Novel approaches to characterize and optimize the reactivity of batter-systems for frozen food

1. EFFoST Symposium: Innovations in food processing and product development 26 & 27 March 2012, Cologne Novel approaches to characterize and optimize the reactivity of batter-systems for frozen food Klaus Lösche Bremerhaven

2. 1. crispy textures, attractive surfaces 2. flavor improvement 3. “seal-in” moisture and fat 4. increase yields allowed to add 30% to product weight as batter and breading Batter/breading (coating) of products has several advantages

3. 1. predust to improve adhesion dry flour or dry batter mix applied first to product surface to make it more receptive 2. batters main function is to provide base for crumbs to adhere to product fluid mixture of flour, flavorings and starch viscosity is very important to the amount of pickup or thickness of batter/breading depends on a. flour/water ratio b. temperature Application process and materials

4. applied by submersion or “overflow” of batter over product viscometers (Brookfield, Zahn, Stein, Bostwick) used to check and monitor batter viscosity a. adhesive batters low to medium viscosity intended mostly to achieve breading (crumb) adhesion b. “tempura” batters includes raising or leavening agents to generate gas and “puff” the product high viscosity for thick coating with minimum mixing or pumping to prevent loss of gas cooked immediately to brown and expand the batter (w/gas) to an open, honey-comb-like texture 2. batters (continued)

5. Equipment for batter and breading is an important factor in the process and needs to be appropriate for the batters/breadings used Basic machining characteristics of batters

6. Coating process • Traditional process • Fry-cook process • Cook-fry process Problems: same recipes same technology different results

7. Heat –transfer during frying A Heat mass transfer / transport of oil Outer heat transfer transport of water steam Inner heat transfer B transport of CO2 and volatile components C Into the meat Nugget Oil transfer • Oil intake can be driven by hydrophobicity • Oil is bounded and not spreaded on the meat nugget surface Fig.: Transport effects and boundary conditions by 1st frying process

8. Coated Meat-products with negative product appearance Bubbles Rough edges Meat Nuggets with negative quality (rough edges, bubbles) REM – Meat Nugget with positive quality REM – Meat Nugget with negative quality

9. Batter • Batter ingredients: • Flour • Starch • Water • Leavening agents • Additives • Air Storage Structure Interactions Water Processing Ingredients

10. Structure effect technology structure, texture, reactivity technology / proceeding(engineering) - molecular construction- physical condition functional characteristics fig.: influence of structure – effect principals by technology

11. Formulation Batter (simplified)

12. Dough / batter

13. Functional characteristics of proteins in food The functionality of proteins ranges within limit states, amongst these: nativ denatured folded unfolded hydrophilic hydrophobic electrically charged electrically neutral reduced (-SH) oxidized(-SS-) dissociated (disaggregate) associated (aggregated) regular superior structure complete irregular structure (random coil) soluble insoluble hydrolysed polymerized uncured cross-linked

14. solubility, bulking: beverages, liquid food… water retention: doughs, mass, cakes, sausage… viscosity: doughs, soups, mass, infant food, waffle mass, wet batter, tempura… gelling: jelly coat, simulate (textural), extruder products, cheese, raw sausage … emulsifying characteristics: mass, cream, ice cream, frozen dessert, milk, sausage, mayonnaise, egg replacer … frothing characteristics: mass, froth (beer), whipped cream, soft candy, sweet protein froth (marshmallow, froth products of all kinds), meringue, whipped toppings… film formation: wet batter, tempura, coatings, microencapsulation, packing material, barrier layer… nutrional value: special products, diabetic pastry, snack products, infant food… Functional characteristics of proteins in food

15. quality profile wheat flour: type 550 gluten intense flour, e.g. for GU, GV, LF, donut (“Berliner”), toast etc. gluten weak flour, e.g. for cookies, mass etc. standard flourfor white bread, bread rolls, baguette, brown bread 400 600 660 680 700 710 720 740 RMT (ml):Protein dry weight (%) ICC No. 105gluten (%)ICC No. 137 sedimentation dataICC No.: 116falling number (g) ICC No. 107maltose number 8-9 10-11 11,2-11,7 12,0 12,5 12,7-13,2 13,5 14,0 20 22 24 26 27 28 30 32 32 34 36 38 39 40 41 42 250-350 280-350 300-400 2-3,5 1,5-2,0 1-1,5

16. Starch • Milling: damage • Water absorption • Availability enzymes • Fermentable sugars • Baking: gelatinization • Water absorption • Increase viscosity • Partly gelatinization retrogradation

17. Viscosity • Gellingviscosity • Structurebuilding • Waterbinding • No valid correlation of viscosityandtempuraquality • Methodforlongtermobservation in order tomeasureproductchanges www.cwbrabender.de Water – Flour – Suspension Breaking of starch granules / Gelling Swelling Swelling 49,7 °C 70,1 °C 90,8 °C 24,1 °C

