From Gluten-free to Whole Grain: Formulating On-trend Products Heather Maskus Project Manager, Canadian International Grains Institute May 4 th, 2016

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1 From Gluten-free to Whole Grain: Formulating On-trend Products Heather Maskus Project Manager, Canadian International Grains Institute May 4 th, Protein Trends & Technologies Seminar

2 What is Cigi? Created in 1972 Independent organization Funding: Farmers, Government of Canada (AAFC) and industry partners Mission: Creating profitable opportunities for Canadian field crops; wheat, pulses, barley

3 2016 International Year of Pulses

4 Opportunities for Pulse Ingredients

5 Canadian Pulses Black 5

6 WHOLE SEED DEHULLED SPLIT GROUND FLAKED FRACTIONATED

7 Pulse Flour Whole pulse flour is a healthy food ingredient containing fibre, protein, vitamins and minerals Pulse flour is a nutrient dense ingredient. Key minerals include iron, potassium, magnesium and zinc. It is also rich in B-vitamins folate, thiamin and niacin.

8 Nutritional Advantage PROTEIN (%) STARCH (%) FIBRE (%) FAT (%) Pea Bean Lentil Chickpea Soy (de-fatted) Corn (de-germed) Wheat (de-branned) Source: Canadian Grain Commission

9 Nutrition and Health Research

10 Other Advantages Sustainable protein Non-GMO Low allergenicity Clean label Global recognition

11 Breakfast Cereals Extruded Snacks Pasta Noodles Bread (Gluten- free & Whole Wheat) Gluten-free Crackers PRODUCT APPLICATIONS

Extruded Breakfast Crisps Whole Red Lentil Flour (1% salt, 2.5% sugar) Pin Mill Coarse Pin Mill Fine Hammer Mill Stone Mill Bulk Density Texture Bowl Life Sensory Characteristics Pin Mill Coarse 174.

12 Extruded Breakfast Crisps Whole Red Lentil Flour (1% salt, 2.5% sugar) Pin Mill Coarse Pin Mill Fine Hammer Mill Stone Mill Bulk Density Texture Bowl Life Sensory Characteristics Pin Mill Coarse Strong lentil flavour, very hard texture Pin Mill Fine Strong lentil flavour, chewy on outside, hard on inside Hammer Mill Mild lentil flavour, crunchy Stone Mill Strong lentil flavour, quiet pop, sticky Extrusion Processing completed at Saskatchewan Food Industry Development Centre

13 Breakfast Cereal Formulation Based on previous study results optimizing extruded product quality. 31.5% Corn Meal 56.5% Pea Flour/Semolina 6.5% Pea Fibre 0.5% Salt 5% Sugar Breakfast Cereal Formulation Salt Pea Fibre Sugar Corn Meal Pea Flour or Semolina

Extrusion Processing- Optimized Product Whole Pea Semolina Refined Pea Semolina Whole Pea Flour Refined Pea Flour

4 Blend feed rate (kg/h)- 36, 36 Screw speed (rpm)- 537, 650 Cutter speed (rpm)- 1178, 1207 Temperature ( C)-

(rpm)- 1079, 1122 Temperature ( C)- 106, 106 Pressure (kpa)- 400, 400 Conditions rep 1, rep2 Water flow rate

2 Blend feed rate (kg/h)- 36, 36 Screw speed (rpm)- 602, 602 Cutter speed (rpm)- 1051, 1221 Temperature ( C)-

14 Extrusion Processing- Optimized Product Whole Pea Semolina Refined Pea Semolina Whole Pea Flour Refined Pea Flour Conditions rep 1, rep2 Water flow rate (kg/h)- 2.1, 2.4 Blend feed rate (kg/h)- 36, 36 Screw speed (rpm)- 537, 650 Cutter speed (rpm)- 1178, 1207 Temperature ( C)- 107, 109 Pressure (kpa)- 700, 300 Conditions rep 1, rep2 Water flow rate (kg/h)- 2.1, 2.1 Blend feed rate (kg/h)- 36, 36 Screw speed (rpm)- 655, 655 Cutter speed (rpm)- 1079, 1122 Temperature ( C)- 106, 106 Pressure (kpa)- 400, 400 Conditions rep 1, rep2 Water flow rate (kg/h)- 2.5, 2.2 Blend feed rate (kg/h)- 36, 36 Screw speed (rpm)- 602, 602 Cutter speed (rpm)- 1051, 1221 Temperature ( C)- 109, 110 Pressure (kpa)- 300, 300 Conditions rep 1, rep2 Water flow rate (kg/h)- 2.5, 2.5 Blend feed rate (kg/h)- 36, 36 Screw speed (rpm)- 537, 673 Cutter speed (rpm)- 1093, 1122 Temperature ( C)- 109, 109 Pressure (kpa)- 300, 200

15 Protein Content (%, dwb unless otherwise indicated) Effects of Processing on Protein Content of Extruded Pea Based Breakfast Cereals Whole Pea 2. Pea Roller Milling 3. Blending; pea, corn, fibre, sugar, salt 4. Optimized Extrusion Processing (as is moisture) Coarse Semolina Refined Pea Flour Whole Coarse Semolina Whole Pea Flour Retail Corn Cereal Control Corn Cereal (Cigi) Yellow Pea Flakes Target 0.00

