Post on 03-Jun-2018
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Pulse-milling:Wet and dry fractionation
applications of peas, lentils andchickpeas in gluten-free foods
Mehmet C. Tulbek, Ph.D.
Technical Director
Northern Crops InstituteFargo, ND
Institute of Food Technologists 2010 Annual MeetingGluten-free foods: Opportunities and challenges
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DRY PEAS, LENTILS and CHICKPEAS
Base ingredient in gluten free foodsHigh protein & dietary fiber
Non GMO
Poor allergen
Low glycemic index
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COMPOSITION OF PEAS, LENTILS & CHICKPEAS
Dietary fiber ≅ 25‐35
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WORLD DRY PEA PRODUCTION (MT)
Source: FAOSTAT 2008
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Major Exporters
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WORLD LENTIL PRODUCTION (MT)
Source: FAOSTAT 2008
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Major Exporters
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WORLD CHICKPEA PRODUCTION (MT)
Source: FAOSTAT 2007
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Major Exporters
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FEASIBLE TO FRACTIONATE ?
Pin Milling, Air Classification and
Fractionation
Lentils and chickpeasStrong and growing market due to changingworldwide agricultural practices
Dry peas (yellow)Price & functional advantages
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GROWER PRICES – JULY 16th 2010
Lentils – $ 25-32 / CWT
Chickpeas - $25-30 / CWT
Green peas – 8-9.5 / CWT
Yellow peas – 6.25-8.00 / CWT
CWT = 100 lbs = 44.5 kg
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LITERATURE OVERVIEW
Pin Milling & Air Classification
Significant research conducted in 1980s
Tyler (1982), Tyler (1984) and Tyler andPanchuk (1982).
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LITERATURE OVERVIEW
Air classification and protein-starchfractionation is similar in all pulses exceptchickpea (Han and Khan 1990).
High fat content
Based on variety 5-8% fat content
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DRY FRACTIONATION PROCESS
Fractionate protein, starch and fiber components indry milling process
Fractionation is conducted based on particle size.
Dehuller
Pin mill / jet mill
Air classification REQUIRED EQUIPMENT
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DRY FRACTIONATION PROCESS
DehullingKey process for the removal of 97-98% of thefiber portion
Dry fractionation
Protein & starch separation
Pin mill OR jet milling
Air classification
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FLOWCHART
Dehulling
– whole
peas
Pin milling – split (dehulled)
peas
Air classification – split
(dehulled) pea flour Packaging
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DEHULLING
Removal of outer kernel
Easier to conduct in peas and lentils
Much difficult process in edible beans andchickpeas due to crop characteristics
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DEHULLING
Impact dehulling
Stone dehulling
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DEHULLING
•1000 kg Dry Pea (%9 Hulls)•90 kg pea hulls removed
•910 kg dehulled or split peas
•Pea hulls are rich in terms of insoluble fiber.
•%85 Insoluble fiber
•%15 Soluble fiber
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DRY FRACTIONATION
•910 kg dehulled or split peas•Pin milled
•High speed pulverizer•%100 under 350 mesh (60 micron)
•Very fine material
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Pin mill
Courtesy
of
Particle
Control LLC
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AIR CLASSIFICATION
•Fluidized tower system
•Particles in vacuum
•Separation based on particle size•2-20 micron - Protein concentrate
•20-40 micron – Starch concentrate
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Air
Classification
System
Courtesy
of
Particle
Control LLC
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Air
Classification
System
Tower and
Dust Bag
Courtesy
of
Particle
Control LLC
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Heavy
Fraction
Starch‐rich
Flour
Courtesy
of
Particle
Control LLC
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Light
Fraction
Protein‐rich
Flour
Courtesy of Particle
Control LLC
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PROCESS OUTCOME
•1 MT = 1000 kg
•90 kg pea hulls•546 kg starch concentrate
•364 kg protein concentrate
•Without any moisture loss (theoretical)
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PROCESS OUTCOME
•1 MT = 1000 kg•6% moisture loss
•940 kg pea flour
•84.6 kg pea hulls
•513.24 kg starch concentrate
•342.16 kg protein concentrate
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Moisture Ash Protein Starch Fiber Lipid APC Mold Yeast
(%) (%) (% dm) (% dm) (%) (%) (CFU/g) (CFU/g) (CFU/g)
Pea hulls 8.2 2.1 2.0 <1.0 >85 0.1 1200 50 20
Split Peas 12.1 2.5 26.5 50.5 1.0 2.2 1000 200 50
Pea Flour 7.2 2.5 26.3 50.1 0.9 2.2 6200 70 30
StarchConcentrate 9.2 1.7 12.4 73.1 0.8 0.7 820 30 10
ProteinConcentrate 8.7 4.6 53.5 8.0 1.0 2.2 500 200 40
DRY FRACTIONATIONINGREDIENT SPECIFICATIONS
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WET FRACTIONATION PROCESSES
Fractionate protein, starch and fiber components indry & wet milling process
Dehuller
Hammer mill
Soaking tanks REQUIRED EQUIPMENT
Decanter
Spray / drum drier
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WET FRACTIONATION PROCESSES
Dehulling
Key process for the removal of 97-98% of thefiber portion / same as dry fractionation
Wet fractionation
Protein & starch separation – high purity
Hammer milling
Soaking and acid-base treatment
Decanter – filtration - spray or drum drying
Packaging
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Dehulling – whole peas
Hammer milling – split
(dehulled) peas
Soaking – split (dehulled)
pea flour
(pH
= 10)
Removal of starch
& protein
Precipitate
solubilized protein
(pH=4.5)
Drying
Starch
&
Protein
Drying
Protein
Packaging
#I#2
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WET FRACTIONATION
•1000 kg peas•Dehulling – remove 90 kg hulls
•910 kg dehulled or split peas•Milling
•High speed pulverizer, or hammer mill
•%100 under 100 mesh
•Fine material
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DEHULLING
Impact dehulling
Stone dehulling
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WET FRACTIONATION
Solubilization of pea proteins, sugars and lipids bybase solution (NaOH solution, pH=10.5-11.0 for 1h.extraction)
Removal of starch & protein by decanter orultrafiltration
Protein can also be held at pH=4.5 for
precipitation
Protein and starch are dried by fluidized bed drieror spray drier.
