Galactic s Solutions for Bakery Products

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1 Galactic s Solutions for Bakery Products CLEAN LABELLING HEALTH AND NUTRITION PROCESS IMROVEMENT TASTE ENHANCEMENT The demand in the bakery industry for clean label, tasty and healthy products as well as faster processing times is increasingly growing. In order to meet this need, Galactic developed a great number of solutions which provide the very best of nature to your bakery products by combining traditional and state-of-the-art technologies.

2 Galactic has acquired an extensive expertise in biotechnology since its creation 20 years ago. Galactic develops natural solutions for applications in the food, feed, body care, health and industry sectors. Specialised in food safety, nutrition and green chemistry, Galactic offers environmentally and health friendly substitutes such as lactic acid, lactates and many other innovative products. In collaboration with its customers and scientific partners, Galactic meets the challenge of sharing the unlimited potential of nature for a sustainable future. 2 ENHANCING THE GENIUS OF NATURE

3 Introduction According to Euromonitor (2013), the size of the global bakery market amounts to $ 330 billion, with Europe accounting for 37%, North and South America for 32% and Asia-Pacific for 14%. The four main supplying channels are industrial bakers, artisan bakers, food service & out of home, and supermarkets & in-store bakeries. Bakery industries are continuously looking for new ingredients to improve the composition and the properties of the dough while consumers increasingly look for fresh, natural and always tastier and healthier home-made products. With the expansion of the world s population, higher nutritional standards and a growing interest in ready-to-eat and ready-to-bake goods, the demand for bakery items has considerably increased over the past 10 years. Galactic proposes innovative solutions specially designed for bakery products based on four main market trends: clean labelling, health and nutrition, process improvement and taste enhancement. Galactic s Solutions Clean labelling Clean labelling is a major trend in the bakery sector. Consumers now want natural and healthy ingredients, even for industrial products. Bakers use chemical leavening systems containing bicarbonate and acidifiers, e.g. phosphates or coated organic acids. The use of phosphates is controversial since they are said to cause many diseases and disorders such as kidney stones, ADHD, etc. Phosphates containing aluminium like SALPs are not allowed anymore in Europe. Organic acids are primarily coated with palm oil which is criticized as it has a negative impact on the environment (deforestation and soil impoverishment), the wildlife (slaughter of animals) and human health (cardiovascular diseases and obesity). BAKERY PRODUCTS 3

4 Galactic proposes a brand-new natural acidifier,, to control the activation of bicarbonate in leavening systems. Thanks to its structure, the activity of can be accurately adjusted to the process by controlling different parameters such as time, temperature, concentration and water content. At low temperatures, the acidity release is slow while it is much faster at higher temperatures (see table below). Thus the CO 2 release can be controlled by the temperature, which can vary during the different steps of the production process. has no taste and demonstrates excellent compatibility with all the other ingredients generally used in bakery. is equally effective in fresh, frozen, and ready-to-bake products. Effect of temperature variation on the ph ph of 0.5% of in running water 10 C 15 C 23 C 30 C 70 C Time (minutes) provides major benefits compared to commonly used acidifiers as shown in the table below. SAPPs/SALPs Coated acids GDL Allowed in organic products No No No Yes Neutral taste No Yes No Yes Phosphate and/or aluminium-free No Yes Yes Yes Palm oil-free Yes No Yes Yes Sodium-free No Yes Yes Yes 4 ENHANCING THE GENIUS OF NATURE

5 Health and nutrition Mineral fortification Calcium is an essential part of the human diet as it helps in the formation and maintenance of healthy bones, teeth, etc. Calcium deficiency can cause serious health problems such as osteoporosis, cardiac rhythm disorders and many others. Iron is mainly found in hemoglobin. It is a mineral involved in oxygen transport and is essential for the regulation of cell growth and cellular differentiation. Lacking iron leads, for example, to fatigue and loss of concentration. Salt (sodium) reduction As cardiovascular diseases and hypertension are becoming major health problems worldwide, sodium reduction is set to be a crucial challenge for the bakery industry. Galimax Flavor TM K is the latest innovation from Galactic in the field of salt replacement and makes it possible to substitute at least 20% of salt contained in bread or flatbread. Galimax Flavor TM K does not impact on the texture, the volume and the breadcrumb structure. Galactic proposes a wide range of mineral lactates such as Galaxium TM (calcium lactate) and Galanium TM Fe (ferrous lactate), which are highly bioavailable sources of minerals, to fortify bakery products (e.g. flour fortification) and help increase calcium and/or iron intake (see Galactic s brochure on nutraceuticals for further information). Process improvement Control of the leavening effect Controlling the activity of the yeast is one of the challenges bakery manufacturers are facing, especially in bake-off products. Yeast is sensitive to sub-zero temperatures and loses part of its effectiveness as a leavening agent when frozen, which impacts on the volume of the final products. Galactic has developped, a solution in powder form that allows a better volume control during baking and is well adapted to chilled and frozen products. BAKERY PRODUCTS 5

