opportunities for gluten- free products: why not corn ... · an auto-immune disorder – not an...

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Opportunities for Gluten-Free Products: Why not Corn? & How to Include…!

NAMA Corn Dry Milling Conference ! Peoria, IL | May 14, 2015!!Matt Gennrich, Cargill Food Applications NA !

© 2014 Cargill, Incorporated. All rights reserved.!Quick Guide to using the new PowerPoint templates!

Outline!

Ø  Introduction!Ø  Celiac Disease – Why the need for Gluten-Free?!Ø  Formulating for Gluten-Free!! !Gluten-Free Ingredients!! !Formulation Challenges!Ø  Where corn / corn products can play a role !Ø  Questions & Answers!!


Food Science & Technology Course!

!Flour Tortilla Seminar!

!Cracker Seminar!Manhattan, KS!

Introduction!Professional Bio! Gustavus Adolphus

College!!

St. Peter, MN!B.A. – Biology, 1997!

Biological Technician!!St. Paul, MN & East Lansing, MI

1998 - 2001!

Lab Technician / Food Scientist!

!Minnetonka & Plymouth, MN!

2001 - present!


Stewart, MN (pop. 550) ~70mi W of MSP!!8 acres, about 5min outside of town!!Brother (Tim) works as farmhand and runs ~50 acres of land, mostly corn (ethanol)!

Introduction!Personal Bio!


Celiac Disease: Why the need for Gluten-Free?!


Celiac Disease (Sprue)!An auto-immune disorder – not an allergy!!

•  Celiac disease is the most common auto-immune genetic disorder in Europe and North America.!!•  Celiac disease can be considered an intolerance to gluten, but not all gluten intolerance is celiac disease.!!•  97% of those with celiac disease do not know they have it.!!•  Currently the only treatment for celiac disease is a gluten-free diet.!!

Celiac disease is a manifestation of the body attacking itself and results in the inability to absorb nutrients:!

Normal villi, showing finger-like morphology!

Villi in a celiac, showing villous atrophy!


Who is avoiding gluten?!Population segments that follow a gluten-free diet:!

Segment! Estimated US Size (2010)! Why?!

Lifestyle! 15 MM! Believe that gluten-free is a healthier way of eating;!Some consumers adopt a gluten-free diet to manage weight !

Celiacs! 3 MM (1 in 133)!The only treatment for celiac is a gluten-free diet;!97% of sufferers remain undiagnosed;!Prevalence is increasing!

Other Health Conditions! 4.5 MM!

Many consumers see a correlation between severity of symptoms associated with autism, MS, AD/HD, and irritable bowel syndrome, among other health conditions.!

Wheat Allergies! 1.5 MM*! Wheat is considered one of the ‘Big 8’ allergens;!11 million Americans live with food allergies!

Gluten Intolerance/ Sensitivity !

15-30 MM!in the US!

Some people cannot tolerate gluten, causing multiple health issues such as: constipation, diarrhea, fatigue, and anemia.!


Formulating for Gluten-Free:Ingredients & Challenges!


Formulating for Gluten-Free:!Gluten and gluten-containing ingredients!

•  Gluten is a storage protein found in grains (glutenin + gliadin = gluten).!!•  In the world of bakery, gluten provides visco-elastic properties to dough and allows bread to achieve a foam to sponge transition.!!•  Greatly contributes to texture, flavor, and shelf-life, especially in breads.!!•  In medicine, gluten = gliadin, which is responsible for celiac disease.!

•  Gliadin antibodies indicate gluten intolerance, even in the absence of celiac disease.!!!

What is Gluten?! Ingredients that contain gluten:!Wheat:!Bran !Bulgur !Dinkel !Durum!Einkorn !Emmer !Farina !Freekeh!Graham flour !Kamut !Matzo!Semolina !Spelt !Triticale !Wheat!Wheat bran !Wheat germ!Wheat germ oil !Wheat starch*!!Barley:!Barley !Malt !Malt extract!!Rye:!Rye !Triticale!!*Oats:!GF oats do exist but are suspect to some GF consumers. Avenins are of concern to a small percentage of Celiacs.!!!!!


Formulating for Gluten-Free:!Commonly used gluten-free ingredients!

