formulation for today's trends...are traditionally nixtamalized corn tortillas whole grain? •...
TRANSCRIPT
Formulation for Today's Trends
Low sodium, high fiber, whole grain, low fat,
gluten‐free and other trends have diversified the market
for today's flatbreads.
Presented By: Daniel J. Brooker, M.S.http://www.brookerlaboratories.com
Trends we will cover
• Gluten Free• Whole Grain
• Low Sodium• Low Fat• High Fiber
• Bonus material –
Sensory Analysis Techniques
– Trans Fat Free regulatory update
Nutrient Content Claims
Factual Statements
Gluten Free
Celiac Disease and Allergies
Nearly 3 million Americans have celiac disease. Celiac is an autoimmune form of
gluten intolerance. These people must eat gluten‐free diet for life.
Other people may have an allergy to wheat
that triggers an immune response.
Gluten and Celiac
In the context of celiac disease, the term "gluten" is used to collectively refer to gluten
in wheat, and to the proteins in other grains that have been demonstrated to cause
harmful health effects in individuals who have celiac disease. These grains are wheat
(including different varieties such as spelt and kamut), rye, barley, cross‐bred hybrids (e.g.,
triticale, which is a cross between wheat and rye), and possibly oats.
What is the FDA's proposed definition of the term "gluten"?
• FDA is proposing to define the term "gluten" to mean the proteins that naturally occur in a prohibited grain
and that may cause adverse health effects in persons with celiac disease.
• “Prohibited grain“
means any one of the following grains:
– Wheat, meaning any species belonging to the genus
Triticum– Rye, meaning any species belonging to the genus Secale– Barley, meaning any species belonging to the genus
Hordeum– Crossbred hybrids of wheat, rye or barley (e.g., triticale,
which is a cross between wheat and rye)
FDA’s proposing to define the term "gluten‐free”.
• A food bearing this claim in its labeling cannot contain any one of the following:
– An ingredient that is a prohibited grain– An ingredient that is derived from a prohibited grain
and that has not been processed to remove gluten
– An ingredient that is derived from a prohibited grain and that has been processed to remove gluten, if the use of that ingredient results in the presence of 20
parts per million (ppm) or more gluten in the food or
– 20 ppm or more gluten
Gluten Free Grains
• Amaranth
• Buckwheat
• Corn
• Millet
• Montina (Indian rice grass)
• Quinoa
• Rice
• Sorghum
• Teff
• Wild Rice
Why Whole Grain?
• 2010 should be the biggest year ever in terms of total whole grain product launches.
• Since 2005, the whole grain product claim has consistently been in the top 20 among all food and beverage claims.
• Nearly 6% of all food products and 18% of all‐ natural food products launched in 2010 have the whole grain claim.
Source : “A Host of Whole Grain Products Driving Sector's Growth”. Mintel and SPINS indicate that whole grain product Innovations and sales to reach record highs in 2010
Whole Grains Council
http://www.wholegrainscouncil.org/
Who is using the Whole Grain Stamp?http://www.wholegrainscouncil.org/find‐whole‐
grains/tortillas‐wraps‐and‐flatbreads
Whole Grain
• Whole grains or foods made from them contain all the
essential parts and naturally occurring nutrients of the entire
grain seed. If the grain has been processed (e.g., cracked,
crushed, rolled, extruded, and/or cooked), the food product
should deliver approximately the same rich balance of
nutrients that are found in the original grain seed. Whole
Grains Council in May 2004
• Cereal grains that consist of the intact, ground, cracked or
flaked caryopsis, whose principal anatomical components ‐
the starchy endosperm, germ and bran ‐
are present in the
same relative proportions as they exists in the intact caryopsis
‐
should be considered a whole grain food. FDA Draft
Guidance: Whole Grain Label Statements February 17, 2006
LIST OF WHOLE GRAINSThe following, when consumed in a form including the bran, germ and endosperm, are examples* of
generally accepted whole grain foods and flours.