16 Quality Protein (g/30g serving) Effects of Processing on Protein Quality of Extruded Pea Based Breakfast Cereals Flour Protein Quality/30g (Quantity*AAS*Protein Digestibility (87.9% PC)) Blend Protein Quality (Quantity*AAS*Protein Digestibility (87.9% PC)) Breakfast Cereal Protein Quality (Quantity*AAS*Protein Digestibility 87.9) 0 Coarse Semolina Refined Pea Flour Whole Coarse Semolina Whole Pea Flour Retail Corn Cereal Control Corn Cereal (Cigi)

17 Advantages Breakfast Cereals Gluten-free Higher Protein Content and Quality Higher Fibre Challenges Colour Flavour Solutions Blending of grain ingredients Processing modifications

18 Whole Yellow Pea Flour Extruded Snacks Pin Mill Coarse 1 cm Pin Mill Fine 1 cm Roller Mill 1 cm Hammer Mill 1 cm Stone Mill 1 cm Corn Meal 1 cm Pin Mill Coarse Pin Mill Fine Roller Mill Hammer Mill Expansion Index Bulk Density (g/l) Stone Mill Texture (N) Extrusion Processing completed at Saskatchewan Food Industry Development Centre

19 Advantages Extruded Snacks Extrusion of whole yellow pea flours is more controlled than for the split yellow pea flours. Additional fibre of whole yellow pea flours acts as a nucleation agent and controls air cell size of extrudates. Challenges Direct expanded products made with whole yellow pea flour are darker in colour and have a greater bulk density than split yellow pea flour. Coating with complementary flavours Small reference amount, difficult to make protein claim Solutions Bending with other ingredients to improve nutrition, taste and texture

20 Pasta Pulse flour milling to produce low medium and high protein content flour Blended with durum semolina 30:70

21 Pasta

22 Pasta Esey Assefaw Head Asian Products and Pasta Department Canadian International Grains Institute

23 Advantages Pasta Increase protein content, quality and nutrient density No change in cooking time Challenges Dough crumb sticky, effects extrusion Darkening of pasta with HTST drying Drying cycle effects pasta cooked firmness Soluble proteins leached in cooking water Solutions 2% reduction in water addition for yellow pea semolina Use LTLT drying profile to minimize colour changes Use fine semolina pulse ingredient and the LTLT drying profile for best appearance and cooked pasta firmness

24 Noodles

25 Sandwich sheeting for whole wheat noodles (Cigi Asian Products Department) Processing method to improve end product quality standard processing method - 2 dough sheets are formed at first pass then 2 dough sheets are laminated to form 1 dough sheet on second pass sandwich sheeting processing method - 3 dough sheets are formed at first sheet forming pass then 3 dough sheets are laminated to form 1 dough sheet. Esey Assefaw Head Asian Products and Pasta Department Canadian International Grains Institute eassefaw@cigi.ca

26 Hoppers (where the noodle crumbs go to) Three rolls in the first pass (sheet formation) Rolls in the second pass (sheet lamination/compounding)

27 Sandwich sheeting for whole wheat noodles (Cigi)

28 Sandwich sheeting for whole wheat noodles Refined WW Sandwich 3 hrs 24 hrs Sandwich sheeting used to improve noodle appearance used to improve noodle texture used to increase nutritional profile of noodle products

29 Gluten-Free Pan Bread

30 Gluten-Free Pan Bread

31 Gluten-free Pan Bread Improved nutritional profile of the bread eligible for a dietary fibre nutrient content claim. The addition of pulse flours resulted in breads with a firmer texture and smaller cell diameters compared to the control bread Among the three pulse types, the bread containing fava bean flour produced a bread with milder flavor

32 Whole Wheat Pan Bread Quality Whole-wheat breads formulated with 15% whole yellow pea flours. Pea flours were milled using four methods ( L to R: Pin Mill Fine, Stone Mill, Hammer Mill, Roller Mill)

33 Whole Wheat Pan Bread Yvonne Supeene Head Bakery Technology Department Canadian International Grains Institute

34 Whole Wheat Pan Bread Quality Dough Properties Pan Bread Properties Whole Yellow Pea Flours Handling after Mixing Handling at Moulding Loaf Height (mm) Overall Bread Quality Score* (/50) Pin mill-fine Slightly sticky Non-sticky Stone mill Slightly sticky Slightly sticky and slightly stiff Hammer mill Sticky Sticky Roller mill Very sticky Very sticky

35 Gluten-free Crackers Pulse flours and pea fibre crackers were more firm and generally thicker compared to the control cracker Yellow pea/pre-cooked navy bean best maintained its texture and produced the thinnest cracker Crackers made with the yellow pea/red lentil flour produced a cracker with the most desirable flavour Pulse flour improved nutritional profile of glutenfree cracker Source of fibre claim

36 Gluten-free Crackers

37 Key Messages Advantages Complementary protein with cereals Sustainable source Global recognition Challenges Flavour/texture Cost Meeting protein claims Solutions Blending ingredients Pulse concentrates/isolates

38 Questions Heather Maskus Project Manager Canadian International Grains Institute

Pulse Processing for End use Application. Ashok Sarkar Senior Advisor, Technology CIGI, Winnipeg, Canada

Pulse Processing for End use Application Ashok Sarkar Senior Advisor, Technology CIGI, Winnipeg, Canada Introduction Pulses are well recognized for their nutritional and health benefits. They are easy