
WHOLE SEED DEHULLEDSPLIT
GROUND FLAKED FRACTIONATED
Pulse Flour
Whole pulse flour is a healthy
food ingredient containing fibre,
protein, vitamins and minerals
Pulse flour is a nutrient
dense ingredient. Key
minerals include iron,
potassium, magnesium
and zinc. It is also rich in
B-vitamins folate, thiamin
and niacin.
Nutritional AdvantagePROTEIN
(%)STARCH
(%)FIBRE
(%)FAT (%)
Pea 20 – 27 42 – 49 15 1.0 - 1.7
Bean 20 – 34 32 – 45 23 0.7 - 2.3
Lentil 21 – 30 42 – 49 14 1.0 - 1.3
Chickpea 18 – 31 33 – 44 25 4.4 - 6.9
Soy (de-fatted) 47 38 18 1
Corn (de-germed) 6 83 2 1
Wheat (de-branned) 10 – 15 73 2 2
Source: Canadian Grain Commission
Nutrition and Health Research
Other Advantages
• Sustainable protein
• Non-GMO
• Low allergenicity
• Clean label
• Global recognition
PRODUCT APPLICATIONS
Breakfast Cereals
Extruded Snacks
Pasta
Noodles
Bread (Gluten- free & Whole Wheat)
Gluten-free Crackers
Extruded Breakfast CrispsWhole Red Lentil Flour (1% salt, 2.5% sugar)
Pin Mill Coarse Pin Mill Fine Hammer Mill Stone Mill
Bulk Density Texture Bowl Life Sensory Characteristics
Pin Mill Coarse 174.3 580.3 Strong lentil flavour, very hard texture
Pin Mill Fine 120.5 358.3 Strong lentil flavour, chewy on outside, hard on inside
Hammer Mill 200.1 641.6 Mild lentil flavour, crunchy
Stone Mill 176.8 513.8 Strong lentil flavour, quiet “pop”, sticky
Extrusion Processing completed at Saskatchewan Food Industry Development Centre
Breakfast Cereal FormulationBased on previous study results optimizing extruded product quality.• 31.5% Corn Meal
• 56.5% Pea Flour/Semolina
• 6.5% Pea Fibre
• 0.5% Salt
• 5% Sugar
Corn Meal
Pea Flour or Semolina
Pea Fibre
SaltSugar
Breakfast Cereal Formulation
Extrusion Processing-Optimized Product
Whole Pea Semolina
Conditions – rep 1, rep2Water flow rate (kg/h)- 2.1, 2.4Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 537, 650Cutter speed (rpm)- 1178, 1207Temperature (°C)- 107, 109Pressure (kPa)- 700, 300
Refined Pea Semolina
Conditions – rep 1, rep2Water flow rate (kg/h)- 2.1, 2.1Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 655, 655Cutter speed (rpm)- 1079, 1122Temperature (°C)- 106, 106Pressure (kPa)- 400, 400
Whole Pea Flour
Conditions – rep 1, rep2Water flow rate (kg/h)- 2.5, 2.2Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 602, 602Cutter speed (rpm)- 1051, 1221Temperature (°C)- 109, 110Pressure (kPa)- 300, 300
Refined Pea Flour
Conditions – rep 1, rep2Water flow rate (kg/h)- 2.5, 2.5Blend feed rate (kg/h)- 36, 36Screw speed (rpm)- 537, 673Cutter speed (rpm)- 1093, 1122Temperature (°C)- 109, 109Pressure (kPa)- 300, 200
Effects of Processing on Protein Content of Extruded Pea Based Breakfast Cereals
0.00
5.00
10.00
15.00
20.00
25.00
30.00
1. Whole Pea 2. Pea Roller Milling 3. Blending; pea, corn,fibre, sugar, salt
4. Optimized ExtrusionProcessing (as is moisture)
Pro
tein
Co
nte
nt
(%, d
wb
un
less
oth
erw
ise
ind
icat
ed
)
Coarse Semolina Refined Pea Flour Whole Coarse Semolina
Whole Pea Flour Retail Corn Cereal Control Corn Cereal (Cigi)
Yellow Pea Flakes Target
0
1
2
3
4
5
6
Flour Protein Quality/30g(Quantity*AAS*Protein Digestibility
(87.9% PC))
Blend Protein Quality(Quantity*AAS*Protein Digestibility
(87.9% PC))
Breakfast Cereal Protein Quality(Quantity*AAS*Protein Digestibility
87.9)
Qu
alit
y P
rote
in (
g/3
0g
serv
ing)
Coarse Semolina Refined Pea Flour Whole Coarse Semolina
Whole Pea Flour Retail Corn Cereal Control Corn Cereal (Cigi)
Effects of Processing on Protein Quality of Extruded Pea Based Breakfast Cereals
Breakfast Cereals• Advantages
– Gluten-free
– Higher Protein Content and Quality
– Higher Fibre
• Challenges
– Colour
– Flavour
• Solutions
– Blending of grain ingredients
– Processing modifications
Corn MealPin Mill Fine 1 cm
Pin Mill Coarse 1 cm
Hammer Mill 1 cm
Stone Mill 1 cm
Roller Mill 1 cm
Extruded Snacks
Whole Yellow Pea Flour
1 cm
Pin Mill Coarse
Pin Mill Fine
Roller Mill Hammer Mill
Stone Mill
Expansion Index 3.8 3.6 4.9 4.0 4.1
Bulk Density (g/L) 31.8 39.7 17.5 28.4 35.5
Texture (N) 234.4 320.6 138.3 276.3 269.4
Extrusion Processing completed at Saskatchewan Food Industry Development Centre
Extruded Snacks• Advantages
• Extrusion of whole yellow pea flours is more controlled than for the split yellow pea flours. Additional fibre of whole yellow pea flours acts as a nucleation agent and controls air cell size of extrudates.
