A technical perspective on challenges in A technical perspective on challenges in providing nutritious lower calorie snack providing nutritious lower calorie snack foods foods –– Case studies on Case studies on SunChipsSunChips, Baked , Baked

Lay’s and future offeringsLay’s and future offerings

Mohan RaoFrito-Lay Research & Development

November 2, 2010Institute of Medicine

Washington, DC

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1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

Natural/Organic

PortionControl

EliminateTrans Fat

SunflowerOil

Pita &Bagel Chips

Multigrain

Low Fat

PortionControlVegetable

DipBaked

Fruit & Veggie Crisps

Protein &Whole grains

2008-2009

2

Frito-Lay Product Introductions

The largest hurdle to lower calorie snacks is not taking The largest hurdle to lower calorie snacks is not taking out the fat…out the fat…

Consumer Liking

Fat reduction (g/1 oz serving)

It is sustaining the consumer liking of the product…

Increased liking

Decreased liking

Below this line, Consumer are much less likely topurchase product

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Pathway to lower calorie snacks are manyPathway to lower calorie snacks are many

• Optimize frying profile and product surface characteristics to pick up less oil

• Develop non-fried snacks that are great tasting• Invent new thermal processes that can mimic heat

transfer coefficients similar to frying without oil as a medium of heat transfer .

Today we will focus on 2 products as case studies illustrating the above principles and take a look at the future

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Attributes renewed from “Prontos” (late 1970’s Frito-Lay test market product):

1. Concept: better-for-you positioning with at least 25% less fat

2. Shape: Prontos die insert, later upgraded (Prontos was a product tested in late 1970’s, made with multi-grains using an extruder)

Better-for-you product design elements have proven visionary

Three of four grains in multi-grain recipe are whole grains:Whole wheatWhole milled cornWhole oat flourRice flour

SunChips: Product Origins

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SunChipsSunChips’ Illustrious Product History’ Illustrious Product History

1990 20102000

1987-1989Develop &

Test market

1990-1991Launch

1995Re-launch

Better-for-you “BFY”

“Project No. 6”“Project Amber”“Project Harvest”

Multi-grainCooked in heart

healthy Canola oil1989 Test market

4-to-1 complements-to-

complaints!

“SunChips”

“30% less fat than regular potato chips”

2005Re-launch

2010Casa Grande

2006-2007Aberdeen

TopekaPerry

England

2009Grainwaves

(PI – Australia)Property of PepsiCo, Inc.

SunChipsSunChips Process Process

Wheat Cooking

Mixer(Dry Mix)

Extruder Fryer Seasoning

Wheat Quench

Packaging

Mix batch Whole corn Rice flour Whole oat flour Sugar Natural Flavor

Moisture Control

Water

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Complexity: In addition to mixing, extruding, frying, and seasoning, SunChips combines two additional operations:

1. Wheat cooking: needed to soften whole wheat so it will pass through dies

2. Corn milling: to provide fresh whole-milled corn

3. Heart of process: extrusion with large distribution die Needed CFD modeling to balance flow across the width

SunChips: Process

Die

Water feed

Mix feed

Extruder ScreenPack

Screw

Barrel plug length

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Extrusion

SunChips: Process

A NEW PARADIGM IN MIXING AND COOKING WHOLE GRAINS ALL TO THE SAME DEGREE

• extruder serves two functions:• excellent distributive mixing of milled grains, cooked

wheat, and added water• metering to filter screen and die – large pressure

drop results in excess viscous energy dissipation which can overheat the dough

Balancing work input, heat/thermal input, gelatinization of starch

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Fryer control

SunChips: Process

Dynamic Matrix Controller elevated frying to a whole new level

fryer utilizes multi-input, multi-output model-predictive controller, enabling “30% less fat than PC” label claim

Process Controls – key to delivering accurate quality and meeting legal claims

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Baked Lay's Baked Lay's –– Basis of InterestBasis of Interest

• Calories, fat and sodium content are leading indicators for H&W for the US population.