• Amaranth• Barley• Buckwheat• Corn, including whole cornmeal and popcorn• Millet• Oats, including oatmeal• Quinoa• Rice, both brown rice and colored rice• Rye• Sorghum (also called milo)• Teff• Triticale• Wheat, including varieties such as spelt, emmer, farro, einkorn,
Kamut®, durum and forms• and wheatberries• Wild rice
Oilseeds and legumes (such as flax, chia, sunflower seeds, soy, chickpeas, etc.) are not
considered grains.
FDA’s Guidance on Whole Grain Labeling
• Manufacturers can make factual statements about whole grains on the label of their
products, such as "10 grams of whole grains," "½
ounce of whole grains," (21 CFR
101.13(i)(3)) and "100% whole grain oatmeal“ (as percentage labeling under 21 CFR
102.5(b)), provided that the statements are not false or misleading.
The main benefits of whole grains• Studies show that eating whole grains instead of refined grains lowers the risk of
many chronic diseases. While benefits are most pronounced for those consuming
at least 3 servings daily, some studies show reduced risks from as little as one
serving daily. The message: every whole grain in your diet helps!
• The benefits of whole grains most documented by repeated studies
include:• stroke risk reduced 30‐36%• type 2 diabetes risk reduced 21‐30%• heart disease risk reduced 25‐28%• better weight maintenanceOther benefits indicated by recent studies include:• reduced risk of asthma• healthier carotid arteries• reduction of inflammatory disease risk• lower risk of colorectal cancer • healthier blood pressure levels• less gum disease and tooth loss
Government Recommendations
• The Dietary Guidelines for Americans, released in January
2005, recommend that all adults eat at least half their
grains as whole grains
– that's at least 3 to 5 servings of
whole grains. Even children need 2 to 3 servings or more.
Recommendations in Canada's Food Guide are almost
exactly the same. (Not surprising, since the human body
changes little from country to country!) • The health evidence has increasingly convinced
governments and health organizations worldwide to
recommend daily consumption of whole grains. • Yet consumption lags far behind these recommendations.
For example, the average American eats less than one daily
serving of whole grains, and over 40% of Americans never
eat whole grains
at all.
Are traditionally Nixtamalized Corn Tortillas Whole Grain?
• The four principal parts of a mature corn kernel consist of
the hull or bran (pericarp and seed coat), germ,
endosperm, and the tip cap (Ref. 2). The tip cap, the
attachment point of the cob, may or may not stay with the
kernel during handling, and, thus, is not considered an
integral part of the kernel or caryopsis. However, the bran,
germ and endosperm are integral parts of the kernel and
should be present in the relative proportions as found in
the kernel to be considered "whole grain." • Answer: Therefore, corn tortillas made from traditionally
nixamalized corn that has been rinsed to remove the
perciarp or “nexayote”
should not be considered whole
grain.
Source: Guidance for Industry and FDA Staff ‐Whole Grain Label Statements Draft
Guidance Feb 06.
Term #1 Nutrient Content Claim
Nutrient Content Claim: A claim that expressly or implicitly
characterizes the level of a nutrient of the type required to
be in nutrition labeling
Examples:• Free
Synonyms for "Free": "Zero", "No", "Without", "Trivial Source of", "Negligible Source of", "Dietarily
Insignificant Source of“.
• LowSynonyms for "Low": "Little", ("Few" for Calories), "Contains a Small Amount of", "Low Source of"
• HighSynonyms for “Highs": "Rich In," or "Excellent Source Of“.
• Good SourceSynonyms for “Good Source": "Contains," or "Provides“.
Term #2 ‐
RACC
What’s a RACC?Reference Amounts Customarily Consumed per
eating occasionManufacturers must use the RACC to determine
a specific serving size for their products. You can Locate the appropriate food category
and RACC for your product in the tables in Section 101.12(b)
of the food labeling
regulations 21CFR.
