IFTSA & Mars Product Development Competition

Transcription

1 IFTSA & Mars Product Development Competition Preliminary Proposal February 1, 2014

2 Product Description: Popples is a better-for-you extruded snack that combines a crunchy apple pomace-based pop with a caramel-flavored coating and peanut topping to create a product that is both satisfying and nutritious. Popples unique formulation and processing create an enjoyable snack that is an excellent source of dietary fiber, a good source of protein, and high in antioxidants, while keeping the calorie count at a reasonable 120 calories per serving [1, 2]. Each serving of Popples (35g) is individually packed for portability [3, 4]. As a shelf stable, on-the-go, sustainable, and healthy snack, Popples delivers an exciting POP! to everyday snacking. Originality: Popples reinvigorates the familiar flavor profile of caramel apples to create a novel, shelf stable, better-for-you snack. An online concept Figure 1. Nutrition Facts Panel survey (n=307), featuring a conjoint analysis, was used to determine desired product attributes based on puff shape, coating type and flavor. Our product was designed to feature multiple flavors and textures; a crispy apple pop, surrounded by a soft caramelflavored coating, and topped with crunchy peanut morsels. Popples use of apple pomace and soy protein creates a product that stands out in terms of sustainability and nutritional composition. More than an original product, Popples is an original solution to the problem of wasted apple by-product. It utilizes apple pomace, which consists of the peels and flesh of pressed apples used for juice production, to deliver fiber and antioxidants to the final product [5, 6, 7, 8]. In addition, supercritical CO 2 extrusion (100 0 C) better maintains the antioxidant activity of pomace, while

3 imparting a unique puff texture characterized by a micro-porous interior and smooth surface, when compared to steam extrusion ( C) [9]. Overall, Popples differentiates itself from other extruded products with its higher levels of fiber and protein, which promote satiety. Marketing: Marketing will focus on Popples great taste, as well as its protein and fiber content, two nutrients which consumers rank as very important attributes in healthy snacks [10, 11]. Popples aims to appeal to the 65%, 24%, and 5% of consumers looking for healthy, gluten free, and vegetarian/vegan snacks, respectively [10, 11, 12, 13]. The product will be sold individually, and in multi-packs in the future, to facilitate convenience. Popples will primarily be marketed to millennials, aged 18 to 34, who are looking for healthy, single-serve pouch snacks that fit their on-the-go lifestyle and established snacking routine. Additionally, Popples will be marketed to baby boomers, aged 48 to 67, whose immense buying power and focus on increasing fiber in their diets make them an ideal secondary market [14, 15]. Profitability: Popples will compete in two market segments, Specialty Foods: Snacks, and Gluten Free Food and Drink, as classified by Mintel [12, 16]. The target market shares in these segments are 0.2% and 0.1%, respectively, totaling to $12.46M (Table 2). Popples will be sold at a competitive price of $1.25 per individual pack. Given its appealing nutritional facts and innovative flavor profile, Popples projects a

4 breakeven point in the first quarter of Year 2, calculated with a 25% manufacturer profit margin, resulting in an estimated 5-year ROI of 61%. The initial launch of Popples will occur in the Northeastern US, where apple processing is popular, allowing greater flexibility in procurement and inventory preparation [17]. Process Description: Food grade wet apple pomace, clearly identified by lot number, date received, and expiration date, is received from a local, audited apple juice processing company (Appendix I). After undergoing inspection for safety and quality, the pomace is loaded into tray dryers (J.K. Ind., SS Tray Dryer) and dried at 40 o C for 48 hours to a moisture content of 6-8% [18]. The dehydrated pomace is then finely ground using a hammer mill and passed through a 0.79 mm screen (W.J.F. Co., D Comminuting Machine) [19]. The pulverized pomace is next mixed with additional ingredients (Stephan Machinery, VCM60E), and stored under controlled conditions to be used as needed (Table 1) [20, 21]. The product mix is added to the hopper of the supercritical fluid extruder (SCFx) (Wenger, Modified TX-52) and hydrated to a dough (35% moisture w/w) [22]. It is then passed through the SCFx at a feed rate of 71 kg/hr (L/D = 27:1, screw speed = 100 rpm), which heats the dough to 100 o C via viscous dissipation. In the final stage of the extruder, supercritical carbon dioxide (>31.1 o C, >7.38 MPa) is supplied by a custom supercritical CO 2 pressurizing unit (Autoclave Engineers) [23, 24]. The supercritical CO 2 is fed into the extrudate at a constant rate of 9.1 g/min through four valves (L/D = 21:1). This provides puffing to the product as it is forced through a circular die (d=1 cm; P= MPa). The die is maintained at 60 o C by the circulation of brine at -10 o C. A revolving, dual-blade knife operates at 1200 rpm to cut the puffed dough into individual balls, which are then carried through a belt dryer (Gongyi Machinery Factory, Belt Dryer) set at 90 o C for 40 minutes to achieve a target moisture content of 5% and A w of [25, 26, 27]. Caramel-flavored coating ingredients are first mixed and heated to 93 o C for 15s in a jacketed, temperature controlled holding tank. Next, 502 g of coating is applied per 10,000 g of pops using an enrobing machine (K & Kurt, KKE400) [27, 28]. The conveyor belt continues to a nut sprinkling unit

