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--
Ways to help reduce Wastage
in the Dairy Food Chain
Stephen Bullin – Business Manager for Sub Saharan Africa
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Wastage
FreshQ®
Keep IT
Extended Shelf Life Yoghurt - ESL
Bio Safe for cheese
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Be profitable Large value potential in scrap reduction in production, distribution & consumption
3
Global Food Losses and Food Waste (2011); Food and Agriculture Organization of the United Nations
Loss and waste of food is a global concern with significant impact on economics and social welfare
180 175 160 160 180
110
200
100 120
80
5
30
15
20
Europe NorthAmerica &Oceania
IndustrializedAsia
Sub-SaharanAfrica
North Africa,West &
Central Asia
South &Southeast
Asia
Latin America
Per Capita loss and waste of food (KG/year)
Supply Chain Waste Consumer Waste
4
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Shelf life is pushed to the limit
Complaint
YES
NO
Re-purchase
YES
NO
Spread word
YES
NO
Source: CH internal survey
5
Product spoilage before end of shelf life can be a silent
brand killer…
Consumers will stop buying and spread the word, but not
necessarily file a complaint!
6
All Natural and Clean Label is a major global trend !
6
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Wastage
FreshQ®
Keep IT
Extended Shelf Life Yoghurt - ESL
Bio Safe for cheese
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Benefits of FreshQ®
Better quality during shelf life
Quality defects is the silent killer..
Potential Shelf life extension
Optimize “open” shelf life
Consumer experience
Natural alternative to preservatives
Clean label
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Mode of Action: What is known from literature
9
LAB have potential for being effective in
combating food borne yeast and mold
Fungi-static effect
A moderate level of antifungal activity is a
relative common property of LAB
Isolates with higher activity than
average can be found with reasonable
frequency
Adequate screening/ application assay
Majority of isolates with high antifungal
activity belong to the genus lactobacilli
Three mechanisms involved in antifungal
efficacy
Antifungal activity mechanisms and
interactions are complex and difficult to
elucidate
Competition for nutrients and space
Cell interaction
Cell communication
Production of antagonist compounds
Peptides, H2O2, diacetyl, benzoic
acid Phenyl-lactic
acid…
Yield of organic acid
Lactate, Acetate
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FreshQ® 2 and 4 inhibit yeast Example: Debaryomyces hansenii (50 cfu/g) in yogurt stored at 7ºC/45ºF
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Number of days until first mold growth is visible (average of two cups):
Still no growth
on day 51
FreshQ® 2 and 4 increase time to visible mold Example: FreshQ® 2 in Greek yogurt 1,5% fat
Challenge test with high contamination level: 1000 spores/spot!
Penicillium commune
Aspergillus versicolor
P. palitans
P. crustosum
P. paneum
P. palitans
P. paneum
P. roqueforti
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Reference
FreshQ® 2
7ºC/45ºF 12ºC/54ºF 22ºC/72ºF
FreshQ® 4
FreshQ® 2 & 4 work over a broad temperature range Challenge test with P. crustosum added at 1000 spores/cup and stored 36 days
FreshQ® as replacement of sorbate in yoghurt
--
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The antifungal efficacy of FreshQ® versus sorbate in Yogurt FreshQ® generally has comparable antifungal effect to potassium sorbate levels in the range 0.2 – 0.4 % (w/v)
Yoghurts made with different levels of potassium sorbate (PS), with FreshQ® (100U/T) or
without (Reference) and spiked with different molds (approx. 500 spores/cup) followed by
60 days storage at 7C
Reference FreshQ® 2 0.1% PS 0.2% PS 0.4% PS
P. crustosum
P. discolor
14
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Wastage
FreshQ®
Keep IT
Extended Shelf Life Yoghurt - ESL
Bio Safe for cheese
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FD-DVS KeepIT 1.0
Primary benefit is low post-acidification at elevated storage
temperatures which translates into better quality within
shelf-life or even extended shelf-life.
Culture provides good gel structure, low ropiness and
medium flavor in set yogurt
Fermentation:
Milk: 1.5% fat & 4% protein
Inoculation: 500U/2500L
Temperature: 43ºC
16
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Post acidification at elevated temperatures
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Wastage
FreshQ®
Keep IT
Extended Shelf Life Yoghurt - ESL
Bio Safe for cheese
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What is Extended Shelf-Life Yoghurt?
Extended Shelf-Life (ESL) Yoghurt is simply stirred Yoghurt that undergoes a
thermisation stage after fermentation
Products are packaged into clean packaging and are stable at ambient
temperatures
The products can be plain and unsweetened but in most cases are
sweetened and flavoured
Differ from UHT Yoghurt drinks in that they have thicker texture and
equivalent protein levels of a fresh, stirred Yoghurt
20
Long Shelf Life & Convenience
Distribution
Cool Chain integrity less
important
Export
Wider geography
Reduction of
Y & M
Enzymes
Bacteria
Contaminants
Post Acidification
Why go the ESL route ?
