Gluten free pasta production

Transcription

1 Gluten free pasta production Basic technological aspects Bühler AG Stefanie Hardtmann

2 About Bühler. Corporate Presentation. 2 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

3 Bühler at a glance. Global market leader with strong roots in local markets. Group turnover (sales) 2014: CHF 2,332 million. Around 10,600 employees. Present in nearly 140 countries. Today, 80 service stations globally, +12 stations compared to Production sites in all regions. Up to 5% of turnover invested in research & development. Consistently high quality standard worldwide. 100% family-owned. 3 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

4 Bühler offers industrial process technologies and solutions in two main markets. Food Grain processing Snacks & Pasta Sweets Advanced Materials Electronics Optics Automotive Bühler Raw materials Technology & process engineering Manufacturing Logistics Services Basic foods & feed Nutritious foods Parts and coatings 4 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

5 Spirit of discovery. Continuous high investments in R&D. 4.2% of turnover invested in R&D in CHF million State-of-the-art innovation management. Bühler Innovation Board. Suppliers. Customers. Employees. Industry Experts. 5 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

6 Business Area Value Nutrition. VALUE NUTRITION Our solutions Innovative process solutions for the feed and food industries: from feed for cattle and poultry to aqua feed and pet food, to pasta and Asian noodles, to cereals and snacks as well as oilseeds. Our customers International, regional and local feed & food producing companies including feed mills but also flour and oil mills in 140 countries all over the world. Key facts Around 40% of the global pasta production takes place on Bühler machines. In addition, 35% of cereals, 30% of oilseeds, and 20% of feedstuff are processed with Bühler solutions. The core technologies relate to the areas of extrusion, drying and flaking. 6 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

7 Agenda Market drivers Technological challenge Process for production of gluten free pasta Why is starch gelatinization important? The role of amylose as glue 6 Raw material requirements 7 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

8 Market drivers gluten-free pasta 1. Gluten free as dietetic product - People suffering from celiac disease don t tolerate gluten (0.01 to 0.5 % of the population) - General tendency of consumers towards low allergen and gluten free nutrition 2. Gluten free as alternative to common pasta -Use of local non-wheat grains for pasta -Use of cheaper non-wheat grains -Transformation of low value by-products (e.g. broken rice) into value added food product like pasta - Consumers looking for food diversity 8 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

9 What s the challenges in producing pasta from gluten free raw material like rice and corn Natural rice Rice and maize contain proteins (~7 to 12 %)....but, the proteins are not able to form a strong elastic network like gluten Therefore, for pasta from gluten free raw material starch needs to be gelatinized to act as glue. 50 µm Rice pasta Note different microstructure of natural rice and of rice pasta (protein is stained green). 9 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

10 Wheat pasta and corn pasta are very different in terms of microstructure Wheat pasta Corn pasta Continuous phase of protein Starch gel of gelatinised starch builds continuous phase 10 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

11 Main difference between conventional wheat pasta and gluten-free pasta Conventional wheat pasta Gluten free pasta Protein is the glue Protein (Gluten) network provides framework of pasta Starch is a filler Starch granules are embedded in protein network Starch is the glue Gelatinized starch provides framework of pasta Small protein patches (no relevance for texture) is embedded in starch gel 11 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

12 The Polymatik pasta press is perfectly suited for producing gluten free pasta Mixing & Kneading in co-rotating twin-screw extruder Forced conveying in the twin-screw enables first-in first-out Nativ, gluten-free raw material Steam Additive Poly-C-one c % of flour Mixer/Kneader Water Press head Presscylinder Vacuum 12 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

13 Industrial short goods line for the production of gluten-free pasta Industrial applications so far for rice and corn flours E.g. Bühler short goods C-line for 1400 kg dried pasta/hour 13 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

14 Industrial short goods line for the production of gluten-free pasta Industrial applications so far for rice and corn flours E.g. Bühler short goods C-line for 1400 kg dried pasta/hour Raw materials dosing systems MSDF MSDA Polymatik-Press Pre-Dryer Zone B1 Cartrapen Shaking predryer Zone A1 Dryer Zone B2 Cooler Zone D1 14 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

15 Industrial long goods line for the production of gluten-free pasta Industrial applications so far for rice and corn flours E.g. Bühler long goods C-line for 1200 kg dried pasta/hour Polymatik Dryer B Spreader Pre dryer A Stabilisation C 1 Cooler D Moistening C 2 15 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

16 Temperature [ C] Comparison of extrusion conditions for wheat pasta and gluten free pasta in the state diagram of starch native flour Mixing & Kneading with H 2 O & steam Extrusion HT HT drying drying HT drying conventional wheat pasta gluten free pasta Tm Melting of starch T g of starch 16 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U Moisture content [g/100 g wb]

17 Upon processing of gluten free pasta the starch is gelatinized in the Polymatik press Native wheat starch After heating in excess water to 90 C native starch Heating in presence of water Melting, swelling & amylose leaching gelatinized starch 17 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

18 Endo HT drying of gluten free pasta contributes to strengthening the amylose network structure. gelatinization Melting of amylose-lipid complexes Native rice flour with Poly C Starch is native and the amylose-lipid complexes have low degree of perfection Rice pasta after extrusion Starch is gelatinized and two forms of amylose-lipid complexes exist Rice after HT drying Further perfectioning of the amlyoselipid complexes has taken place Rice pasta will not fall apart during cooking and presents low levels of stickiness 18 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

19 Suitable raw material for gluten-free pasta. Flours and starches of gluten-free cereals like rice or maize Flours of pseudo-cereals like Amaranth, Buckwheat, Millet or Quinoa General requirements: - Granulation of the flours 100 % < 250 µm 15 % < 125 µm - Amylose content > 20 % - Fat content < % - Ash content as low as possible (< 0.7 %) - Note the special technical requirements for raw material handling for dietetic products 19 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

20 Raw material requirements Additives. Additive Poly-C-one - Promotes starch (amylose) complexation and yields pasta with high firmness, low cooking loss and low stickiness - Acts as lubricant and reduces stickiness of pasta at the die during cutting. - Poly-C-one is a specially designed emulsifier E471 (mono- and diglycerides of food fatty acids) - Amount to be added 0.5% 1% of flour quantity Additive Beta-Carotene - Optional additive for rice or white maize flour to give pasta of yellow color - Amount to be added 0.02% of flour quantity Additive Curcumin - Optional additive for rice or white maize flour to give pasta of yellow color - Amount to be added 0.2 % of flour quantity 20 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

21 Target product qualities of gluten-free pasta processed by Polymatik. Quality-benchmark for glutenfree pasta is wheat pasta Good texture features of cooked pasta - bite > 0.8 N High surface integrity of cooked pasta - cooking loss < 5% Gelatinization degree 50-70% (enzymatic method) Gluten content < 20 mg/kg dried pasta 21 Bühler Gluten free pasta production basic technological aspects. S. Hardtmann - U

22 Thank you!