• Challenges– Direct expanded products made with whole yellow pea flour are
darker in colour and have a greater bulk density than split yellow pea flour.
– Coating with complementary flavours
– Small reference amount, difficult to make protein claim
• Solutions– Bending with other ingredients to improve nutrition, taste and texture
Pasta
• Pulse flour milling to produce low medium and high protein content flour
• Blended with durum semolina 30:70
Pasta
Pasta
Esey AssefawHead Asian Products and Pasta Department
Canadian International Grains [email protected]
Pasta• Advantages
– Increase protein content, quality and nutrient density
– No change in cooking time
• Challenges– Dough crumb sticky, effects extrusion
– Darkening of pasta with HTST drying
– Drying cycle effects pasta cooked firmness
– Soluble proteins leached in cooking water
• Solutions– 2% reduction in water addition for yellow pea semolina
– Use LTLT drying profile to minimize colour changes
– Use fine semolina pulse ingredient and the LTLT drying profile for best appearance and cooked pasta firmness
Noodles
Sandwich sheeting for whole wheat noodles (Cigi Asian Products Department)
Processing method to improve end product quality
standard processing method
- 2 dough sheets are formed at first pass then 2 dough sheets are laminated to form 1 dough sheet on second pass
sandwich sheeting processing method
- 3 dough sheets are formed at first sheet forming pass then 3 dough sheets are laminated to form 1 dough sheet.
Esey AssefawHead Asian Products and Pasta Department
Canadian International Grains [email protected]
Hoppers (where the noodle crumbs go to)
Three rolls in the first pass (sheet formation)
Rolls in the second pass (sheet lamination/compounding)
Sandwich sheeting for whole wheat noodles (Cigi)
3 hrs
24 hrs
Refined WW Sandwich
Sandwich sheeting for whole wheat noodles
Sandwich sheeting
used to improve noodle appearance
used to improve noodle texture
used to increase nutritional profile of noodle products
Gluten-Free Pan Bread
Gluten-Free Pan Bread
Gluten-free Pan Bread
• Improved nutritional profile of the bread– eligible for a dietary fibre nutrient content
claim.
• The addition of pulse flours resulted in breads with a firmer texture and smaller cell diameters compared to the control bread
• Among the three pulse types, the bread containing fava bean flour produced a bread with milder flavor
Whole Wheat Pan Bread Quality
Whole-wheat breads formulated with 15% whole yellow pea flours. Pea flours were milled using four methods
( L to R: Pin Mill Fine, Stone Mill, Hammer Mill, Roller Mill)
Whole Wheat Pan Bread
Yvonne SupeeneHead Bakery Technology Department
Canadian International Grains [email protected]
Whole Wheat Pan Bread QualityDough Properties Pan Bread Properties
Whole Yellow Pea
Flours
Handling after Mixing
Handling at Moulding
Loaf Height (mm)
Overall Bread Quality Score*
(/50)
Pin mill-fine Slightly sticky Non-sticky 124 50
Stone mill Slightly sticky Slightly sticky and slightly stiff
118 48
Hammer mill Sticky Sticky 118 41
Roller mill Very sticky Very sticky 121 38
Gluten-free Crackers• Pulse flours and pea fibre
crackers were more firm and generally thicker compared to the control cracker
• Yellow pea/pre-cooked navy bean best maintained its texture and produced the thinnest cracker
• Crackers made with the yellow pea/red lentil flour produced a cracker with the most desirable flavour
• Pulse flour improved nutritional profile of gluten-free cracker
– Source of fibre claim
Gluten-free Crackers
Key Messages
• Advantages– Complementary protein with cereals
– Sustainable source
– Global recognition
• Challenges– Flavour/texture
– Cost
– Meeting protein claims
• Solutions– Blending ingredients
– Pulse concentrates/isolates
Questions
Heather Maskus
Project Manager
Canadian International Grains Institute