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Value-Added Processing and Applications of Specialty Grains

Explore the value-added processing and applications of specialty grains in the food industry. Learn about gluten-free products, quinoa, pulse crops, millets, and the processing quality of ingredients.

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Value-Added Processing and Applications of Specialty Grains

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  1. Value-Added Processing and Applications of Specialty Grains Girish Ganjyal School of Food Science

  2. Presentation Outline Value-added food processing overview Food ingredients Gluten free products Quinoa Pulse crops Millets Processing quality of ingredients Conclusions

  3. Food Industry - Overview Farm Specialty Flours Ingredient Manufacturing Companies Colors/Gums Starches Chemicals Proteins Food Equipment Manufacturers Meals Snacks Consumer Packaged Goods (CPG) – Companies Nutrition Staple Foods Frozen Foods Cereals Consumers

  4. Overview • Increase in consumer demand for the specialty grains. • Many are viewed as source of good nutrition. • Numerous efforts are ongoing to understand ways to utilize these grains to develop new value-added products. • With the opportunities comes the challenges of utilizing these grains in our food systems. • There are many needs to understand the handling and processing of these grains.

  5. Value-Added Processing Overview INGREDIENTS (formulations/interactions) Science PROCESS Safety (process effects/efficiencies) Technology PRODUCTS (to promote well being) Has to make Business Sense

  6. Common Processes • Baking • Drying (Air, Microwave, RF and others) • Extrusion • Frying

  7. Food Ingredients • Basic components of the food system • Nutritional benefits • Functional benefits in the food system • Texture • Taste • Maintain its properties in storage and handling • Basic chemical make-up of the ingredient and how this impacts its function in various food systems is critical

  8. Ingredients Interactions • Every ingredient added to the recipe, contributes different functionality in the final product • The reactions between ingredients, • along with the effects of the processing conditions (mechanical shear, temperature etc) • will affect the overall quality of the final product.

  9. Food Ingredient Groups Minor Ingredients Lipids Proteins ‘ Carbohydrates

  10. Carbohydrates • Starches • Sweeteners (sugars) • Hydrocolloids (gums) • Fibers ‘ Carbohydrates

  11. Starch Sources Cereal Grains Wheat, corn, rice, barley, sorghum, rye, millet, oat, triticale Tubers Potato, tapioca (cassava), arrowroot, yam Fruits Banana, plantain Stem-pith Sago, pineapple, bean seedlings, potato sprouts Other seeds Beans, peas, lentils, grams

  12. Types of Food Starches • Unmodified/Native • Pregelatinized starches • Modified • Acid thinned - hydrolyze to reduce molecular weight • Crosslinked - Chemically linking OH's from two adjacent molecules. Toughens granule. Adds acid and heat stability • Derivatized - Add bulky groups to starch to reduce retrogradation and Changes hydrophobicity • Crosslinked - Derivatized - Does both • Oxidized - reduces retrogradation

  13. Minor Ingredients • Flavors • Colors • Vitamins • Minerals • Emulsifiers • Leavening Agents • Nucleating Agents Minor Ingredients

  14. Bread - Example Wheat Flour Whole Grain High Fiber Water Gluten Properties Leavening Agents Leavening Agents Emulsifying Agents Chemical Yeast Oil Salt

  15. What does insoluble fiber do? Inclusion of fibers (A: Control (0% fiber); B: 5% whole fiber; C: 15% whole fiber; D: Smaller particle size; E: Bigger particle size).

  16. Pseudograins

  17. Pseudograins • A pseudocereal is a plant that produces a grain-like fruit. That is not a true caryopsis. • Often, these plants are grown in areas that are too cold, too dry, or too high to grow cereals successfully. • Are gluten free.

  18. Gluten Free Products • 3 cereal grains dominate the world’s food supply: wheat,rice and corn. • Gluten free bakery products tend to have minor volume and fragile crumb > lack of gluten network. • Commonly used raw materials in gluten free bakery products: corn and rice flour > lower nutritive value (compared to others). • Distinguished alternative/ supplement: pseudocereals.