Amaranth ! ! ! Buckwheat!Coconut ! ! ! ! Corn (see breakout below) ! !Flax Seed / Meal ! ! ! Flours from nuts, beans, & seeds:!Millet ! ! ! ! - Legumes (Pulses) !Potato Flour / Starch ! ! - Peanuts!Quinoa ! ! ! ! - Tree Nuts !Rice ! ! ! ! Rice Bran! - Rice Flour ! ! ! Sorghum (Milo)! - Brown Rice Flour ! ! ! Soy (Soya)! - Sweet Rice Flour ! ! ! Tapioca (Cassava) Flour / Starch!Teff!!Corn-derived Ingredients:!Corn Meal / Grits ! ! ! Corn Flour (Whole Grain)!Corn Starch (native & modified)! ! Corn Sugar (Dextrose)!Corn Bran ! ! ! Maltodextrin!Masa Flour!!!!!!!


Formulating for Gluten-Free:!Focus on Ancient Grains and Pulses!Ø  Focus on “Ancient Grains:”!!

•  Amaranth – high in quality protein (lysine), calcium, iron, magnesium; very distinct flavor!!•  Millet – rich in B vitamins; pleasant nutty flavor; poor water binding!!•  Sorghum (Milo) – moderate potassium, fiber, phosphorous; mildly sweet flavor; poor water binding!!•  Teff – rich in B vitamins, calcium, iron, magnesium; molasses-like flavor; moderate water binding!!•  Quinoa – complete protein, rich in calcium, fiber, phosphorous, iron; nutty, earthy flavor;!

!moderate water binding!

Ø  Focus on Pulses (peas, lentils, beans, chickpeas):!!

•  Peas (yellow/green, whole/split) – PDCAAS range of 0.50-0.64!!•  Lentils (red/green, whole/split) – PDCAAS range of 0.54-0.63!!•  Beans (pinto, kidney, black, navy) – PDCAAS range of 0.53-0.67!!•  Chickpeas – PDCAAS value of 0.52!


Formulating for Gluten-Free:!Lesser-used and associated minor ingredients!

Arrowroot (somewhat common)!Lupine – see image below!Montina (milled Indian Ricegrass)!Sago (tropical palm starch)!!

More obscure GF ingredients:!

© fineartamerica.com!

Hydrocolloids (xanthan, guar, LBG)!Maltodextrin*!Leavening Agents!Inulin (chicory root fiber)!Enzymes (depending on substrate)!Dextrose*!Emulsifiers & Crumb Softeners! - Lecithin! - DATEM! - Mono- & Di-glycerides! - Soy Flour!Flavors (some)!Preservatives!!*Corn-derived!!

Minor ingredients used in GF:!


Formulating for Gluten-Free:!Formulation Challenges!

Product! Difficulty in Formulating!

General Approach! Key challenges!

Cookies! Easy!!

Replacement of wheat flour with other flours. Common ingredients used. Standard processing.!

Gritty texture; Lack of !spread; Higher Cost!

Cakes & Muffins!

Medium! Blend of flours and starches with hydrocolloids. High-ratio cake formula is possible. Standard processing.!!

Gummy texture; Shrink !after baking; Shelf-life;!Higher Cost!

Bread! Hard! Composite flour. !Process: batter to intermediate batter-dough consistency.!

Process; Poor flavor / texture;!Much Higher Cost; Shelf-life;!Distribution (typically frozen)!


Formulating for Gluten-Free:!Formulation Challenges - Bread!

Tapioca Starch! Brown Rice Flour! Potato Starch! Wheat Flour Control!


Formulating for Gluten-Free:!Formulation Challenges – Starch Comparisons!

Starch Source!

Granule Size (µ)!

Amylose %! Gelatinization Temp (°F/°C)!

Morphology! Paste Characteristics!

Attributes of Bread!

Corn (dent)! 5-20! 25% (common)! 143-171 °F!62-77 °C!

Polyhedron! Medium-firm Gel! Opaque, brittle, fine crumb, corn flavor!

Potato! 15-75! 20%! 133-160 °F!56-71 °C!

Smooth oval! Medium Gel! Opaque, brittle, fine crumb, potato flavor (chlorine?)!

Rice! 3-8! 20% (common)! 142-180 °F!61-82 °C!

Irregular polygon!

Firm Gel (Long Grain); Soft Gel (Short Grain or Sweet Rice)!

Opaque, fine crumb, some flexibility, neutral flavor!

Tapioca! 5-25! 15%! 145-176 °F!63-80 °C!

Smooth, irregular spheres!

