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Bart Van Droogenbroeck - ILVO
Bernd Lambrechts – Greenyard Prepared
November 26th 2018, Interpom
Kortrijk XPO
Reduced losses and improvednutritional value in potato processing
International efforts are rewarding
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The INPROVE project is funded under the SUSFOOD2 ERA-NET.
VLAIO is the Flemish funding agency, via the O&O program.
Project duration: 36 months - 04/2018 - 03/2021
Total budget: € 959.000
Innovative Processing of Vegetables and Potato
ILV
OInnovative Processing of Vegetables and Potato
7 partners:
•BELGIUM: Institute for agriculture, fisheries and food research (ILVO) and Greenyard Prepared (GP)
•SWEDEN: Research Institutes of Sweden
•NORWAY: HOFF SA and Fjordland AS
•TURKEY: Central Research Institute of Food and Feed Control (CRIFFC) and Ankara University (AU)
•SPAIN: MONDRAGON GOI ESKOLA POLITEKNIKOA JOSE MARIA ARIZMENDIARRIETA S COOP (MGEP)
Bron: Wageningen World, 2012 (1), 10-15
Losses throughout the value
chain:
Multiple reasons:
- Fresh:
- Esthetic defects, grading
- Microbiological safety
- Chemical safety
- Surplus pro²duction
- Processing:
- Waste & by-products
- Retail:
- Smaller families - packaging
- ‘Use by…’ date
- …
INPROVE: CHALLENGES TACKLEDFood waste & by-products
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http://www.voedselverlies.be/
INPROVE: CHALLENGES TACKLEDFood waste & by-products
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Source: Kretschmer et al. 2013:86, adapted after Eickhout (2012), based on http://www.biobasedeconomy.nl/themas/bioraffinage_v2/
INPROVE: CHALLENGES TACKLEDFood waste & by-products
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OINPROVE: CHALLENGES TACKLED
Innovative & more nutritive products
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OINPROVE: CHALLENGES TACKLED
Innovative & more nutritive products
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INPROVE: CHALLENGES TACKLED
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INPROVE: PROJECT SETUP
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OWP1: Processing Design and Innovative Technologies
WP1 will consist of two main approaches: where optimal process design contributes to increasedunderstanding of how the process will affect the functions and properties of the treated food as well ashow the process design will contribute towards desired properties. This is strongly linked to theprediction of kinetic changes of the food in terms of nutritional quality, based on achieved time-temperature profiles which will be explored in detail in WP3.
We will test how efficiently three new microwave techniques (tubular, tunnel and batch) can processpotatoes and vegetables. Microwaves require little power and water in order to neutralize bacteria,compared to autoclaves. For some products, the process time can be reduced by up to 90 percent.. Themicrowave treatment will also be combined with different pressure techniques.
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OWP1: Processing Design and Innovative Technologies
Canning is still a universal and economic method for processing potatoes and vegetables. Heat transferrate in canning is mainly influenced by container shape and product type. During canning, convectiveheat transfer coefficient is very high. This leaves the container shape as the only option to modify forincreasing heat transfer rate and reducing process time. An innovation in this field is the toroid can.
In WP1 self-built prototypes of toroïd cans will be used to investigate the potentialadvantages for the processing of potatoes, vegetables and derived products, with focus onprocess energy savings and improved product quality.
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OWP1: Processing Design and Innovative Technologies
First preliminary experiments with toroid cans and control can:- filled with colored water to check leaking, prototype robustness- Test sensors, experimental setup in retort autoclave- Get a first view on heating rate in toroïd vs. control cans
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OWP1: Processing Design and Innovative Technologies
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0 200 400 600 800 1000 1200 1400
Tem
per
atu
ur
in b
lik (
°C)
Procestijd (s)
Sensor 2 in blik 1 Sensor 3 in blik 2 Sensor 4 in blik 8 Sensor 7 in blik 7
Faster heating rate prototype toroid cans filled with water confirmed, as expected Next step: process vegetable puree and soups, evaluate energy use & quality
Toroïd cans
Regular, control can
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OWP1: Processing Design and Innovative Technologies
A recent study has shown that by replacing conventional preheaters with PEF
equipment, the energy requirements can be reduced by 85 % and water
consumption can be reduced by 90 %. In addition, a reduced fat uptake,
an improved product quality and a 1 to 1.5 % increase of product yield
have been observed (McHugh and Toepfl, 2016, Fauster et al., 2018). For a
typical 50.000 kg/h line that corresponds to 60 – 70.000.000 litres of water
and 20 GJ of thermal energy savings per year.
http://elea-technology.de/systems/
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WP2: BY-PRODUCT PROCESSING
In WP2 different approaches will be followed to create added value from the potato andvegetable by-products abundantly available from the industrial partners in InProve.
Potatoes and vegetables such as carrot and black salsify are rich in minerals, dietary fibers,vitamins and bio-active compounds, all nutritional compounds highly relevant in a balanceddiet we are looking for. Therefore, these by-products represent an excellent, cheapsustainable source for process and product development as envisaged in InProVe.
