Low fat industrial margarine products

ByPernille Gerstenberg Kirkeby

Manager of Technology and Marketing

Agenda

• Why low fat products?• Industrial products: puff pastry margarine

cake margarinecream margarine

• Crystallisation process• Optimal processing recommendations• Trends

Why low fat?The price of commodities has increased dramatically due to boom in bio-fuel, other emerging applications and markets.

Low fat: 63,200,000 hitsLow fat margarine: 1,620,000 hitsLow fat industrial margarine: 279,000 hits

Why low fat?• Past 40 years market for low fat spreads• Healthy lifestyle by decreasing the caloric intake • Compromise in functionality and quality ?

• Industrial products of interest now

Quality

Stability High VariesHigh

Complex Poor and good

Poor melting and taste

Future Present Past

Low fat products

• Spreads: Nice appearance, good texture, good stability, nice mouth-feel and taste

• Industrial products: Nice appearance, good texture and performance

PerformanceAccording to application

Puff pastry margarine • Barrier fat promotes lift and

volume in baked goods

Cake and cream • Crumb structure and volume

aeration of cream (whippability)

Fat reduction solutions

Fat reduction solutions

TexDesignTM (patent application pending) –carbohydrate-based fat replacement system that achieves the full functional and sensory characteristics of traditionally baked goods.Replaces oil or margarine in current recipe as a dry mix.

Fat reduction solutions

How low can you go? Various emulsifier and stabiliser solutions are available for low fat products. Puff pastry margarine containing 40% fat produces excellent baking results compared to standard full fat systems.Grindsted® FB 850K (pectin/alginate)Grindsted® PS 404Grindsted® PGPR 90

Fat reduction solutions

Low salt – great taste?A revolutionary taste potentiator, Maxarite™, enables salt reduction and provides strong taste improvement in a range of bakery and dairy applications. All can be reformulated in line with ‘better for you’ trends and deliver at the same time sensory eating enjoyment.

Fat reduction solutions

Reduced and low fat solutions are available. Solutions improve volume in finished product regardless of fat content. Puff pastry margarine containing 60% fat + a combination of 2 emulsifiers showed improved expansion in puff pastry and better mouth feel compared to 80% reference. Palsgaard® 1311Palsgaard® 0291

Crystallisation line

Crystallisation

Consistency of fat products depends on: • SFC profile• Type of emulsifier• Crystallisation habit and rate• Optimal processing • Possible correct tempering

Optimal processing

Fat blend

Emulsifier

ConfigurationProcessingparameters

Tempering

Practical issues

Product residence time

0.37-0.56-145Shortenings

0.62-1.12-110-145Low fat spreads

0.56-110-145Soft table margarine

0.5636-7236-72Table margarine

0.8-1.4360-5406-9 min

60-1801-3 min

Puff pastry margarineApprox. time in min.

Capacity (m2 required *)

Resting Tube(sec)

Pin Machine(sec)

* Per 1000 kg/h

Trends

• Cold extrusion• High pressure processing • Non and low trans FA products • Low fat products (including butter)• Very low fat products (20%)• Functional foods (Sterol, DHA, Calcium) • Fluid or pumpable shortening• Sophisticated products

Trans FA issue

Global trend → reduction of trans fats in foods

Market drives:• Large food suppliers • January 2006

FDA fat labelling• January 2004

Danish legislation

Trans free products

Interesterified

Non hydro

CombinationsFully hydro

Fractionated

Process

Processing trans free products

In general:1. change of configuration 2. lower capacity 3. lower packing or filling

temperature4. relatively easy to

process filled products5. pilot plant trials often

required

Interesterified based:1. less oxidative stable 2. softer consistency3. tendency to overwork →

less pin volume or less intensive kneading

4. longer tempering time

Low trans puff pastry margarine

• High palm stearin blend containing 80% and 60% fat in emulsion

• Low trans FA recipe• 60% puff pastry is an interestering

alternative to the traditional 80% puff pastry margarine due to current high cost of e.g. oil

Recipes

1.51.5Salt2.0-Pectin

34.716.7Water0.80.8Lecithin1.01.0Emulsifier7.510.0Liquid oil

15.020.0RBD palm37.550.0Palm stearin

60%80%

After tempering at 18°C for 3 daysEvaluation:• Kneading test• Baking test

Results: • Similar plasticity • 60% slightly moist

when kneaded • Similar baking

performance• 60% is appearing flaky

and less fatty

Final remarks

• Various optimisation possibilities exist in regard to processing of crystallised products containing high palm content

• Trans FA question is answered but initiates a renewed discussion concerning acceptable level of saturated FA (and which SAFA) in respect to good health