• Over 70 percent of Americans are consuming reduced fat foods – Nat’l Eating Trends research

• Baked is being purchased by all consumers

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High Heat Transfer is Critical for Texture

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Product Design GoalsProduct Design Goals

• Texture: crispy, light, airy• Smaller size appealing to consumers• Sodium 140 mg

in 1 oz serving• All Natural ingredients• Consumer Acceptability for Potato Flavor

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Chemical Leavening Agents Chemical Leavening Agents Provide a Number of Functions in Baking ApplicationsProvide a Number of Functions in Baking Applications

Four Methods of Leavening1. Air2. Steam3. CO2 from Yeast Fermentation4. CO2 from acid/base reaction

Chemical Leavening Systems• Provide lift in Baked Goods via the release of CO2

Fast acting leavening agent (off gases in under 60 sec)• Control Yeast Fermentation• Reduce proof time• Modify flavor• Encourage Maillard Browning Reactions via alkaline system• Control Color

SodiumBicarbonate

MonoCalcium Phosphate

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Leavening Removed

Reference

SEM MicrographsSEM Micrographs

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By adjusting process conditions in mixing, By adjusting process conditions in mixing, we can achieve a range of product textureswe can achieve a range of product textures

INDEPENDENT VARIABLES• Ingredients• Feed Rate• Water• RPM• Screw configuration• Temperature

Flaky texture

Hard, dense

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Effect of Work Input in MixerEffect of Work Input in Mixer

Ø Increasing work input leads to a more cohesive dough.

Ø Blisters observed to be more uniform and robust leading to a reduced breakage.

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GC-MS analysis of relevant flavor compounds may provide a ‘roadmap’ of how this technology impacts the flavor reactions for development of toast note.

We can compare proposed improved designs by studying the flavor compounds produced during baking.

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The work continues with The work continues with Future OfferingsFuture Offerings

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Overall objectives are to answer consumer Overall objectives are to answer consumer experiencesexperiences

Consumer measures- Sensory profile -

Physical measures- Oral processing profile-

Product ExperienceWhat changes when fat is

taken out of our chips?

What physical and chemical structures create mouth feel?

Physiology- Receptor modeling -

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We evaluate various analytical techniques for characterizationWe evaluate various analytical techniques for characterization

Attributes Analytical Techniques

Pore size distribution o Mercury Intrusiono BETo Pycnometero Micro CT- Scan

Surface topography o ESEMo SEMo CLSMo Optical Microscope

Oil distribution o CLSMo Raman Spectroscopyo Micro CT- Scan

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Digging deeper in porosity data to develop insightsDigging deeper in porosity data to develop insights

Penetration of liquids into a porous body: If a porous body behaves as an assemblage of very small cylindrical capillaries, thevolume which penetrates in t time would be proportional to the square root of ( γ t / η) Edward Washburn, March 1921

( ) trL ∗∗∗= 2/cos ηθγ

0.000

0.200

0.400

0.600

0.800

1.000

1.200

1.400

1.600

1.800

2.000

0 25 50 75 100 125 150 175 200 225 250 275 300C

apill

iary

pre

ssu

re (

Psi

)

Pore diameter (Microns)

DCOSP θγ4

≡

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

0 1 2 3 4 5 6 7 8 9 10

Ris

e in

liqu

id le

vel (

m)

Time (sec)

300 micron 200micron 100micron 25micron

Values used in the calculation are taken from the research paper published by Sam Saguy, 1994 in JFS

1degree temperature drop in temperature is approximately 1psi change in pressure

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We are We are leveraging CTleveraging CT--scan scan to study oil distributionto study oil distribution

Background

q CT stands for Computerized Tomography, where X rays are used to create image on the detector

q X rays are absorbed differently (attenuation coefficient) by different components (density differences) in a given material

q Image generated by CT scan has bright spots (high density), gray spots (lower density) and black areas (voids/air)

q Image generated by CT scan can be separated into different density components using various imaging software's

CT Scan: Pros CT Scan: Cons

§ Non- invasive technology

§ No dyes are required

§ Entire piece can be scanned

§ Image analysis is time consuming

§ No standard methods for our products

§ Data analysis methods are complex12

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Snack 1 Snack 2

Snack 3 Snack 4

Different snack surfaces will need different Different snack surfaces will need different approaches approaches

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Our scientific understanding of the Our scientific understanding of the process and development of analytical process and development of analytical tools coupled with technical innovation tools coupled with technical innovation will deliver snacks that will meet and will deliver snacks that will meet and

exceed consumer experience with lower exceed consumer experience with lower caloric densitycaloric density

The Journey Continues The Journey Continues

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