Gluten-Free Tortillas: Challenges & Solutions

Gluten-free tortillas: Challenges & Solutions

• Market Snapshot • Gluten-free tortilla formulation challenges • Gluten-free tortilla formulation solutions – Gluten-free flour and starch systems – Pulse flours and proteins – Fibers – Hydrocolloids

Gluten-free by Removing gluten results in choice – the majority formulation challenges when of products purchased is developing gluten-free for reasons other than tortillas, e.g. building back the intolerance/sensitivity1 texture to maintain the original eating experience and texture

Gluten is an essential component of taste Using the right combination and texture of tortillas of key functional ingredients through its unique can replace gluten without functional properties compromising the eating quality of gluten-free tortillas

Sales of tortillas in the U.S. surpassed $12 billion in 2015 and are expected to steadily rise about 9-10% per year[1]: – 20% of sales are chips, taco shells, and similar items – 80% of sales are soft tortilla divided evenly between flour and corn varieties with each just over 40% of the market Sales of flour tortillas accounted for about $5 billion in 2014 Gluten-free tortillas, corn ones not included → small fraction of that market share Gluten-free market expecting to reach $2.3billion end of the decade [2] → the gluten-free tortilla segment should not be underestimated

[1] Presentation: Industry Overview, by Jim Kabbani, Tortilla Industry Assn. Executive Director; Tortilla Industry Assn. Technical Conference 2015 [2] “Gluten-Free Foods in the U.S.”, 5th Edition; Packaged Facts/ Market Research Group, LLC ( January, 2015)

Total gluten-free U.S. consumers: The majority buys gluten-free products by choice:

60.9-100MM

ONLY 3MM DIAGNOSED AS CELIAC

Respondents buy gluten-free products for perceived benefits

Source: Ingredion proprietary research with Mintel, April 2016 Copyright © 2017 by Ingredion Incorporated GLUTEN-FREE TORTILLA FORMULATION CHALLENGES Flour tortilla parameters Flour tortillas should be: • Flexible • Easy to roll without cracking or ripping • Round with even shape • Somewhat elastic in texture, but not rubbery, and layered • Slightly moist without being tacky • Easily separated Gluten is the main components in flour tortilla responsible to provide functionality to tortillas

Wheat contains 8-16% of gluten-forming proteins:

Dough cohesiveness GLIADIN GLIADIN Dough + extensibility GLUTENIN + = GLUTEN • Viscoelastic and cohe WATER dough→ Good mach Dough resistance + • Able to retain gas du to extension fermentation GLUTENIN MIXING Dough elasticity • Sets the dough durin

TEXTURE, TASTE, NUTRITION PROCESSING SHELF LIFE APPEARANCE PROFILE

Lack of viscosity or • Poor rollability • Shorter shelf life • Lack of protein, nutrients elasticity compared to the and fiber • Dry, powdery, and rubbery • Increased staling rates wheat-containing dough, texture due to increased water • Use of high levels of leading to difficulties in mobility sugars and fats to mask processability and • Poor surface color the texture and flavor machinability • Off flavor challenges

SAFETY, QUALITY ASSURANCE, INGREDIENTS SOURCING LABELING DISTRIBUTION AND COSTING

HYDROCOLLOIDS GLUTEN-FREE • Xanthan gum BAKED GOODS • Guar gum • HPMC, etc.

STARCH GRANULES • Gluten-free flours PROTEIN • Cook-up starches • Egg • CWS (cold water swelling) starches • Whey • Pulses

Gluten-free products STORAGE REQUIREMENTS suffer changes upon storing: • Dry Most gluten-free Some gluten-free tortillas tortillas in the U.S. are sold at • Loss of elasticity/rollability are sold frozen: room temperature: • Hard Important to maintain Shelf-stable: ≈10-35days soft texture and • Rancid Important to maintain freshness after soft texture and freeze/thawing freshness after storing Fresh tortilla at room temperature folded in half: Freeze/thaw no cracking stability Shelf life stability Old tortilla tortilla folded in half: cracking

Regular tortillas Gluten-free tortillas • Good rollability • Poor rollability • Moist and cohesive texture • Dry, powdery, and rubbery texture • Light yellowish color with • Poor surface color with large blisters small brown blisters on the surface • Translucent • Opaque • Off flavor • Hearty flavor

LESS CALORIES BUT MORE C Caloric content FROM FAT Total fat content SLIGHTLY HIGHER IN FAT

Protein and carbohydrate content LOW IN PROTEIN

Mineral content LOW IN MINERALS

BREAD, PIZZA, TORTILLAS • Lack of volume Typical defects • Lack of elasticity of commercial products • Dryness CAKE/MUFFIN • Gumminess BISCUITS & • Lack of volume • Not homogeneous COOKIES • Crumbliness • Crumb • Grittiness • Dryness • Taste • Sandiness • Gumminess • Nutrition profile • Lack of bite • Taste • Taste • Nutrition profile