18. influence of cooking salt on the starch gelatinisation characteristics viscosity (BE) temperature (°C) time (min) WM 550 + 1,0 % salt WM 550 + 2,0 % salt WM 550 zero trialWM 550 + 0,5 % salt

19. characterization and modification of potato starch (Klingler, 2004) gelatinisation and dispersibility of native and heat-moisture modified potato starch gelatinisation chararacteristics of potato starch

20. hydrothermic modified wheat flours in comparison temp. gradient wheat flour type 550 (net weight: 80 g) wheat flour type 550 (net weight: 50 g) HT-wheat flour (Roland-Mühle, Bremen) (net weight: 50 g) chemically modified starch (cross-linked starch) (net weight: 50 g) viscosity (BE) temperature (°C) time (min) • Comparative viscosity and gelatinisation characteristics of thermically modified wheat flours, chemically modified starches and standard flours in the amylograph (company Brabender).

21. HT-Flours: Novel Instrument tobatterFrozenFish conventional:amylomaize-flour-basis(inconvenient charge-situation) • fluctuations of „breading-Adhesion“ and -distribution • inadequate gas-permeability • little allowance concerning fluctuations in the water content • rejections 10-15% (problem: quality of product) • declaration in the case may be: “modified amylomaize” new:hydro thermic treated flour(“Roland-Mühle“, Bremen) (wanted charge-situation) • good breading-Adhesion and -distribution • good gas-permeability • high allowance concerning the water content • rejections < 5% • clean label

22. Water solute interactions Ionic polar solutes • React readily with water and most are usually soluble in water • Water HYDRATES the ions • Charge interactions due to waters high DIELECTRIC CONSTANT • Can easily neutralize charges due to its high dipole moment • Large ions can break water structure • Have weak electric fields • Small ions can induce more structure in water • Have strong electric fields

23. Water solute interactions Nonionic polar solutes • Weaker than water-ion bonds • Major factor here is H-bonding to the polar site • Example: SUCROSE • 4-6 H2O per sucrose • Concentration dependent • >30-40% sucrose all H2O is bound • T dependent solubility • C=O, OH, NH2 can also interact with each other and therefore water can compete with these groups • H-bond disrupters • urea - disrupts water Water bridge

24. Water solute interactions Nonpolar • Unfavorable interaction with water • Water around non-polar substance is forced into an ordered state • Water affinity for water high compared to non-polar compound • Water forms a shell • Tries to minimize contact • Hydrophobic interactions • Caused because water interacts with other water molecules while hydrophobic groups interact with other hydrophobic groups

25. Water has high surface tension 72.75 dynes/cm (20ºC) Because of the high surface tension special considerations are needed in food processing To affect it one can: Increase T (more energy)  reduces surface tension Add solutes NaCl and sugars  increase surface tension Amphipathic molecules  reduce surface tension Effect of solutes on water

26. Examples of “man made” pH control Leavening systems Bicarbonate (NaHCO3) - source of HCO3 and CO2 Leavening acids Drive bicarbonate (HCO3) to CO2 Rate of acid release varies and therefore CO2 release Phosphate - rapid release of CO2 Sulfate – slow release of CO2 Pyrophosphate - can be cleaved by phosphatases becoming more soluble - used in refrigerated doughs d-Glucono-lactone - used in refrigerated doughs Effect of solutes on water

27. Concept: Swelling of Batters (FEI-Project DIL/BILB Project-Nr… Daten fehlen) • New observation: Protein layers on starch granules • Barrier function • Heat mass transfer • Higher water temperatures allow a better swelling and hydration • Extension of swelling time • Influences the starch swelling • Better hydration of starch • Better hydration of proteins • Less dehydration during pre-frying • Better transport of volatile components during frying • Oxygen addition during mixing • Oxygen enriched water could improve the tempura quality in presence of ascorbic acid • Improvement of dough and batter/tempura rheology • Analysis • Correlation of results with quality with battered frozen food www.foodsnews.com Source: www.cfs.com

28. Particle Charge Detection : PCD food as electrolytic interacting system • Expected applications: • Measurement of blend compositions, quality of mixtures • Prediction of adhesive properties of coatings, breaders, etc. • Measurement of influences of emulsifiers, etc. • Determination of flour shelf live (or other ingredients) • Prediction of other functional properties Lipids Salt Proteins Starches Interaction of the functional groups total charge detection Quelle: BTG Instruments GmbH; Herrsching Functional characteristics

29. Correlations: Maize and Wheat flour mixtures PCD measuring of wheat flours type 550 & maize flour of different ratio of mixture (ratio of mixture of wheat flour : maize flour indicated) and whey mass-specific charge swelling time (min) wheat flour : maize flour 1:2 mixture wheat flour : maize flour 5:1mixture wheat flour : maize flour 1: 5 mixture wheat flour : maize flour 2:1 mixture whey maize flour wheat flour : maize flour 1:1 mixture wheat flour