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Decanters
Starch &protein removal
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Decanters
Starch &protein removal
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Separation
decanters
16 level
99.9% starch and85%protein purity
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Spray drier
Proteindehydration -
drying
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Drum drier
Starchdehydration -
drying
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Moisture Ash Protein Starch Fiber Lipid APC Mold Yeast
(%) (%) (% dm) (% dm) (%) (%) (CFU/g) (CFU/g) (CFU/g)
Peahulls 8.2 2.1 2.0 <1.0 >85 0.1 1200 50 20
Split
Peas 12.1 2.5 26.5 50.5 1.0 2.2 1000 200 50
Peafiber 10.0 2.2 2.1 <1.0 >85 0.2 6200 70 30
Pea
starchisolate 11.0 0.1 0.4 >98.0 0.1 0.1 820 30 10
Peaprotein
isolate 11.2 4.2 >85.0 <1.0 1.1 2.1 500 200 40
WET FRACTIONATIONINGREDIENT SPECIFICATIONS
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CHINESE VERMICELLI NOODLE MAKING
Traditional & long process
Mung bean or dry pea
Soaking in tap water
Then acid addition
h Gl b l k l
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CHINESE VERMICELLI NOODLE MAKING
C i i h Gl b l M k l
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CHINESE VERMICELLI NOODLE MAKING
C ti i th Gl b l M k t l
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CHINESE VERMICELLI NOODLE MAKING
Liquid starch sent directly to starchnoodle process
Extrusion
C ti i th Gl b l M k t l
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CHINESE VERMICELLI NOODLE MAKING
Starch is gelatinized
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CHINESE VERMICELLI NOODLE MAKING
Drying vermicellinoodles
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PEA HULLS (PEA FIBER ISOLATE)
GLUTEN FREE END USE
High water binding capacity
Modifies texture
Veggie burges, hamburgers, sausages,nutritional bars, sauces, fillings, bakedproducts
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PEA PROTEIN RICH FLOUR
(PEA PROTEIN CONCENTRATE)
High level of functionality,
bioavailability and lysine content.Bland taste
Good alternative to soy flour/proteinconcentrate (Non GMO and non allergen)
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PEA PROTEIN CONCENTRATE
Beverages
Granola bars
Baby foods
Pasta
TVPs
Meat products - sausages
Veggie burgers
Baked goods
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PEA STARCH RICH FLOUR(PEA STARCH CONCENTRATE)
Rich source of starch (>%72)
Good source of protein (%12)
Acid, retort and shear stable similar tomany modified starches
Improves texture in gluten free bakedproducts
Increases volume/expansion in extrudedproducts
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PEA STARCH CONCENTRATE
PastaBaked products
Batters and coatingsExtruded snacks
Fillings and dressings
Soups, sauces
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PEA PROTEIN ISOLATE
High level of functionality, bioavailabilityand lysine content.
>%85 Protein, %3 Fat, %4 Ash
Good alternative to soy protein isolate(Non GMO and non allergen)
TVPs, beverages, granola bars, babyfoods, pasta, baked products, dressings,
meat products, veggie burgers
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g p
PEA STARCH ISOLATEExcellent gel strength and bland taste
>%98 purityGelling and film forming properties
Vermicelli noodle
Excellent acid, retort and shear stable similar tomany modified starches
Improves crispness in baked products
Increases volume/expansion in extruded products
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g p
CONCLUSION
Pin milling, air classification and wet fractionation
processes can be used in dry pea, lentil and chickpeaprocessing.
Raw material availability, sustainability and price
Dry yellow peas can be utilized based on marketneeds
Vermicelli noodles, TVPs
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8/12/2019 Gluten Free Pulse Milling Wet and Dry Fractionation Applications of Peas Lentils and Chickpeas in Gluten Free Foods
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THANK YOU
Mehmet Caglar Tulbek, Ph.D.Technical Director
Northern Crops Institute
North Dakota State University1240 Bolley Dr. Fargo, ND 58102
Phone: 701-231-5493
Fax: 701-231-7235
Email: mehmet.tulbek@ndsu.edu
http://www.northern-crops.com