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WP2: BY-PRODUCT PROCESSING
Greenyard Processed generates yearly more than23.000 ton of potato by-product, 10.000 ton ofblack salsify by-product and 7.500 ton of carrotby-product.
Hoff generates up to 85.000 ton of potato by-products per year.
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WP2: BY-PRODUCT PROCESSING
The primary objective is to optimize the processing of these by-products with
the goal to recycle as much as possible of these biomass fractions back into
the food chain.
www.foodpilot.be
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T2.1 Minimal processing of the by-products into valuable fractions
Low-oxygen spiral filter press: Liquid fraction can be valorized as such: juice, puree..
Stabilization by heat treatment: pasteurization, sterilization; PEF, HPP….
Solid fraction can be stabilzed by drying (concentration of solids) Dry-On-Water technology Pre-treatment with PEF/enzymes to increase drying efficiency
WP2: BY-PRODUCT PROCESSING
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‘Dry On Water’ = based on IR radiation hot water , self-limiting technology
Low product temperature, fast, energy-efficient, environmentally friendly
Thin-layer, homogeneous biomass application
Stabilisation with innovative drying technology
WP2: BY-PRODUCT PROCESSING
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FD RWD FD RWD
Am
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of
bio
acti
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Apple Pear
Dry-On-Water ™ vs. Freeze-drying
Maximal retention diversity bio-actives Ideal to stabilize wet biomass such as vegetable & fruit press
cakes
Value as functional or technical ‘clean label’ food ingrediënt,
feedstock for the extraction of specific compounds ….
WP2: BY-PRODUCT PROCESSING
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WP2: BY-PRODUCT PROCESSING
T2.2 Extraction of selected by-product fractions
Press-cakes: solid residue after juice extraction/fractionation Peels – enriched in bio-actives
RISE expertise: PEF-pretreatment of biomass before extraction – e.g. carrot press cake Supercritical CO2 extraction of bioactives – e.g. carotenoids
The influence of PEF pretreatment on the subsequent SFE will be evaluated by evaluating thequantity and quality of the extracted target compounds (carotenoids). This analysis will beused to assess the influence of the major points of regulation during the process of SCCO2extraction, being changes in extraction temperature and applied pressure.
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WP2: BY-PRODUCT PROCESSING
T2.3 Product development using the fractions produced1. Pureed vegetables – mono or mixed products
Taste, texture, colour…..
3. Use of SFE extracts, enriched in target compounds as flavor, colorant, anti-oxidant or other natural/clean label/ functional ingredient in a product selectedfrom the portfolio of the industrial partners GP and/or Hoff
2. Potato & Vegetable powders for use in extruded snacks using for taste, as naturalcolorant, as (functional) food & drink ingredients
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WP2: BY-PRODUCT PROCESSING
T2.3 Product development using the fractions produced as
ingredients/products
4. Use of by-product derived fractions to produce vegan products with the texture of meat using the High Moisture Extrusion Cooking (HMEC) (CLEXTRAL) or in hybrid meat products
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WP2: BY-PRODUCT PROCESSING
https://www.avebe.nl/nieuws/avebe-winnaar-protein-award/
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WP2: BY-PRODUCT PROCESSING
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TASKS
T4.1 Characterisation raw materials & by-products Macroscopic parameters: MC, pH, color, aw… Nutritional value: protein, fat, carbohydrates (sugar, starch & dietary fibre),
vitamins, minerals Specific bioactives with associated health beneficial properties
Carotenoids, phenolic compounds, sesquiterpenes Dedicated LC-MS/MS methods
WP4: PRODUCT QUALITY & SAFETY
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TASKS
T4.2 Intermediate fractions & food products Macroscopic parameters+ Nutritional value + bioactives
Extra analyses specifically relevant to assess the quality of the food product or the functionality of a by-product derived ingredient Particle size Texture Viscosity/rheology Water binding activity ORAC (antioxidant capacity assays) …
Sensory evaluation
WP4: PRODUCT QUALITY & SAFETY
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TASKS
T4.3 Food safety & stability Chemical safety
• Pesticides• Heavy metals• Mycotoxins
Microbiological safety Pathogens (e.g. Listeria) Hygiene-indicators (e.g. E. coli) Spoilage organisms (
Product stability – shelf-life Microbiological Physico-chemical
WP4: PRODUCT QUALITY & SAFETY
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Conclusions
• Innovative technologies open up new opportunities for process &
product development that can result in :
– Energy savings
– Improved product quality
– Improved use of biomass used
=> more sustainable potato production chain
• Relevant opportunities to create value out of potato biomass fractions
which are currently underutilized
• Upcycling potential depending on detailed characterisation of
feedstock, both compositional & functional = R&D intensive
• International collaboration with different players in agri-food & bio-
economy chain right from the start of an R&D project speeds up
innovation
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Thanks for your attention!
Questions? Suggestions?
Instituut voor Landbouw-en Visserijonderzoek
Burg. Van Gansberghelaan 1159820 Merelbeke – België
T + 32 (0)9 272 28 00F +32 (0)9 272 28 01
Contacts:Dr. ir. Bart Van [email protected]
++32 9 2722839++32 492 154442
@bartvd_ILVObartvd_at_ilvo
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