Rick GreenKeyLeaf Life Sciences

Plant Protein Ingredients Summit Saskatoon, SKMay 31, 2019

Opportunities for Production of Higher Value Plant Proteins and Co-products

KeyLeaf Overview

• Recently changed trade name from POS Bio-Sciences to KeyLeaf Life Sciences.

• Evolved from fee-for-service R&D lab and pilot plant process development company.

• Now - Commercialization of our own ingredients or ingredients with partnering companies.

Key Trends/Drivers for Value-added Protein

• Natural ingredients (replace synthetics)

• Clean labels

• Sustainable production of ingredients, foods

• Organic foods

• Healthy foods – reformulation!

– low fat

– no-trans

– Omega-3

– low sodium

– high fibre

• Alternative sources of protein

• e.g. Hemp, quinoa, pulses

• unique functionality

• gluten-free

• non-allergenic

• alternatives to animal protein

Key Trends/Drivers for Value-added Protein

Protein Seed Sources

• Defatted oilseed meals

• Soybean

• Canola

• Hemp seed

• Pulses (e.g. peas, lentils, faba bean)

• Cereals (e.g. oats, wheat)

• New crops (e.g. quinoa, camelina)

• Fruit & vegetable seeds

Composition of Crops

25%

2%

6%

3%64%

DRY PEAS

27%

44%

11%

4%

14%

CANOLA SEED

14%

5%

12%

4%

65%

OATS

Protein

Carb./starch

Crude fibre

Oil

Ash

Protein

Oil

Crude fibre

Ash

Hull

Protein

Carb./starch

Oil

Crude fibre

Ash

• Nutritional value

• Emulsification

• Aeration

• Foaming

• Gelation

• Protect from oxidation (microcapsules)

• Viscosity

• Water holding capacity

• Texture modification

• Elasticity in baked goods

• Health benefits

• Reduce risk of disease

• Mediate symptoms

Function of Plant Proteins in Foods & Nutraceuticals

Opportunity to replace/reduce food additives (higher value use)!

Current Challenges for Utilization of Plant Proteinsin Final Formulated Foods

• Off-flavours

• Protein functionality is not well characterized

• Food formulators are not familiar with new proteins

• Limited availability of new protein sources ingredients

– Only a few types of protein isolates

• Processing technology is costly so prices are higher for some plant proteins

– High water usage for wet extraction

– Low yield of extraction

– High starch and fibre content in the seed which is lower in value

– Large economy of scale for viability

Processing Technologies for Plant Protein

• Dry milling

• Wet processing (extraction and isolation)

• Wet fractionation of the protein

Starch and fibre are also produced by these dry and wet processing techniques.

Commercial Protein Ingredients

Seed SourceDry Milled

ConcentrateWet Processed

ConcentrateWet Processed

Isolate

Oilseeds --- 60 – 70% >90%

Pulses 50 – 65% 50 – 70% 80 – 87%

Cereals 50 – 65% 50 – 70% >85%

High variability in functionality/performance!

Dry Milling & Air Classification of Pulses and Cereals

De-hulling

Air classification/screening

Milling

Flour

Insoluble fibre

Seed

Hulls

De-hulled split seed

Starch enriched flour

Dry milled protein concentrate

Wet Processing of Plant Protein Concentrates & Isolates

Meal or Flour

Alkaline extraction

Acidify

Recover protein extract Recover protein solids

Dry

Drying

Protein Isolate

Protein Concentrate

Acid or ethanol leaching

Wet Processing (IEP) of Plant Proteins

Flour/Meal

Alkali Extraction

Centrifugation

Solids

Protein Solution

Acidify

Centrifugation

Protein Solids

Washing & Centrifugation or

Ultrafiltration

Spray Dry

Protein IsolateFractionation

Water

Water

Water

Starch and/or Fibre

Specialty protein fractions

Attributes of Wet Processing of Protein

• Higher purity protein isolates, 80 – 90%

• Lower microbial content (typically pasteurized during processing)

• Typically better flavour

• Best for protein with a narrower isoelectric pH range

• Larger production plants: viable economy of scale (>10,000 MT/yr)

• High water usage (>25:1, water:protein)

Effective Equipment Selection to

Maximize Protein Yield & Quality

DryingUltrafiltrationCentrifugation

Dry Milling Air Classification Screening

Select processing technology and product that is optimum for your business!

Alternative Wet Processing Method – Wet Dough Washing

• Mix flour & water to produce a dough. (Protein must form an insoluble mass for this technique)

• Dough is kneaded in water to develop the protein mass and suspend the starch in wash water.

• Starch is removed in wash water.

• Protein is recovered.

• Typically only viable for wheat gluten production.

