1. Novel ingredients in Free-From Food manufacturing
Dale Whiteman
Technical Development Manager
Daymer Ingredients

2. Who are ? Food Ingredient distributor established 2003
based in Atherstone on Stour, Warwickshire
providing:-
stabiliser systems
texturiser blends
starches and modified starches
maltodextrins, dextrose & glucose
proteins and emulsifiers
yeast extracts and HVPs
natural savoury flavours
gums and hydrocolloids
dairy ingredients

3. Free From Ingredients An ever growing area
Can even lead to nut free “nuts”
Limagrain Céréales Ingrédients Nutricorn Nuts
Announced beginning of September
Maize based toasted corn germ
Nutty texture, flavour and aroma

4. Free From Ingredients Gluten free Dairy Free Egg free
Is Xanthan the only answer?
Dairy Free
Completely dairy free
Lactose free dairy ingredients
Egg free

5. Gluten free Function of gluten
Different products have different requirements
Bread and cakes
Provides an elastic network controlling air cell size during formation of dough and cooking
On cooking gluten coagulates interacting with other proteins and fat to control toughness and elasticity of structure
Pasta
Elasticity
Al dente texture/chewability

6. Gluten free bakery Flour replacement
Typically combinations of corn and potato starch, rice flour, tapioca flour and occasionally include other flours e.g. Buckwheat
Ratios depend on end application
Bread flour
Assorted blends used, all need additional gluten replacers to function
Pasta
Primarily corn flour
Occasionally rice based but can become gummy on cooking
Frying batter
Usually rice flour based
Buckwheat & HPMC – recent research J.Food Hydrocoll. Pub. Jan 2013 Vol 30 issue 1 Univ. Milan

7. Gluten free bakery Common options to replace gluten Xanthan,
Can lead to crumb hardening & gummy mouthfeel
Xanthan alone can control air cell size but volume often restricted
May not be suitable for all
Egg proteins
Currently unstable pricing
Brings another allergen issue
Guar gum
Availability
Cost!!

8. Gluten free bakery HPMC (Hydroxypropylmethylcellulose)
Used successfully with corn starch/rice flour blend
Can be tricky to disperse in water
better if premixed with other materials
Typical application rate 2%
Enhances volume
Controls air cell size and distribution
Reduces staling
Current research
Food Hydrocolloids Issue 30 Vol 1 (Jan 2013) p
Clear demonstration of improvement to commercial gluten free flours using HPMC with or without buckwheat flour

9. Other cellulose based materials
Gluten free bakery
Other cellulose based materials
WellenceTM
Combination of HPMC and CMC specially modified for application
Gives excellent volume increase and air cell control
Relatively low addition rate
Without WellenceTM
With WellenceTM

10. With 1.6% Solanic potato protein isolate
Gluten free bakery
Vegetable proteins
Combinations of potato or pea proteins with a blend of corn starch, rice flour and potato starch
More even air cell distribution, enhances volume, improves surface browning
Control
With 1.6% Solanic potato protein isolate

11. Gluten free bakery Vegetable fibre Insoluble pea fibre
Proposed as a guar substitute
appears to work well with bread and cakes at between 2:1 to 2.5:1substitution level
some cost benefit while maintaining dough viscosity on kneading

12. Gluten free bakery Future technology? Sourdough approach
(University College Cork)
Selected lactic acid bacteria and enzymes used to treat wheat flour to produce fully hydrolysed wheat flour with <10ppm gluten
Lactic acid bacteria produce exopolysaccharides i.e. Materials similar to xanthan
Small scale studies seem to indicate no toxicity to coeliac patients however much larger studies are required to confirm safety of this approach

13. Gluten free Processed meat
Replacement of breadcrumbs and rusk
Used as a binder in sausage and burgers
Found in over 90% of sausages
Usually based on wheat flour
Reduce moisture/fat loss on cooking maintaining juiciness
Usual GF alternatives
Higher fat meat content
Soy flour
Daymer option for low fat gluten free
Blend of potato starches and rice flour

14. Dairy free Basic functions of milk proteins Emulsification
Foam stabilisation
Structuring e.g. cheese
Glazing
Typical alternatives
Soya
Brings another allergen issue
GM free requirements of many customers
Unless high quality/price can bring flavour or colour problems
Egg
Another potential allergen
Pricing currently very unstable

15. Dairy free emulsification
Newer options for emulsifying
Non dairy proteins including-
Other vegetable proteins (pea, potato, rice)
Generally successful although flavour or colour issues can still be found unless high quality ingredients used
Animal proteins
Gelatin
Fish gelatin

16. Dairy free More recent options Modified starch
(Starch sodium octenyl succinate) E1450
Some emulsifying capacity
Typical addition rate 0.5-1%
α–Cyclodextrin
Novel Foods approval gained 2008
Can be effective in a range of applications such as sauces, mayonnaise etc
Optimum effect at high oil levels
Limitations on pH and heat treatment during emulsification

17. Dairy free - foam Current usual stabiliser choices More recent options
Egg albumen – see earlier issues!
Soy protein isolates
Gelatin and other animal protein
More recent options
Potato and pea proteins
E1450 Starch octenylsuccinate
Emulsifies but may also contribute to aeration
α–Cyclodextrin
Can double overrun on non protein systems
Combinations of cellulose ethers and surface active materials e.g. E481 SSL which is already found in many bread improvers
Bovine plasma isolates etc.

18. Dairy free Analogue cheese Blends of modified starches
Selected to control firmness and melting properties as well as emulsify fat
Made using standard processed cheese equipment
Other hydrocolloids can be added to improve properties like stretch

19. Lactose free Lactose free milk powders
Typical Skim milk powder 50% lactose
Lactose removed by a combination of ultrafiltration and enzyme hydrolysis to <0.1%
Some conversion to glucose & galactose
Overall increase in protein content

20. Dairy & Egg free - glazes
Milk and egg wash glazes
Seal surface
Add sheen
Enhance browning
Alternatives
Based on dextrins and starches
Addition of vegetable proteins such as potato can enhance finish
Control
Milk glaze
Egg glaze
Enhance sheen and browning
Images from “The Fresh Loaf”

21. Egg free - Emulsification
Similar solutions to dairy free
Egg free mayonnaise dressings
Combinations of modified starches can provide the emulsification and viscosity provided by egg at a range of fat levels
Enhance sheen and browning

22. Do you have a challenge for Daymer?

23. Further Contact email – info@daymer.com
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