Merseyside fire incident reduction partnership project update
Reduction 2020 Technology Update
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Transcript of Reduction 2020 Technology Update
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Reduction 2020TechnologyUpdate
StefanTöpflDeutschesInstitutfürLebensmitteltechnike.V.
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• Functionalization• Structure modification• Fermentation
Salt,fat and sugar reductionStrategies
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Saltreduction
Example:Proteinfunctionalization bypressure
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Reduction of salt content inarange of 1.2– 2.2%
Abb.1:Drip loss (%)of scalded sausage with varying salt content
• WHC– drip loss
èReducing salt contentresults inlower WHC
Lowsalt meat productsScalded sausage
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Serotype 4b(3987/04)
p-T isokineticity diagrams for 5 log inactivation of 3 pathogenic strains of Listeria monocytogenes in “Black Forest Prosciutto” (Ham) after 15-240 s.
Serotype CLIP 74903Serotype CLIP 74902 1/2a
HighPressure ProcessingMicrobial inactivation
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Oligomeric Structure
Monomere Structure
Intermediate, melted state
Unfolding
Aggregation
0,1 MPa 100 – 200 MPa > 700 MPa300 – 500 MPa
Pressure treatmentImpactonproteins
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Abb.3:(1)Control,(2)HPP100MPa– Saltaddition prior to HPP,(3)HPP400MPa– Saltaddition prior to HPP,(4)HPP100MPa– Saltaddition afterHPP,(5)HPP400MPa– Saltadddition afterHPP,(6)Saltand phosphateaddition (0,06%)
• Saltcontent 1.8%• 100 MPa
• 400 Mpa
• No phosphate (except 6)
Nr.2und6
• Good structure• Good WHC
1 2 3 4 5 6
Lowsalt meat productsHPPconditioning
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Ø Declarationwiththeclaim“reducedinsalt”ispossible
Cooked sausage Cooked ham
NaCl 1.26% 1 % 1.33 % 1.1%Phosphate 0.25 % 0.25 % 0.25% 0.25%KCl - 0.26% - 0.2%Processconditions
- - 100MPaaftertumbling
100MPaaftertumbling
Finalsaltreduction
30% 45 % 30 % 42%
Lowsalt meat productsResults
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Fat reduction
Example:Replacing fatby lean meat
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HighPressure ProcessingHPPstructure modification
HPP treatment of lean meat (e.g. turkey breast or thigh)
• 600 MPa 3 min at ambient temperature
• Freezing
• Use to replace fat or lard in meat products
Benefits
• Reduction of fat content < 10 %
• No use of plant based oils or other animal types
• „Clean-Label“ – no gums, thickeners or fibers
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DIL– HighProSticks•Proteincontent >50%(dependent onmoisture removal)
•Fatcontent<10%•Fitness,bodybuilders,kids …
ExampleformulationTurkeythigh70%Turkeybreast(600MPa,3min)30%Curingsalt2,0%Dextrose0,25%Pepper0,2%Startercultures
HighPressure ProcessingHPPstructure modification
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Fat reduction
Example:Reducing fat indispersesystems
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Example of a high pressure gap
Stansted Fluid Power HydLok
• pressure up to 400 MPa
• 2 – stage pressure system
• 100 l/h continuous flow rate
• 15 kW power consumption
• 8 bar pneumatic air supply
HighPressure HomogenizationEquipment
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Structuralmodification
• Particlesizereduction(Nanoparticles,nanosuspensions)
• Modificationofconstituents(proteins,starchetc.)