30. PCD of wheat flour and gluten : Kinetics

31. Impact of Temperature: Dynamics of Particle Charge in Wheat Flour-Water Slurries

32. Impact of Flour –ripening: PCD and Kinetics of different flours during swellingNew and old harvest (English flours) T = 25 °C

33. influence of salt (NaCl) on the charge characteristic of wheat flour type 550, harvest 2010

34. influence of baking powder (phosphate etc.) on the charge density vitality of spelt flour type 630 (average values from dual determination) charge density of spelt flours type 630 by adding different amounts of baking powder (average values from dual determination) mass-specific charge QM in C/g spelt flour A spelt flourB swelling time in min sample: A + 1% baking p. sample: B + 1% baking p. sample: A + 3% baking p. sample: B + 3% baking p. sample: A + 2% baking p. sample: B + 2% baking p. sample: A sample: B comparison of two spelt breads (spelt bread A and spelt bread B) in a box-baking trial.

35. Coacervation of complex systems (interaction of wheat gluten and whey proteins) whey proteins wheat gluten novel protein + SH ⊖ S + ⊖ + S SH SH ionic interaction reduction – oxidation ⊖ ⊖ + ⊖ S SH S + + ⊖ charge balancing: novel protein individual amonst others mutated physical structure, mutated functional characteristics positive charge (cationic) negative charge (anionic)

36. influence of whey and baking powder on the electrical charge of watery suspensions of maize flour and wheat flour (1:1) PCD – measurements of maize flour & wheat flour (1:1) by adding different amounts of whey and 0,6% baking powder mass-specific charge QM in C/g swelling time in min 1,5% whey 3,5% whey wheat flour : maize flour 1:1 2,5% whey

37. Interaction of batter-components with frozen meat (schematically description) Left: Schematic figure of a meat piece covered with a batter system, including reactive components and its particle charge characterization. + + + Redox-Situation different a) Right: Theoretical model of possible structural protein molecule changes, caused by e.g. whey , phosphates. ... b)

38. Freezing induced changes in foods (examples) Destabilization of emulsions Flocculation of proteins Increased lipid oxidation Meat toughening Cellular damage Loss of water holding capacity Properties of ice Example: Effect of freezing on seafood

39. Changes of functional properties in food-systems with freezing Changes associated with freezing • Volume changes • Pure water expands ~9% • Foods expand but to a less extent • Expect High (sucrose) solution – small net concentration Changes associated with freezing • Concentration of non aqueous constituents • pH • Ionic strength • Viscosity • Freezing point • Surface interfacial tension • Redox potential

40. Weight loss of the Cod samples after different defrosting technologies Several advantages are possible using innovative-Technology: Time-reduction during freezing Time-reduction during defrosting (up to 80 %) Energy –savings Decrease in water-loss , in many cases water uptake/increase is accessible Increase in quality data in comparison of defrosted food / fish ( taste, color, consistency, texture, surface …) Other

41. Impact of different freezing- and defrosting-technologies on the weight loss of frozen salmon Several advantages are possible using innovative-Technology: Time-reduction during freezing Time-reduction during defrosting (up to 80 %) Energy –savings Decrease in water-loss , in many cases water uptake/increase is accessible Increase in quality data in comparison of defrosted food / fish ( taste, color, consistency, texture, surface …) Other

42. Zusammenfassung und Schlussfolgerungen • The protection and control of qualitative characteristics of battered frozen products is characterized by several variables: functionality of wet batter and functionality of the frozen products themselves. • the technical and functional characteristics of milling products (e.g. wheat flour) can not sufficiently be determined or predicted by using conventional methods. • The particle charge of recipe components or rather ionic interaction of electrolytes have a considerable influence on functional features. • The understanding and comprehension of possible interactions – also in simple systems like wet batter can help to optimize and standardize the quality in the end product by integrating novel concepts (e.g. PCD – measurements, coacercation, hydrophobic interactions etc.) • Physically modified flours can generate favorable features e.g. as a comparative novel ingredient namely for wet batter (amongst others gelling features, clean label) and can serve as a substitue for chemically modified starches (E-number). • The freezing of food changes its functionality, partly enormously: water retention ratio, redox potential, texture, batter ability, etc. • A novel defrosting system can generate considerable favourable data for frozen food and can therefore provide a decisive requirement for a safe and above all a continous good batter quality.

43. Thanks to the co-workers: • Mrs Dipl.-Ing. L. Ringer • Mr M. von Bargen • Mrs Dipl.-Ing. J. Börsmann • Mrs C. Gamert • Mrs Dipl.-Ing. B. Hajek

44. Thank you for your attention! baking and cereal technology Klaus Lösche ttz Bremerhaven Am Lunedeich 12 27572 Bremerhaven Tel. : +49 471 97297-0 Fax.: +49 471 97297-22 E-Mail: loesche@ttz-bremerhaven.de