  19. Cereals, pseudo-cereals and more… Gluten free Gluten free Pulse crops

  20. Quinoa

  21. Quinoa Chenopodium quinoa Wild • Native to the Andes of South America • Small seeds: 1 - 2,5 mm diameter • Grain enveloped in two-layered pericarp > contains saponins (= bitter substances, must be removed before consumption) • Considered as one of the most nutritive grains used as human food. • Raw material for nutritious gluten-free foods

  22. Quinoa Composition A Vega-G´alvezet al. J Sci Food Agric(2010). DOI 10.1002/jsfa.4158

  23. Quinoa Processing Cooking Boiling Toasting Pearling Dehulling Extrusion Seeds A Vega-G´alvezet al. J Sci Food Agric(2010). DOI 10.1002/jsfa.4158

  24. Quinoa Breakfast Cereals • Delicious breakfast made with quinoa and cocoa. • Organic white rice flour, organic quinoa flour, organic cane sugar and organic cocoa powder. • Price: $ 6. 99, 260 g • Manufacturer: gogoquinoa.com • Made in : Canada • Made from quinoa that has been rolled flat and toasted. • Use as a gluten-free breading for chicken or mix into baked goods for some added protein. • Price:$5 for 11 oz • Manufacturer:http://www.naturecrops.eu • Made in : Europe /

  25. Quinoa Breakfast Cereals • Organic, fair-trade quinoa. • Price: $7 for 1 lb • Manufacturer: Alter eco • Made in: USA • This breakfast must-have combines whole-grain quinoa, light coconut milk, real fruit and natural sweeteners to create a protein-packed, gluten-free cereal. • Flavor choices include banana-cinnamon, wild blueberry, honey-almond and orange-cranberry. • Price: $21 for 6 packages • Manufacturer: cocomammafoods.com • Made in: USA

  26. Snacks • All-natural baked quinoa chips. • Available in sea salt, sour cream–and-onion, cheddar and barbeque. • Price:$2.50 to $3.50 for 3.5 oz • Manufacturer: Simplysnakcs.com • Made in: USA • Orgranmultigrain crispibread with quinoa is a quality product produced from a nutritious combination of wholesome cereals and the revered superfood quinoa. • Price: NA • Manufacturer: Orgran.com • Made in: Australia

  27. Snacks • Dairy-free treat, consisting of a delicate chocolate shell filled with creamy, salty almond butter, with added crunch from puffed organic quinoa. • Price:$8 for 2.1 oz; • Manufacturer: mouth.com • Made in: USA • In addition to protein-packed quinoa, these small-batch energy bars are made from wholesome ingredients that are natural energy sources. Each cookie-like bar is full of nuts, fruits, seeds, grains and rich almond butter. Wheat-free and vegan, they are perfect for anyone on the go. • Price: $21 for twelve 2 ozbars. • Manufacturer: earnesteats.com • Made in: USA

  28. Other Products • Silky-smooth chocolate bar, the quinoa is puffed for a little crunch and the sesame seeds add a subtle toastiness that pairs very well with the agave. • Ingredients: Milk chocolate (sugar, milk, cocoa butter, chocolate liquor, soya lecithin, natural vanilla), agave glazed quinoa (cane sugar, quinoa, blue agave, rice syrup, salt), toasted sesame, sea salt. • Price: $8 for 3 oz; • Manufacturer: jcocochocolate.com • Made in: USA • Released in 2011, this American whiskey is distilled from red and white quinoa and malted barley. • The grains lend an unexpected nuttiness to this spirit that definitely makes it worth a taste. • Price: $50 for 750 ml; • Manufacturer: binnys.com • Made in: USA