RACC – Cont’d
How to determine the serving size for your tortillas using the RACC.
A.12 ct 24oz package of tortillas24oz/12 tortillas = 2oz per tortilla (or 57g)
Serving Size is “1 Tortilla (57g)”
B.36 ct 24oz package of tortillas24oz/36 tortillas = 0.67oz per tortilla (or 19g)
Serving Size is “3 Tortillas (57g)”
Term #3 ‐
Disclosure Statement
When levels exceed:
13 g Total Fat4 g Saturated Fat60 mg Cholesterol480 mg Sodium
per RACC or per labeled serving
a disclosure statement is required as part of
the nutrient content claim:
"See nutrition information for___content“
with the blank filled in with nutrient(s) that exceed the prescribed levels).
Why Reduce Sodium in Tortillas?
The maximum recommended daily allowance for sodium is that of about 1
teaspoon (2,400 mg). For those 40 and over, African‐American, or with
high blood pressure, it is about 1,500 mg per day. Americans consume
(3,500mg) about 1½
to more than 2 times these recommended amounts.
Only 11% of the sodium in Americans’
diets comes from their own
saltshakers;
nearly 80% is added to foods before they are sold – i.e.
tortillas.
Flour Tortillas are a major source of dietary sodium. A 13 inch
burrito size
tortilla typically has 25% (600mg) of the RDA for sodium.
The food industries prevailing trend is to reduce sodium in its products. As
awareness increases among regulators, health care professionals and
consumers as to the negative health aspects of sodium the trend will only
get stronger.
Source: Quality Assurance & Food Safety Magazine: Reducing Sodium Teaspoon by Teaspoon
Follow the leaders…
In recent months major food companies have announced product
reformulations to lower the sodium levels.
• March, Kraft Foods announced a two‐year plan to reduce sodium
by an average of 10 percent in its North American products.
• April, General Mills pledged a 20 percent reduction in about 40
percent of its products by 2015.
• May, Heinz
reduced sodium by 15 percent in all the ketchup it sells
in the U.S.
• June, The Campbell Soup Company reformulated 21 soup varieties
to reduce sodium by 25 to 45 percent.
• July, Cargill
showcased a reduced sodium tortilla made with
SaltWise, a blend that provides the taste and functionality of salt
with 25 to 50 percent less sodium.
How can I make a Low Sodium Nutrient Content Claim?
• Definition: 140 mg or less per RACC • If you make this claim ‐
Don’t forget to check
if disclosure statements are required!
When levels exceed:
13 g Total Fat
4 g Saturated Fat
60 mg Cholesterol
480 mg Sodium
Strategies to remove sodium in Tortillas
• Reduce Salt (which is only about 40% sodium by weight)
• Adjust and/or replace sodium
based leavening salts– Sodium bicarbonate, SAS, SALP,
SAPP
– Alternatives include potassiumand calcium salts
• Adjust process, shelf‐life, and flavor profile.
How can I make a Low Fat Nutrient Content Claim?
• 3 g or less per RACC • If you make this claim ‐
Don’t forget to check
if disclosure statements are required!
When levels exceed:
13 g Total Fat
4 g Saturated Fat
60 mg Cholesterol
480 mg Sodium
Strategies to remove fat in Tortillas
• Take the fat out (oil, shortening, lard, etc…)• Compensate for the fat reduction.
– Water
– Fiber– Gums
– Emulsifiers
– Protein– Address Flavor loss, texture and Shelf life issues
How can I make a High Fiber Nutrient Content Claim?
• HighSynonyms for “Highs": "Rich In," or "Excellent Source Of“. Definition:
Contains 20% or more of the DV per RACC.
• Good SourceSynonyms for “Good Source": "Contains," or "Provides“. Definition: 10%‐
19% of the DV per RACC.
