WELLENCE Smart Fry: Innovative Ingredients for reducing fat by 30% in fried foods Caroline SIMON 23 rd November 2016 www.dowfoodsolutions.com
What is WELLENCE Smart Fry? Background WELLENCE Smart Fry Food matrix contains significant amount of moisture (e.g., Potato contains ~75-85% moisture) During the frying process much of the water evaporates Leads to voids and capillaries New range of methylcellulose with faster hydration and improved film forming properties Saguy, Ufheil & Livings, 1998 No Barrier Mallikarjunan, et al., 1997 WELLENCE Smart Fry Oil Barrier 2
How to use WELLENCE Smart Fry? Predust / Batter system: Predust / Batter / Breader system: Reformed system: Food Matrix Pre-dust Batter containing WELLENCE Smart Fry Food Matrix Pre-dust Batter Breader or Breadcrumb Solution of WELLENCE Smart Fry Food pieces Matrix containing WELLENCE Smart Fry WELLENCE Smart Fry is based on methyl cellulose technology, it needs to be hydrated in aqueous systems below 10 C. 3
Using WELLENCE Smart Fry in breaded chicken tenders UPSCALE TRIALS Pre-Dusting In line breading machine Batter Coating Batter applicator Breading Breader machine Solution Dipping Batter applicator Frying Dow trials at JBT Food Tech, upscale trials production line Sandusky (OH, USA) April 2015 4
Using WELLENCE Smart Fry in breaded chicken tenders UPSCALE TRIALS WELLENCE Smart Fry 60 was added via a clear coat solution (1%) on top of the breader Fat reduction results after finish frying (Soxhlet analysis) 1,05% WELLENCE Smart Fry 60 in the solution = ~0,11% of WELLENCE Smart Fry 60 in the final chicken tender product Control Plant trials samples, assessed in Midland, April 2015 WELLENCE Smart Fry 60 solution dipping ~30% Fat Reduction Par-frying: 185 C, 40s Finish-frying: 174 C, 4min45s 5
Using WELLENCE Smart Fry in breaded chicken tenders UPSCALE TRIALS Sensory evaluation at Ohio state university in May 2015: With 150 people Using a 9 point hedonic liking scale 9 8 7 6 5 4 3 2 1 0 Overall product liking Crispiness Crunchiness Overall texture liking Juiciness of chicken Control Sample with WELLENCE FR 60 (added via dipping solution) 6
Using WELLENCE Smart Fry in tempura chicken tenders UPSCALE TRIALS WELLENCE Smart Fry 60 was also tested in a tempura coating (predust / batter / breader / batter) Fat reduction results after finish frying (Soxhlet analysis) 1% of WELLENCE Smart Fry 60 in the batters Batter with 1% WELLENCE Smart Fry 60 CONTROL batter with guar gum Control with guar gum April 2015 Tempura system with WELLENCE Smart Fry 60 ~34% Fat Reduction 7
Using WELLENCE Smart Fry in breaded fish Lab data Fat content comparison of WELLENCE coated vs. Control breaded fried fish (Soxhlet analysis) Full Fat Control WELLENCE Smart Fry 900 (0,5% solution sprayed on the coating) Control WELLENCE Smart Fry 900 ~40% Fat Reduction Internal trials, Midland - Jan 2015 Additional benefits: Reduce or eliminate coating ruptures during frying, resulting in smoother, intact coating Improve moistness in fish, better eating quality Par-frying: 185 C, 40s Finish-frying: 185 C, 3min15s 8
Using WELLENCE Smart Fry in tempura shrimp Lab data Fat content comparison of WELLENCE battered vs. Guar battered tempura shrimp (Soxhlet analysis) Control 9.55% 6.10% 6.74% Sample B 29% fat reduction Control with guar Sample A Sample B Control: Tempura batters with 0.2% guar Sample A: Batter 1 with 0,2% guar / Batter 2 with 1% WELLENCE Smart Fry 60 Sample B: Both batters with 1% WELLENCE Smart Fry 60 Sample A 36% fat reduction Internal trials, Midland - 2015 For applications with multiple passes of batter coating, optimum fat reduction can be achieved by just adding WELLENCE Smart Fry 60 in the outermost surface coating 9
Using WELLENCE Smart Fry in reformed matrix potato tots Lab data Fat reduction results after finish frying (Soxhlet analysis) WELLENCE Smart Fry can be added directly into the matrix of potato pieces. 22.3% 11.9% 0,2% WELLENCE Smart Fry 900 Control ~47% fat reduction Control 0,2 WELLENCE Smart Fry 900 Control Sample with 0,25% WELLENCE Smart Fry 750 Internal trials Midland, April 2015 10
Conclusions WELLENCE Smart Fry forms a barrier against oil absorption during frying Up to 30% (or more) fat and calorie reduction in fried foods Additional benefits: improved final yield, juicier product and crispier coating Performance validated through a scaleup process Improved coating adhesion and integrity during frying Reduce coating blow off during frying to reduce rate of frying oil degradation 11
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