6 Production of emulsifiers Galacid TM Heat-Stable lactic acid is used as raw material in the production of emulsifiers like sodium stearoyl-2-lactylate (SSL) and calcium stearoyl-2-lactylate (CSL). SSL and CSL: Production time reduction Sourdough is produced through lactic acid fermentation. Production time can be drastically reduced by direct acidification with lactic acid. Galactic proposes its Galacid TM range, which is perfectly adapted to that use. present the best ability to form a complex with amylose; strongly interact with gluten to strengthen the gluten starch matrix, which improves dough stability; slow down starch retrogradation; improve the shelf life of the products. These emulsifiers are therefore used to obtain good dough properties. Taste enhancement Reducing the salt content of bakery products often leads to loss of taste. Galactic offers Galimax Flavor TM K, a natural flavour produced by fermentation of sugar. It enhances the salty taste and allows manufacturers to reduce the salt content in their formulations by at least 20%. enhances the butter taste in cakes and the chocolate taste in cookies. Galactic s solutions for bakery products Galaxium TM Galanium TM Fe Galimax Flavor TM K Galacid TM Main feature Process improvement Health & nutrition Health & nutrition Health & nutrition Process improvement Other key benefits Clean labelling Process improvement Taste enhancement 6 ENHANCING THE GENIUS OF NATURE

7 Examples of Applications Clean labelling Phosphate-free leavening system in flatbreads & tortillas Galactic has developed an innovative solution called for tortilla producers who want to replace SAPPs (sodium acid pyrophosphates) and coated organic acids by a natural, healthy and cost effective substitute. Benefits of : Replacement of coated organic acids and SAPPs Allowed in organic products No taste impact Sodium-free Palm oil-free Fewer E-numbers Quality improvement of the final product Phosphate-free leavening system in cakes Phosphates in cakes can also be replaced by a natural solution,. Ingredients Control (%) Trial (%) Flour (11% protein) Egg Butter Sugar Sodium bicarbonate SAPP Total Source: The tests were conducted by the Hogeschool Gent. Phosphate and aluminium-free leavening system in pre-baked frozen pizzas Leavening index Effect of on pizza crust volume at different steps Preparation Storage (6 days at -18 C) Pre-baking Baking SALPs are no longer allowed in bakery products. Galactic offers to replace them. enables the dough to rise even after freezing. BAKERY PRODUCTS 7

8 Phosphate-free leavening system in chilled and bake-off cookies It is also of interest to eliminate SAPPs in chilled and bake-off cookies (less sodium and no phosphates). successfully replaces them. Ingredients Control (%) Trial (%) Flour (11.5% protein) Margarine Sugar Brown sugar Chocolate chunks Cocoa powder Salt Sodium bicarbonate SAPP* Total *Galactic tested this recipe with SAPP 15, but it is possible to replace all SAPPs used in bake-off products with. The results of the sensory tests showed that the cookies made with had an enhanced chocolate flavour and were crunchier compared to the cookies containing SAPPs. Process improvement Improvement of dough properties Control Spreadability Appearance Good Good Colour Crunchiness Taste Good Better Galaxium TM (calcium lactate) improves the baking properties of flour (arrival time, peak time, stability and volume). Table: farinogram data on dough containing various additives Parameter Control Calcium lactate 0.5% Calcium gluconate 0.5% Sodium gluconate 0.5% Water absorption (%) Arrival time (min) Peak time (min) Stability (min) ENHANCING THE GENIUS OF NATURE

9 The effects of additives on the specific volume of baked bread were measured. The control had a specific volume of 3.7 cm³/g, calcium lactate 0.1%w/w 3.9, calcium gluconate 0.1%w/w 3.7 and sodium gluconate 0.1%w/w 3.8. The values of the control and the test samples were analysed by a Student s paired t-test. Six trials were conducted. Source: Gembloux University. Structure improvement of gluten-free bread The absence of gluten network in gluten-free bread often leads to a very heterogeneous distribution of pore size. By partially substituting the yeast (about 25%), avoids this phenomenon and enables a much more homogeneous breadcrumb. Ingredients Trial 1 (%) Trial 2 (%) Water Tapioca starch Rice flour Potato starch Rapeseed oil Maize starch Beet sugar Dried white eggs Fresh yeast Salt Rice starch Calcium propionate Sodium bicarbonate Total Reference (with yeast) Trial (with and a 25% yeast reduction) The picture on the left clearly shows the heterogeneity in the pore size while the picture on the right displays a much more homogeneous pore size distribution. BAKERY PRODUCTS 9