5 (Sollich, NBD), where 125 g of pulverized dry roasted peanuts (<0.1 cm) are applied per batch [29]. The puffs are then partitioned by mass into 35 g serving sizes on the conveyor and cooled to 23 o C using a sanitary fan (FOODesign, Cryo-Jet) [30]. The product is packaged at room temperature, sealed, subjected to metal detection, and stored at 23 o C [31]. Safety/Shelf Life: The consistent safety of Popples is upheld through Good Manufacturing Practices (GMPs), Prerequisite Programs and the HACCP Plan (Appendix I), as well as, the use of ingredient suppliers chosen for their audited status and detailed Certificates of Analyses (COAs). Ingredients are inspected upon arrival to ensure quality, and a collection and inspection protocol has been developed to ascertain that the aseptically-collected, wet apple pomace acquired from a local apple juice manufacturer is food grade and safe. GMPs are implemented to ensure that the pomace is packed in sanitized containers and shipped under refrigerated conditions (<5 o C) to the Popples facility. It is verified that the pomace has been properly handled before being inspected by line technicians trained to remove branches and leaves. The pomace is then washed and disinfected with Tsunami 100, an antimicrobial water additive, to remove any excess debris [32]. Next, total coliform, yeast, and mold analyses are conducted to ensure safety before further processing. In addition, acceptable levels of patulin, arsenic, and pesticides are ensured via COAs. The HACCP plan was developed through a thorough hazard analysis and the identification of critical control points. CCPs 1 and 2 control vegetative pathogens, such as E. coli, S. aureus and L. monocytogenes, in the pop and coating components of Popples via supercritical CO 2 extrusion and thermal processing, respectively [33, 34]. To avoid introducing additional microbial hazards, the pulverized dry roasted peanuts are added to Popples following GMP procedures. The shelf stability of Popples is upheld by maintaining a final product water activity of less than 0.6, to prevent the growth of spoilage and pathogenic organisms post-processing [35]. This water activity is measured for the completed product upon cooling to room temperature (CCP3), and achieved through the drying of the pop component (A w : 0.45-

6 0.50), thermal processing of the coating (A w : ), and ensured through COAs for the dry roasted peanuts (A w : ). CCP4 implements a metal detector to prevent metal contamination in the finished product. In addition, Quality Control Points (QCPs) were established to ensure a consistently high quality product (Appendix I). Finally, a decrease in organoleptic quality, not a compromise in food safety, will guide shelf life, which is expected to be 1 year if left unopened. This is consistent with other shelf stable extruded snacks [36]. Technical Problem Solving: Extruded Pop: Given its high fiber formulation, the major challenge in the extruded component of Popples was to enlarge pop size. Since the product s glass transition temperature (T g ) is lower than the temperature at the die, pop shrinkage occurred post-extrusion. Introducing gel-forming soy protein isolate helped improve the expansion of the product, while maintaining the puffed structure formed by the pregelatinized starch [37, 38, 39]. Four formulations with different protein and apple pomace content were tested, and the current formulation demonstrated optimal puffing capability and nutritional quality. Coating: The combination of glycerin and gum arabic allowed the coating to develop a caramel-like viscosity capable of adhering the ground peanuts, while maintaining nutritional targets for sugar and fat [40]. Moisture Migration: To prevent softening of the pop texture due to moisture migration, glycerin was incorporated into the coating to achieve a similar water activity (A w ) in each component [40, 41]. The target A w s in the pop and coating are and , respectively. These values were achieved by formulation adjustment, including the redistribution of the proportions of ingredients in the coating. Packaging: Stickiness and lipid oxidation can be prevented with N 2 filled metalized polyester packaging, which is an excellent barrier to light, oxygen and moisture (OTR=0.95cc/m 2 ; MVTR=1.2g/m 2 ) [42]. Sensory Evaluation: A central location test, in which 90% of panelists represented the primary market (ages 18-34), found the overall liking of Popples with hedonic and JAR sensory evaluations (n=60). Test results guided reformulation to optimize pop size and minimize periodic stickiness of the coating.

7 Appendix I: Process Flow Diagram and HACCP Plan

8 Appendix II: Product Photographs Figure II.1. Close-up of Popples Figure II.2. Uncoated Pops Figure II.3. 5 x 7 Popples Serving Suggestion