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Grain-Based Technologies to Reduce Food Energy Density

Fred Shih & Kim Daigle, SRRCFred Shih & Kim Daigle, SRRCGeorge George InglettInglett, NCAUR, NCAUR

Based Technologies to Reduce Food Energy Density

Elaine T. Champagne

USDA ARS

Southern Regional Research CenterFred Shih & Kim Daigle, SRRCFred Shih & Kim Daigle, SRRC

Challenges for Developing Foods with Reduced Energy Density

p Need to target foods consumers love to eat p Need to reduce fat without compromising flavor

and texture or nutritional valuep Products should not present gastrointestinal

issuesp Products need to be as easy or easier to prepare

than full-fat productp Environmentally-friendly, economical process for

ready adoption by industry

Challenges for Developing Foods with Reduced Energy Density

Need to target foods consumers love to eat Need to reduce fat without compromising flavor and texture or nutritional valueProducts should not present gastrointestinal

Products need to be as easy or easier to prepare

friendly, economical process for ready adoption by industry

Met Challenges

pTRIM Technologies

pLow-Oil Uptake Rice Batters

TRIM Technologies

Oil Uptake Rice Batters

THE TRIM TECHNOLOGIES

ALL BECAME COMMERCIAL PRODUCTSALL BECAME COMMERCIAL PRODUCTS

THE TRIM TECHNOLOGIES

C-Trim

ALL BECAME COMMERCIAL PRODUCTSALL BECAME COMMERCIAL PRODUCTS

THE TRIM TECHNOLOGIES

C-Trim

Soluble Fiber FatSoluble Fiber Fat--ReplacersReplacers

Oat or barley flour or branOat or barley flour or bran

Specific sequence of Specific sequence of steps involving aqueous steps involving aqueous extraction & jetextraction & jet

THE TRIM TECHNOLOGIESReplacersReplacers

Oat or barley flour or branOat or barley flour or bran

Amylodextrins + Amylodextrins + 11--10% 10% ββ--glucanglucan

Specific sequence of Specific sequence of steps involving aqueous steps involving aqueous extraction & jetextraction & jet--cookingcooking

Low level Low level amylodextrinsamylodextrins + + 2020--50% 50% ββ--glucanglucan + + 1414--27% protein + 27% protein + bioactive bioactive phenolicsphenolics

αα--amylaseamylase

JetJet--cookingcookingAmylodextrins + Amylodextrins + 11--15% 15% ββ--glucanglucan

Soluble hydrocolloid Soluble hydrocolloid fractionfraction

Properties

p Amylodextrins provide smooth mouthfeel n Fat replacer

p β-glucan provides beneficial physiological effects n Reduction of blood cholesterol

p “Tasteless” white powdersn Easy to incorporate into food products

p Heat stablen Suitable for cooked/baked foods

provide smooth mouthfeel

provides beneficial physiological effects Reduction of blood cholesterol

Easy to incorporate into food products

Suitable for cooked/baked foods

The Soluble Fiber Fat

C-Trim

As dried powder4 kcal/g compared to 9 kcal/g for fatFat-like gel upon hydration and heating 1 kcal/g

Flows like dairy cream, coconut cream, smoothFlows like dairy cream, coconut cream, smooth4 kcal/g4 kcal/g

Very high viscosity for increased satiety2.5

The Soluble Fiber Fat-Replacers

As dried powder4 kcal/g compared to 9 kcal/g for fat

like gel upon hydration and heating 1 kcal/g

Flows like dairy cream, coconut cream, smoothFlows like dairy cream, coconut cream, smooth4 kcal/g4 kcal/g