10 Time saving in the production of breadcrumbs Yeast is regularly used in the production of breadcrumbs, which requires a waiting time for the dough to rise before baking. With Galactic s new natural solution,, the waiting time is no longer needed. As a result, manufacturers substantially reduce the production time without losing the volume of the final product. In case of need, the use of allows to adjust the colour of the breadcrumbs (from yellow to orange). A = Control with yeast (orange) B = 0.66% (orange) C = 1.00% D = 1.50% (yellow) Health and nutrition Reduction in the salt content Galactic reduced the salt content by 25% by using 0.25% of Galimax Flavor TM K without impacting on the organoleptic properties. The dosage of Galimax Flavor TM K may however fluctuate between 0.25 and 0.50% depending on the customer s recipe. Ingredients Control (%) Trial (%) Wheat flour (11% protein) Water Fresh yeast Salt Margarine Galimax Flavor TM K Total When the salt content is reduced, gluten poorly develops and the bread loses volume. Galimax Flavor TM K enables manufacturers to reduce the salt content without losing volume. Reference (with salt) Trial (with a 25% salt reduction % Galimax Flavor TM K) 10 ENHANCING THE GENIUS OF NATURE

11 Iron fortification Galanium TM Fe (ferrous lactate) is the most soluble and the most bioavailable source of iron. The recommended dosage is between 3 and 7.5 mg Fe for 100 g of product (3 mg = 20% of the recommended daily intake). It has no effect on the appearance, the colour and the taste of bread. Calcium fortification Galaxium TM (calcium lactate) is the most soluble and the most bioavailable source of calcium. Formulation of fortified biscuits Ingredients % dry weight Wheat flour Min. 60 Sugar Min. 10, max. 20 Vegetable fat Min. 10 Dry skim milk Min. 5 Galaxium TM 1.4 (amounts for 200 mg/ serving size of 100 g) 200 mg of calcium accounts for 25% of the recommended daily intake of calcium for an adult in the European Union and for 20% in the United States. Summary of Galactic s Solutions Clean labelling Health and nutrition Process improvement Taste enhancement Mineral enrichment Sodium reduction Dough properties Bread Gluten-free bread, sourdough bread, croissant, white toast bread, roll, bun, etc. Galaxium TM Galanium TM Fe Galimax Flavor TM K Galacid TM Galimax Flavor TM K Flatbread Tortilla, pizza, pitta, etc. Galaxium TM Galanium TM Fe Galimax Flavor TM K Galimax Flavor TM K Cake Brioche, doughnut, sponge cake, muffin, brownie, etc. Galaxium TM Galanium TM Fe / Biscuit Cookie, shortbread, etc. Galaxium TM Galanium TM Fe / BAKERY PRODUCTS 11

12 Since 1994 Galactic has become one of the world leaders in biotechnology serving the food, feed, personal & health care, and industrial markets. Based on its valuable experience in the fermentation of lactic acid and in the production of its derivatives, Galactic continuously develops sustainable, innovative and health-friendly solutions in the field of food safety, nutrition and green chemistry. With its headquarters and an Innovation Campus in Belgium, production facilities and front-labs in the United States (Milwaukee), China (Bengbu) and Europe (Escanaffles, Brussels), and additional sales offices in Germany (Düsseldorf), Italy (Milan), Japan (Tokyo) and Brazil (Curitiba), Galactic employs about 370 people worldwide and is active in more than 65 countries. HEADQUARTERS NORTH AMERICA Galactic Inc W. Silver Spring Drive Milwaukee - WI USA Tel.: LATIN AMERICA Galactic Bioquímicos Ltda. Batel Business Center Av. Batel, n 1230 Cj Torre BBC Curitiba - PR - Brazil Tel.: EUROPE & AFRICA Headquarters & production plant Galactic s.a. Place d Escanaffles, Escanaffles - Belgium Tel.: Galactic Innovation Campus Allée de la Recherche, Brussels - Belgium Tel.: ASIA & OCEANIA Anhui COFCO Biochemical & GALACTIC Lactic Acid Co., Ltd. 1 Cofco Avenue, Bengbu Anhui Province - China Tel.: JAPAN B&G Japan Co., Ltd. AIOS Meguroekimae, Kami-osaki 2-chome, Shinagawa-ku Tokyo Japan Tel.: ENHANCING THE GENIUS OF NATURE

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