Soft Gel! Translucent, coarse crumb, flexible, neutral to slightly off flavor!

Wheat! 22-36!2-3!

25%! 126-151 °F!52-66 °C!

Bimodal;!Smooth round!

Firm Gel! Opaque, fine, brittle without gluten!


Gluten-Free & Corn:Where corn & derivative!products can be utilized…!


Gluten-Free & Corn:!Utilization in GF Cookies & Crackers!

•  Have formulated variations of a GF “Kettle Corn Cookie” (Caramel Corn, Mexican Chocolate, Lemon) & have also used the base mix for these cookies to produce a GF “Blondie.” Cookie is ~80% whole grain.!!•  This GF base mix utilizes whole grain corn flour (~15.0% of bowl formula for Blondie; ~23.5% for the cookie – also ~1.0% corn bran used as part of the topping for the cookie).!

•  Have recently worked on a cracker project where we made a prototype GF Ancient Grain cracker. This formula could be adjusted to include a small percentage of whole grain corn flour.!

Gluten-Free Ancient Grain Crackers!

Formulation contains:!Instant Starch ~20.0%!Maltodextrin !~2.0%!!


Gluten-Free & Corn:!Utilization in GF Cakes & Muffins!

Wheat Starch!

Tapioca Starch!

Corn Starch!

GF Cake Development:!

Combination of tapioca starch and corn starch closely mimics viscosity / gelatinization curve of wheat flour.!


Gluten-Free & Corn:!Utilization in GF Cakes & Muffins!

Formulations contain:!Corn Starch ~6.0 - 9.5%!Dextrose !~1.5%!!

•  Three flavor variations: White, Chocolate, & Yellow (Vanilla).!

Formulation contains:!Corn Starch !~8.5%!Dextrose !~1.5%!Instant Starch !~0.5%!!

•  Have also done a corn muffin variation, with ~18.5% corn meal.!


Gluten-Free & Corn:!Utilization in GF Pretzels!

Formulation contains:!Corn Starch ~29.5%!Maltodextrin !~1.0%!!•  Use of corn starch allows dough to be firmer, much closer to an actual pretzel / bread dough than a typical gluten-free dough formulation.!


Gluten-Free & Corn:!Utilization in GF Pancakes!

•  Addition of a small amount of whole grain corn flour improves texture and flavor profile, while still allowing enough flexibility to roll. !

Formulation contains:!Maltodextrin !~7.0%!WG Corn Flour !~3.5%!Dextrose !~2.0%!Instant Starch !~1.0%!!


Gluten-Free & Corn:!Utilization in GF Breads!

•  Using 100% corn not feasible!

•  Whole grain corn flour, in combination with other starches and GF whole grains, can result in a multi-grain loaf that achieves a 51% whole grain content.!

Formulation contains:!WG Corn Flour !~6.0%!Instant Starch !~1.5%!Maltodextrin !~1.0%!!


Gluten-Free & Corn:!Utilization in GF Pasta Products!

•  The Mrs. Leeper’s® Brand (produced in Italy) offers a line of corn-based pastas. These are produced with 100% corn flour. De Boles® also offers corn spaghetti and corn elbows products, with their ingredient declaration being a combo of corn meal and corn flour.!

Corn Spaghetti! Corn Rotelli! Corn Elbows! Corn Vegetable Radiatore!


Gluten-Free & Corn:!Corn-based products that have typically been GF!

Corn Tortillas!

Puffed Corn Snacks (Pirate’s Booty®)!

Taco Shells!


Gluten-Free Resources:!

Ø  Celiac Sprue Association – www.csaceliacs.org!Ø  The Gluten Intolerance Group – www.gluten.org!! Gluten Free Certification Org. – www.gfco.org!Ø  GlutenFree.com – www.glutenfree.com!Ø  Gluten-Free Baked Products, J.L. Casper & W.A. Atwell!Ø  The Gluten-Free Bible, T. Hunt & M. Posius!Ø  Gluten Freedom, A. Fasano & S. Flaherty!Ø  Gluten-Free Baking Classics, A.G. Roberts!


Questions?!

Acknowledgments:!!Jeff Casper & Bill Atwell: Gluten-Free Baked Products!!Keith Smith, Cargill DCI!!NAMA Corn Dry Milling Conference!!!

Thank You!!

opportunities for gluten- free products: why not corn ... · an auto-immune disorder – not an...

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