Very high viscosity for increased satiety2.5 – 3.5 kcal/g

Soft Ice Cream with OATserving

p 135 versus 298 caloriesp < 1 g versus 22 g fatp 4 mg versus 85 mg

cholesterol

Soft Ice Cream with OATRIM: 4 oz

135 versus 298 calories< 1 g versus 22 g fat4 mg versus 85 mg

OATRIM TRIALS – Crossover Study

pAfter 1 week standard equilibration diet, 50 g (1/2 cup) OATrim powder in various foods thoughout the day for 5 weeks at each of 2 β-glucan levels (0.8

pReplaced ¼ to all fat in foodspOATrim supplied 10% calories, other

carbohydrates 45%, fat 30%, protein 15%

Crossover Study

After 1 week standard equilibration diet, 50 g (1/2 cup) OATrim powder in various foods thoughout the day for 5 weeks at each

glucan levels (0.8-1.2 g or 5.1-7.6 g) Replaced ¼ to all fat in foodsOATrim supplied 10% calories, other carbohydrates 45%, fat 30%, protein 15%

OUTCOME

pDecrease in LDL cholesterol without decrease in HDL

p Improvement in glucose tolerancen Reduced insulin levels 11n Glucagon dropped 16n Blood glucose levels 7

pVolunteers lost an average 4.5 lbspSatiety (gastrointestinal viscosity)

Decrease in LDL cholesterol without

Improvement in glucose toleranceReduced insulin levels 11-24%Glucagon dropped 16-36%Blood glucose levels 7-12% lower

Volunteers lost an average 4.5 lbsSatiety (gastrointestinal viscosity)

COMMERCIALIZATION

p In 5 years from lab to grocery: label as hydrolyzed oat bran

p Foods containing OATrim: n Pasteurized cheesesn Baked products (breads,

cookies, muffins)n Processed meatsn Extra lean ground beefn Nutrition bars

COMMERCIALIZATION

C-TRIM

pYogurtpSmoothiespBaked goodspChocolatesn25% replacement

of cocoa butternDramatic increase

in taste scores for mouth coating

THE TRIM TECHNOLOGIESInsoluble Fiber Fat ReplacerInsoluble Fiber Fat Replacer

Grain (oats, corn, rice, wheat, soy) bran or hullsGrain (oats, corn, rice, wheat, soy) bran or hulls

MultiMulti--stage process involving alkali stage process involving alkali and intensive shearing (and intensive shearing (

Cellular debris: With textural variation from particlecreaminess to gel.

THE TRIM TECHNOLOGIESInsoluble Fiber Fat ReplacerInsoluble Fiber Fat Replacer

Grain (oats, corn, rice, wheat, soy) bran or hullsGrain (oats, corn, rice, wheat, soy) bran or hulls

stage process involving alkali stage process involving alkali and intensive shearing (and intensive shearing (jet cookingjet cooking))

Cellular debris: With textural variation from particle-like structure to

Z-TRIM

p Zero-Energy Insoluble Fiber/Fat Replacern At daily recommended amount

of fiber consumed as 1/1 replacement by 75 kg person = 225 kcal reduction in energy

p Gels have high viscosity and absorb 24 times weight in watern Satiety

p Not as effective as soluble fiber in lowering glucose and insulin responses

Energy Insoluble Fiber/Fat

At daily recommended amount

replacement by 75 kg person = 225 kcal reduction in energy

absorb 24 times weight in water

Not as effective as soluble fiber in lowering glucose and insulin

Rice Batter

Unique Properties of Rice Starch and Flour

p Small starch granule: 3nMouthfeel of fat

p White color, bland tastep Hypoallergenic p Gluten-free

Unique Properties of Rice Starch and Flour

Small starch granule: 3-5 microns

White color, bland taste

Preparation of Batter

p Rice or Wheat Flour plusn1% sodium bicarbonaten3% sodium chloriden0.7% pyrophosphaten70 g of batter base and 80.5 g of water

Preparation of Batter

Rice or Wheat Flour plus1% sodium bicarbonate3% sodium chloride0.7% pyrophosphate70 g of batter base and 80.5 g of water

RICE VERSUS WHEAT BATTER

p Fried batter made from rice flour absorbed less oil than that made from wheat flournRice Flour – 28% oil nWheat Flour – 49% oil