  29. Other Products • The hearty grain sides come in flavors such as miso with edamame and scallions, and Indian coconut curry. Prepare it on the stovetop, in the microwave or in a rice cooker. • Price:$3.50 for 4 oz • Manufacturer: Urbanegrain • Made in: USA • This quinoa fusilli will satisfy any pasta lover, and has the added benefit of quinoa’s high protein content and gluten free. • Ingredients: Organic Rice Flour, Organic Quinoa Flour • Price: $5 for 8 oz • Manufacturer: Andeanshooping.com • Made in: USA

  30. Pulses

  31. What are Pulses? • Pulses are: • legume crop. • found in their pods • yielding 1-12 seeds • dried naturally in field • variable shape, size, and color • not grown for oil extraction • Food and Agricultural Organization of the United Nations (FAO) recognizes 11 primary pulses: • Dry beans • Lentils (Lens culinaris), • Dry peas (Pisum spp.); • Chickpea (Cicerarietinum)

  32. LEGUMES Includes: Peanuts Soy Mesquite Pulses PULSES Includes: Peas Lentils Chickpeas Dry edible bean

  33. Adzuki Lentil Dark red kidney Dry Yellow Pea Dry Green Peas Pinto Pink bean Black bean Navy Great northern Lima Chikpeas

  34. USA Lentil ‘Laird’ ‘Richlea’ • Shape like lens ‘Eston’ ‘Pardina’ ‘Crimson’ ‘Morton’

  35. Chemical Composition Table 1. Protein, Lipid, and Carbohydrate Composition (%) of pulses and soybean.* *Values are based on USDA National Nutrient Database and recalculated on a dry weight basis. 2012

  36. Traditional uses of Pulses • Soups • Snacks • Drinks • Roasting • Dips • Cereal products (bread, cakes, porridge, noodles etc..). • Sauce products (fermentation)

  37. Whole Pulses • Raw • Cooked shelf stable • Cooked frozen/refrigerated • Retort Canned Raw Frozen

  38. Whole Pulses

  39. Worldwide Pulse Soups pulse soup Lentil and rice Pea starch noodle Vegetable soup Meat & pulse soup Cereal pulse Soup Organic bean Soup

  40. Dips Most products in this category are Hummus! Chickpea Hummus Lentil hummus Pulse Dip

  41. Snacks • As general market attitudes turn away from traditional salty or fatty-type snacks to healthier, trans-fat-free options, the global volume of international snack foods is expected to continue to increase to meet these demands. • Though the U.S. remains the largest single market for such foods, Latin America, Asia Pacific, and Eastern Europe represent the greatest opportunities for manufacturers of snack foods. • In 2012, there are 264 snack products made with pulse ingredients launched worldwide, (Mintel GNPD 2012.) USA Lentil Singapore- pea China Green pea Chickpea Canada UK lentil

  42. Millets

  43. Millet • Small-seeded grass • • Oldest cereal: at least 10,000 years • • Important crops in semi-arid and sub-humid zones of Asia and Africa • • Most grown millet: pearl millet, foxtail • Pearl millet (Penicetumglucum) • Finger millet (Eleusinecoracana) • Foxtail, (Sestariaitalia) The major millets include: • Foxtail millet (Sestariaitalia) • Little millet (Panicum miliare) • Poroso millet or Proso millet (Panicummiliaceum) • Kodomillet (Paspalumsorobiculatum) • Barnyard millet (Echinocholacolona) The minor millets include: Subramanian, et al., BiosystemsEngineering (2003) 84 (3), 289–296

  44. Proximate Composition of Millets vs other Cereals Integration of Millets in Fortified Foods, NAAS 2012

  45. Processing Integration of Millets in Fortified Foods, NAAS 2012

  46. Millet Products

  47. Processing Quality of Ingredients

  48. Viscosity profile of Starch From: Starch Handbook, AACCI.

  49. Example of Importance of Ingredient Quality Flour (New Lot) Temp Profile Flour (Normal)

  50. Quinoa Varietal Differences

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