22
Technical Commercial
Process Line
23
Wide Aperture Plate
Heat Exchanger
Tubular Heat
Exchanger
24
Heat Treatment
75°C for 15 seconds is sufficient to eliminate both S. thermophilus
& Lb. bulgaricus
Heat treatment up to 80°C / 30s does not influence concentration
of volatiles* compared to reference yoghurt
* Acetaldehyde, Acetone, Ethanol, Diacetyl, Acetoin
Heat-treatment ST (cfu/g) LB (cfu/g)
75 °C/15s 0 0
85 °C/15s 0 0
95 °C/15s 0 0
85 °C/ 300s 0 0
Reference (2 bar PTU) 6.3 x 108 4.7 x 108
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Base Formulation
Base formulation is crucial to product quality, but unlike fresh stirred
Yoghurt goes beyond milk protein alone
Pectin is utilised to protect the coagulated milk protein during post
thermisation stage and prevent syneresis
Starch is necessary due to high-shear in process
Gelatine can be used although we see a trend away from this ingredient
Gellan Gum is effective for smoothness and viscosity
Culture selection is also an important consideration
26
Recipe Optimisation
27
For a sweetened recipe, the
following formulation has proven
effective :
2.8 % Milk protein
6.0 % Sugar
1.50 % Modified Starch
0.15 % LM Pectin
0.03 % Gellan Gum
0.02 % YoFlex YF-L901
Milkbase Mod.
Starch
(%)
Pectin
(%)
Gellan
Gum (%)
A 1.50 0.30 -
B 1.50 0.15 0.03
C 1.75 0.15 -
Effect of Strike pH
28
Lower cut pH gives
improvement in both texture
& appearance
Yoghurt heat-treated at 80°C/15s
From left to right; cut pH 4.60, 4.50, 4.40
Culture Selection
29
As with any Yoghurt, the culture used will impact upon the flavour,
texture, acidity and fermentation time
Due to heat-treatment post-acidification is not a consideration
ESL yoghurts tend to have a mild flavour profile
A culture is required which will drop to pH 4.3
Any contribution to texture from EPS can be beneficial as product
relies on hydrocolloids for stability
The ideal culture therefore needs to impart:
Acidification to pH 4.2 Moderate to high EPS Mild flavour profile
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Culture selection - YoFlex® Range
Yoghurt flavor intensity
Viscosity (mouth thickness)
Low
Very mild Very strong Medium
Extra high
High
YC - X 11
YC - 183
YC - 190
YC - X 16
YC - 180
YC - 280
YF - 203
YF - L800
YF - 202
YC - 470
YC - 471 YC - 370
YC - 380
YC - 381
YF - LX700 YF - LX701
YF - L702
YF - L703
YF - L811
YC - X 11
YC - 183
YC - 190
YC - X 16
YC - 180
YC - 280
YF - 203
YF - L800
YF - 202
YC - 470
YC - 471 YC - 370
YC - 380
YC - 381
YF - LX700 YF - LX701
YF - L702
YF - L703
YF - L811
YF L812 -
YF L901 -
YF L902 -
YF L705 -
YF L706 - Very high
YF L903 - YF L904 -
Advance 1.0
Advance 2.0
Mild 1.0 Classic 1.0 -
Premium 1.0
YF-3331
Part of range most
relevant to PPY
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31
Wastage
FreshQ®
Keep IT
Extended Shelf Life Yoghurt - ESL
Bio Safe for cheese
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New BioSafe culture range
for natural ripened cheese
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Late blowing
Late blowing is a serious defect associated with mainly brine salted semi-
hard and hard cheeses
Caused by Clostridium spp. particularly C. tyrobutyricum
2 Lactate butyrate + 2 H2 + 2 C02
If no measures are taken to inhibit clostridia growth, it is recommended to
have <10 spore per 100 ml cheese milk (<1 spore/g cheese).
33
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Removal of spores from milk
Bactofugation (98%)
Micro filtration (99,9%)
Prevention of growths by additives
Nitrate
15g/100 l milk sufficient to prevent <10.000 spores/l
High heat treatment (82°C/20 s) inactivate xanthine oxidoreductase
which convert nitrate to nitrite and prevent use of nitrate
Lysozyme
Ways to prevent late blowing
Gel
Curd
Ripened cheese
Milk
Consumer
BioSafe for inhibition of clostridia Potentially in combination with bactofugation
if clostridia level in milk is high
34
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BioSafe challenge test example
Control* + BS-10 50 spores + BS-10
50 spores 25 spores
*Control means no clostridia spores added,
so only the natural content in the milk.
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Nisin levels obtained in cheese trials
36
Continental customer trial Germany
Dosage: 45U/10.000 l
Edam customer trial Poland
Continental pilot plant trials (DK)
Vat no. Culture Nisin (mg/kg)
3 BS-20 2,0
10 BS-20 1,4
17 BS-20 1,6
23 BS-30 2,9
30 BS-30 3,1
37 BS-30 2,0
63 BS-10 3,0
77 BS-10 1,0
Vat no. Culture Nisin (mg/kg)
6 BS-20 0,42
12 BS-20 1,04
18 BS-30 1,54
25 BS-30 2,62
BS-10 BS-20 BS-30
Nisin (mg/kg) after brine 8,0 6,5 7,6
Nisin (mg/kg) two weeks
3,9 1,2 0,7
Nisin (mg/kg) 6 weeks
3,1 0,5 1,0
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BioSafe mode of action
Concentrated strains of Lactococcus lactis subsp. lactis
Metabolic activity results in production of nisin during the cheese process
Nisin is a known bacteriocin that inhibits gram+ anaerobic spore formers
Sold as F-DVS BioSafe BS-10, BS-20 and BS-30 in 10x65 unit bags
Dosage recommendation: 20-25 U per 5.000 l milk
37
Spore
Germination
Vegetative
growth
Sporulation
NOTE: Nisin kill bacteria via pore
formation in cell-wall following
binding with Lipid II in different
pathogen, like listeria and clostridia.
Similar to lysozymes, nisin mode of
action also target vegetative cells
and has no effect on their spores.
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Thank You
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