RICE VERSUS WHEAT BATTER

Fried batter made from rice flour absorbed less oil than that made from

28% oil 49% oil

Why?

p Hydrophobic wheat gluten gave wheat flour greater affinity for oil than rice flour

p Leavening effect of gluten made it more porous which enhanced moisture release and oil uptake

Hydrophobic wheat gluten gave wheat flour greater affinity for oil than rice

Leavening effect of gluten made it more porous which enhanced moisture release and oil uptake

Just Rice Flour

p Batter was brittle and hard to chewp Low in viscosity

Batter was brittle and hard to chew

Improved Properties by Adding

p Phosphorylated Starchp Pre-gelatinized FlournEnhance the batter’s water

ability making it a more effective oil barrier during fryingnFilm-forming properties lead to harder

crust

Improved Properties by Adding

Phosphorylated Starchgelatinized Flour

Enhance the batter’s water-holding ability making it a more effective oil barrier

forming properties lead to harder

THE BIG TEST: FRIED CHICKENWheat Rice

1.6% PViscosity 94 RVU 220 RVU

Wet Pick-up 13% 21%

Dry Pick-up 15% 20%

Oil Fried Batter 38% 14%

Oil Fried Chicken 5.6% 2.9%

THE BIG TEST: FRIED CHICKENRice1.6% P

RicePre-Gel

220 RVU 183 RVU

21% 18%

20% 12%

14% 20%

2.9% 2.4%

Rice Batter

U.S. patent 6,224,921 May 1, 2001 issuedU.S. patent 6,224,921 May 1, 2001 issued

Howard County Community College Enterprise Class

The team Batter UpThe team Batter UpTM TM

students from the Enterprisestudents from the Enterprisein the Fall of 2006 assessed commercial in the Fall of 2006 assessed commercial feasibility of USDA invented rice batter feasibility of USDA invented rice batter

“Five“Five--guys with a fryer” founded guys with a fryer” founded CrispTek and licensed the technology CrispTek and licensed the technology from the USDA in 2008. from the USDA in 2008.

Howard County Community College Enterprise Class

TM TM consisting of consisting of students from the Enterprisestudents from the Enterprise--215 class 215 class in the Fall of 2006 assessed commercial in the Fall of 2006 assessed commercial feasibility of USDA invented rice batter feasibility of USDA invented rice batter

guys with a fryer” founded guys with a fryer” founded CrispTek and licensed the technology CrispTek and licensed the technology from the USDA in 2008. from the USDA in 2008.

Crisp Tek, LLC

StartStartMaryland Technology Maryland Technology Development Corp.Development Corp.

NeoTech Incubator at NeoTech Incubator at Center for Business & Center for Business & TechnologyTechnology

www.choicebatter.comwww.choicebatter.com

StartStart--Up Funding from Up Funding from Maryland Technology Maryland Technology Development Corp.Development Corp.

NeoTech Incubator at NeoTech Incubator at Center for Business & Center for Business & TechnologyTechnology

www.choicebatter.comwww.choicebatter.com

Crisp Tek, LLC

p Cooperative Research & Development Agreement (CRADA)nResearch to extend technologies to food

service – pre-breaded, frozen food products

Cooperative Research & Development Agreement (CRADA)

Research to extend technologies to food breaded, frozen food

Low Oil-Uptake Batter with C

p 4% addition of C-trim 30 to wheat battern Increased batter viscosityn Increased batter pickn Reduced moisture lossn Reduced oil content 40%

Uptake Batter with C-TRIM

trim 30 to wheat

Increased batter viscosityIncreased batter pick-upReduced moisture lossReduced oil content 40%

LOOKING INTO THE FUTURE

n Fat-replacers with multiple benefitspβ-glucanpBioactive

polyphenolicsn Rice with higher

levels of resistant and slowly digestible starches

LOOKING INTO THE FUTURE