Foodpreservation
• Reductionofmicrobialload• Enzymeinactivation
control 100 MPa
200 MPa 300 MPa
HighPressure HomogenizationEquipment
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1. Preparation
- Water 56 %
- Egg yolk (PLA2 modified)* 8 %
- Sugar 2 %
- Mustard 1 %
- Salt 1 %
2. Oil addition and acidification
- Slow oil addition 28 %- Vinegar 3 %
- Citric acid 1 %
3. Homogenisation
- Variation of pressure level (100-350 MPa)
HighPressure HomogenizationLowfat mayonnaise
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0,1 mm
0,1 mm 0,1 mm
APV (18/5 MPa)
300 MPa200 MPa
100 MPa
0,1 mm
300 MPa200 MPa
100 MPa
Light microscopyConfocal laser scanning microscopy (CLSM)
APV (18/5 MPa)
HighPressure HomogenizationLowfat mayonnaise
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Flow rate: 360 l/h
Max. Pressure: 3800 bar (380 MPa)
Input Power: 56 kW
UHPHequipmentDILdevelopment
High pressure pump
Valves:
1st Stage und 2nd Stage
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Fat reduction
Example:Reducing fat uptake duringfrying
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PEFtreatment influences the structure of potatoes
Pulsed Electric FieldsStructure impact onfat uptake
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Pulsed Electric FieldProcessingCutting improvement
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Productquality
• Texturesofteningandsmoothercut
• Higheryield(lessbreakage),Longerfries
• Reducedoiluptake(upto10%)
• Possibilitytodevelopnewcutsandshapes(e.g.Latticecut)
Processing
• Energyandwatersavings
• Increasedknifedurability(upto60%)
PEF
Oilcontent
5.7% 5.1%
Pulsed Electric FieldProcessingBenefits for FrenchFriesProcessors
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Productquality:• Reducedfat→smoothercut→countercurrentmasstransfer
• Crisperchip
PEF
OilcontentFryingtime:– 25%
Fastermoisturerelease→shorterfryingtime
0
2
4
6
8
10
12
14
16
160 180 200 220
Moisture%
Fryingtimeat175°C[s]
untreated PEF
Fryingtime:– 25%
0
2
4
6
8
10
12
14
16
160 180 200 220
Moisture%
Fryingtimeat175°C[s]
untreated PEF
1%
Fryingtime:– 25% 38.3% 25.5%
Pulsed Electric FieldProcessingPotato Snacks
-33 %
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Equipment design
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Sugarreduction
Example:Replacing sucrose by othersugars /sugar alcohols
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SugarremovalBakery products
Pleasure Project, Le Bail, 2015
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Dough rheology:Nativeegg(55%)foamed with Saccharoseor Fructose(45%)with addition of 25%wheat flour and 0,5%salt
SugarreplacementBakery products
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SugarreplacementBakery products
DSC:Nativeegg(55%)foamed with Saccharoseor Fructose(45%)with additionof 25%wheat flour and 0,5%salt
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Globuar proteins
native
Heat
Shear
unfolded denaturéd
60 – 70°C > 80°C
Stable due to
molecular interactions
Stabilized by covalent
bonds (-S-S-)
poss.
reversible
Instable, potential for
interactions and reactions
SugarreplacementProteindenaturation
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Fructose SaccharoseSugar alcohol
Xylit
SugarreplacementBakery products
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Colour (Melanoidins)
Volatiles, roasted and bitter flavours
Saccharose: non-reducing sugar
Maillard Reaction
Non-enzymatic
reaction of
sugars and
amino acids
SaccharoseFructose
!
SugarreplacementBrowning
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Sugar alcohols
à No reducing sugar
à no Maillard-Reaction?!
Water removal during baking: 2
à increased reactivity
à dehydration
à Maillard-Reaktion
Slow reaction with complex
reaction paths
Sugar alcohol
Xylit
Xylit
SugarreplacementBrowning
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25°C 35°C 45°C 55°C
65°C 75°C 85°C 95°C
Dough with Saccharose
SugarreplacementBaking
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25°C 35°C 45°C 55°C
65°C 75°C 85°C 95°C
Dough with Fructose
SugarreplacementBaking
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Dough with
Fructose
25°C 95°C
Dough with
Saccharose
SugarreplacementBaking
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Sugarreduction
Example:Reducing sugar byfermentation
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SugarreplacementEnzymatic hydrolysis
Pleasure Project, Le Bail, 2015
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SugarreplacementEnzymatic hydrolysis
Pleasure Project, Le Bail, 2015
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SugarremovalFruit products
In purees up to 30 % reduction reached, no significant change in fruit ingredients.
Pleasure Project, Lötzbeyer, 2015
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SugarremovalFruit products
Pleasure Project, Lötzbeyer, 2015
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SugarremovalFruit products
Pleasure Project, Lötzbeyer, 2015
Biotechnological approach for sugar reduction processes, other reaction
pathways e.g. gluconic acids possible as well
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Structure design
Example:Snackand highmoistureextrusion
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Extrusion
65 % protein concentrate (soy, pea, dairy, algae…)
35 % waterFat free impingement or mold baking
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Targeted processing allows structure modification and functionalityenhancement:
• Pressure induced protein unfolding can increase water binding capacity andallow partialreplacement of salt
• Reduction of lipid droplet size by ultra highpressure homogenization allowsviscosity increase and reduction fat content
• Structure modification of planttissue results incutting improvement andlower fat uptake
• Sugarreduction can be achieved by replacement or fermentation
• Extrusionallows designof low fat carbohydrate and protein based structures
Conclusions