Increased functionality of gluten

TYPE EXAMPLES USAGE LEVEL FUNCTION

Native flours and starches Corn, potato, rice, tapioca, sorghum, 20-50% • Bulk/backbone of the recipe amaranth, buckwheat, quinoa, soy, • Texture modifier: body, elasticity and chewiness, millet, teff, pulse, nut crumb structure

Cook-up native functional Corn, tapioca, rice, potato 20-50% • Texture modifier: body, elasticity and chewiness, or modified starches crumb structure • Freeze/thaw stability

Pre-gelatinized native Corn, tapioca, rice, potato 2-10% • Dough viscosity control functional or modified • Texture modifier starches • Prevent staling • Freeze/thaw stability

Proteins Whey protein, soy protein, zein, egg 2-5% • Build structure white powder, pulse proteins • Color development

Other hydrocolloids/gums Xanthan gum, guar gum, cellulose -.5-3% • Dough viscosity control gum, alginates, konjac, psyllium husk • Texture modifier • Prevent staling • Freeze/thaw stability

Gluten-free Wheat-containing market samples benchmark

LOOSE COMPACT

Cohesiveness of mass: the degree to which a chewed product forms a bolus/ball/holds together

Gluten-free Wheat-containing market samples benchmark

HIGH LOW oughness of mass: the amount of graininess as perceived on the surface of the product during its masticatio

A A

B C B C

Preliminary screening Optimization DOE Final optimal composition

Process Descriptive Final product Dispersibility, dough Sensory Analysis measurements rheology, machinability, Cohesiveness, graininess, Hardness via handling dissolvability, hardness, denseness, Texture Analyzer, yield, firmness, springiness, mouthcoating height, moisture, cost

Copyright © 2017 by Ingredion Incorporated GLUTEN-FREE FORMULATION SOLUTIONS Gluten-free flour and starch systems Pulse flours and proteins Fiber Hydrocolloids Use of gluten-free flour and starch systems in gluten-free tortillas

Stretch to Break MT Commercial Gluten- Free Benchmark 3 Solution 3

Commercial Gluten- Free Benchmark 1

Toughness Front Teeth IMT

Cohesiveness Commercial Wheat- Commercial Gluten- of Mass IMT Based Benchmark Free Benchmark 4 Solution 2 Moisture Absorption IMT Hardness IMT Commercial Gluten- Free Benchmark 2

Solution 1

– Manual Texture Roughness MT – In-Mouth Texture

INGREDIENTS TRUE %

Tapioca flour and rice flour blend 39.47 Chickpea flour 14.89 Pregelatinized tapioca flour 6.38 Faba bean protein concentrate 1.80 Water 25.53 Vegetable oil 9.06 Salt 0.74 Sugar 0.98 Glycerin 1.06 Xanthan gum 0.08 TOTAL 100

What’s unique about Solution 1? • Good dough handling properties: good stretchability, low d stickiness, good dough elasticity and sheetability

• Chewy texture and bland flavor

• Light golden color with blisters distributed among surface, layered internal texture

• Clean label and simple flour label declaration

Stretch to Break MT Commercial Gluten- Free Benchmark 3 Solution 3

Commercial Gluten- Free Benchmark 1

Toughness Front Teeth IMT

Cohesiveness Commercial Wheat- Commercial Gluten- of Mass IMT Based Benchmark Free Benchmark 4 Solution 2 Moisture Absorption IMT Hardness IMT Commercial Gluten- Free Benchmark 2

Solution 1

– Manual Texture Roughness MT – In-Mouth Texture

NGREDIENTS TRUE % odified tapioca, corn starch, and 37.10 tato starch blend hickpea flour 14.00 egelatinized modified tapioca starch 6.00 ba bean protein concentrate 1.69 ater 30.00 getable oil 8.52 t 0.69 gar 0.92 ycerin 1.00 nthan gum 0.08 OTAL 100.00

Copyright © 2017 by Ingredion Incorporated Solution 2 Base flour is a highly functional starch-based solution made out of modified tapioca starch, potato starch, corn starch What’s unique about Solution 2? • Excellent dough handling properties: good stretchability, no stickiness, good dough elasticity, and excellent dough shee

• Soft to the touch, flexible while bending, not hard or tough bitten, forms a ball and absorbs moisture when chewed, bu powdery in the mouth, bland flavor

• Light golden color with darker blisters distributed among layered internal texture

Stretch to Break MT Commercial Gluten- Free Benchmark 3 Solution 3

Commercial Gluten- Free Benchmark 1

Toughness Front Teeth IMT

Cohesiveness Commercial Wheat- Commercial Gluten- of Mass IMT Based Benchmark Free Benchmark 4 Solution 2 Moisture Absorption IMT Hardness IMT Commercial Gluten- Free Benchmark 2