*In addition to disclosure statement levels; If a fiber claim
is made and the food is not low in total fat, then the label
must disclose the level of total fat per labeled serving. 21
CFR 101.54(d)(1) The disclosure shall appear in immediate proximity to such
claim, be in a type size no less than one‐half the size of the claim and precede any
disclosure statement required under 101.13(h) (e.g., "contains [x amount
] of total fat
per serving. See nutrition information for fat content").
Strategies to add Fiber in Tortillas
• Choose a fiber• Increased water absorption• Reduced shelf life• New flavor and texture profile
Sensory Evaluation of Tortillas
• Sensory data is difficult to obtain and rely upon because we (people) are the analytical
instruments. • Difference tests and preference tests are the
most common test that you will need in the tortilla factory. Below are two examples
adapted to tortillas from Laboratory Methods of Sensory Analysis of Food [28] by Poste
et
al..
Example of Questionnaire for Triangle Difference Test
Product: Tortilla
Name:
Date:
Two of these three samples are identical, the third is different. Taste the samples in
the order indicated and identify the odd or different sample.
Identify the odd sample.
Code
Check odd sample385
___639
___719
___
Comments:
Example of Questionnaire for paired comparison preference test
Product: Tortilla
Name:
Date:
Taste the tortillas in the following order:
385
719
Which Tortilla do you prefer?
Why?
Negatively Influencing Factors
Things that can influence testing include:• Test method• Facilities – no bosses in the room!• Sample preparation• Panelists• Experimental design• Statistical treatment of the data collected.
If you decide to implement sensory into your product development program you be well advised to consult
appropriate texts and to receive some sensory training.
Trans Fat Update.
You may want to re-examine your product labels if they are labeled with “0g trans fat”.FDA’s position in a Warning Letter issued to David’s Cookies this month 9/1/10:
“The phrase “0 grams TRANS FAT” meets the definition of a nutrient content claim because it characterizes the level of trans fat, which is a nutrient of the type required to be declared in nutrition labeling. 21 USC § 343(r)(1)(A); 21 CFR 101.13(b). ”
What you should do:a) Revise the claim to “0g trans fats per serving”.b) Check that any of these other nutrients do not exceed the following values per
serving and per RACC:Total Fat 13gSaturated Fat 4gCholesterol 60 mgSodium 480mg
c.) If you exceed the values listed above you must add a disclosure statement next to the 0g trans fat claim. i.e. “See nutrition information for fat, saturated fat, and cholesterol content.”
Trends we covered
• Gluten Free• Whole Grain
• Low Sodium• Low Fat• High Fiber
• Bonus material –
Sensory Analysis Techniques
– Trans Fat Free regulatory update
Nutrient Content Claims
Factual Statements
To teach you what you need to know to capitalize on formulation trends.
Oats are Gluten Free right?• Why did FDA not include oats as one of the "prohibited grains" in its proposed
definition of the term "gluten‐free"?
• FDA did not include oats as one of the "prohibited grains" in its proposed
definition of the term "gluten free" for the following reasons:
– There is no consensus among nutrition experts or authorities on the unconditional exclusion
of oats from the diet of individuals with celiac disease. For example, the following celiac
disease experts/authorities do not support the unconditional exclusion of oats: The National
Institutes of Health, the American Dietetic Association, and some celiac disease
research/treatment centers.
– Research data suggest that the majority of individuals with celiac disease can tolerate a daily
intake of a limited amount (e.g., 50 grams) of oats that are free of gluten from wheat, rye,
barley or their crossbred hybrids.
– Oats are reported to add variety, taste, satiety, dietary fiber,
and other essential nutrients to
the diet of individuals with celiac disease and may make their diet more appealing.
– Allowing oats free of gluten from wheat, rye, barley or their crossbred hybrids, to bear a
"gluten‐free" labeling claim would make it easier for consumers to identify such oats in the
marketplace and may serve as an incentive for more manufacturers
to produce such oats.