Fractionation – Higher Value Ingredients

FractionsIngredientFeed stock

Flour/Meal

Protein

Insoluble protein

Soluble protein

Functional protein

Starch/Fibre

Increase in ValueUltrafiltration

Continuous Separator

Fractionation by Ultrafiltration

Flour, meal, protein concentrate

Alkali Extraction

Centrifugation

Solids (starch, fibre, insol. protein)Fractionation by

Ultrafiltration

Small MW permeate fraction

Large MW retentate fraction

Protein Fractionation by Salting In/Out

• Protein solubility depends on concentration of dissolved salts (e.g. NaCl, (NH4)SO4, MgSO4).

• As the salt concentration (ionic strength) increases the proteins become less soluble – a salting out effect.

• Recover high-value protein fractions

Voet, Voet & Pratt, 2013

Salt In Salt Out #1 Salt Out #2

Protein Hydrolysis to Produce High-value Fragments and Peptides

• Chemical hydrolysis

• Enzyme hydrolysis

Protein

Hydrolysis

H2O

Peptides

• Chemical• Enzyme

Bioactivity,Increased solubility (beverages)

e.g. Protein isolate (~$5/kg) --> Bioactive Peptides ($200/kg)

Chromatographic Separation

Ion exchange Size exclusion

Oregonstate.eduwww.medicinecomplete.comwww.novasep.com

Chromatography is generally too expensive for fractionation of proteins.

May be viable for final purification of high value proteins/peptides.

• Database of process parameters

• Correlate process parameters to protein functionality

• Determine effect of equipment operating conditions on protein structure and function

• Establish algorithm to optimize process conditions for maximum yield and quality of protein

Efficient and Effective Processing through Machine Learning

2,000 MT/day (Dry Basis)

P-1

Pulse Transportation

Feedstock

166.66 MT/h

P-2 / WSH-101

Seed Washing

S-103

Waste Water 1

16.58 MT/h

P-30 / DC-101

Centrifugation

P-31 / DS-101

Centrifugation

P-5 / MX-108

MixingS-105

soft w ater

w ater

solids

P-4 / V-101

Blending / Storage

NaOH solution

S-106

P-6 / V-102

Blending / Storage

S-107

S-108

P-7 / V-103

Blending / Storage P-8 / DS-102

Centrifugation

P-9 / PZ-101

PasteurizationP-10 / SDR-101

Spray Drying

S-109

acid solution

solids 2

w aste w ater

P-11 / V-104

Blending / Storage

S-113 S-114

P-12 / V-105

Blending / Storage

S-115 S-116

2,000 MT/day (Dry Basis)

Pulse processing

S-102

protein pow der

P-3 / GR-101

Grinding

S-101

S-104

air

S-111

Value-added Applications: MicroencapsulationMicroencapsulated ingredients ▪ Oils: polyunsaturated, DHA enriched oils▪ Flavours & Aromas▪ Nutraceuticals

Benefits of Microencapsulation▪ Increase stability▪ Powdered form for easier handling▪ Masking of off-flavours▪ Higher value protein!

Starch/Modified Starch

• Food ingredients

• Bioplastics

• Conversion to syrups

• Energy source for fermentation – higher value compounds

• Absorbent

• Carrier, microencapsulation

Potential Co-product Opportunities:

Cereals and Pulses

Soluble Fibre

• Prebiotic

• Thickener in foods & beverages

• Health benefits– Low glycemic index

– Beta-glucans

• Increase satiety

• Binders

Hulls/Insoluble Fibre

• Bio-composites

• Antioxidants in hulls

• Feeds

Potential Co-product Opportunities

Oil/Lipid Fractions

• Phospholipids (emulsifiers)

• No-trans fat

• Omega-3 fats

• Greater frying stability

• Industrial oils

• Biodiesel

OilseedsCereals, Pulses, Oilseeds

Develop prototypes to maximize utilization of protein and co-product ingredients

Pulses, Grains,

Oilseeds

Protein

Soluble Fibre

Insol.

Fibre

Bio-actives

Starch

Bakery

Meat Analogues

Nutrient Bars

Beverages

Dairy Alternatives

Extruded snacks, cereals

Product Development

PastaUnderstand the value of co-products!

Plant Protein Process Scale-up

Lab Pilot Plant Semi-WorksCommercial

Manufacturing

Seed/Crop Development

Gap in services/facilities

Connect breeders to processors

Successful Ingredients are a Result of Team Effort

R&D

Engineering

Production

Quality Assurance

Regulatory

Marketing

Sales

Finance

• Drivers for new proteins → clean-label, sustainable foods, health & wellness demands by consumers.

• Develop alternative protein processing methods to reduce cost of processing and increase protein functionality/value.

• Fractionation of proteins can produce specialty, higher value ingredients.

• Develop processes to recover high value co-products to increase economic viability of protein production.

• Develop product applications for plant proteins to increase utilization.

Ingredient Opportunities Summary

KeyLeaf Life Sciences

118 Veterinary Road

Saskatoon, SK

CANADA S7N 2R4

Tel. (306) 978 2800

email: rgreen@keyleaf.ca

http://www.keyleaf.ca

Thank You!