Solution 1

– Manual Texture Roughness MT – In-Mouth Texture

INGREDIENTS TRUE % Starch and gum blend 51.94 Salt 0.87 Double acting baking powder 0.27 Distilled monoglycerides 0.52 Fumaric acid 0.08 Baking soda 0.14 Postassium sorbate 0.08 Enzymes 0.25 Sodium stearoyl lactylate 0.25 Sodium Acid Pyrophosphate powder 0.25 Vegetable oil 7.10 Water 38.25 TOTAL 100.00

Copyright © 2017 by Ingredion Incorporated Solution 3 Base flour is a highly functional blend of starches and gums made out of m food starch, rice flour, potato starch, tapioca starch, carboxymet cellulose, dextrose, guar gum, and xanthan gum a What’s unique about this product? • Especially designed to make high-quality gluten-free tortilla

• Provides excellent tortilla stretchability, rollability without cracking, flexibility, good machinability, bland flavor and high water-holding capability

Pulses are the dried seeds of plants in the legume family. They include: • Peas • Beans • Lentils • Chickpeas

ENRICHMENT BENEFITS

High in High in protein dietary fiber

Rich in minerals Source of (iron, zinc, B vitamins phosphorus) and folic acid

OOD PROTEIN FAT STARCH & SUGAR FIBER

Tapioca flour 0.2 0.0 87.8 0.9

Whole corn flour 8.0 7.0 62.0 8.0

Whole rice flour 5.6 1.4 77.7 2.4 Exceptional

Whole soy flour 35.0 20.0 25.6 9.6 nutrition value Whole wheat flour 13.2 2.5 61.3 10.0 • High in protein (high in lysin Dry pea 23.7 1.3 45.5 16.6 dietary fiber, micronutrients (iron, zinc, selenium, entil 26.3 1.1 45.0 13.6 -carotene) Chickpea 24.4 5.9 41.1 8.7 • Low glycemic index Dry bean 24.5 1.5 41.5 22.5 (GI=40-55)

Pulse flours and pulse protein concentrates

FUNCTIONALITY VALUE REGULATORY STATUS

• Emulsification • Enhance texture • Certified as FSSC, ISO 9000, Kosher, Halal and provide moist • Texture mouthfeel • Capability to produce organic product • Gelation • Good synergy • Certified as Gluten-Free by Intertek with other • Certified as Non-GMO Project Verified • Water-holding gluten-free flours • GRAS status: • Adhesion • Increase protein ⎼ Pulse flours considered traditional food • Film forming • Eliminate other ingredients proteins, such • Blending as egg whites ⎼ Pulse proteins are self-affirmed GRAS

ten-free tortillas with an enhanced nutrition INGREDIENTS PERCENT % PROCEDURE file that deliver the taste and texture of 1. Pre-heat grittle to 400F and tortilla pr eat-based versions Modified tapioca starch 37.10 at 130F 2. Combine dry ingredients in mixing bow dified tapioca starch mimics the Chickpea flour 14.00 with paddle at speed 1 for 30 seconds ctionality of wheat flour in gluten-free 3. Add glycerine and combine at speed 1 ducts Pregelatinized modified 30 seconds 6.00 tapioca starch 4. Add slowly the water and the oil simu ckpea flour is a gluten-free, pulse-based Faba bean protein while mixing at speed 1 until 1.69 a cohesive dough starts forming r. Adds color to the tortilla and and concentrate roves nutrition 5. Switch to dough hook and continue m Water 30.00 speed 1 for another 1.5 min or until d properly mixed gelled modified tapioca starch is a high- Vegetable oil 8.52 6. Cover dough with plastic wrap; let do formance cold water swelling modified food for 5-10 min ch derived from tapioca; it exhibits many of Salt 0.69 7. Divide dough into 58g balls properties of a modified cook-up starch and 8. Lightly coat both tortilla press surface sesses a very bland flavor profile with good Sugar 0.92 spray oil and remove excess with a pa uth melt-away characteristics 9. Place dough ball in the center of the to Glycerine 1.00 press and press down strongly ba bean protein concentrate helps with 10. Cook tortilla in the grittle for 60 seco gh handling, adds color, improves elasticity Xanthan gum 0.08 side tortilla resilience 11. Let tortilla cool down covered with to TOTALS 100.00

AFTER MIXING SHEETING AFTER CUTTING HOMECRAFT® Pulse CT 1203 clean-taste pea flour Gluten-free crackers we scaled up on pilot-scale sheeting equipment • No issues with stickin or breaking observed

Copyright © 2017 by Ingredion Incorporated Versatility in gluten-free baked goods n level (g/28g serving): PULSE INGREDIE 2g/serving 2g/serving 5g/serving 6g/serving PROVIDE: • Golden brown color contributed by protein • Natural color (e.g., ye green, red, etc.) inherit from pulses low pea flour Yellow pea flour Green pea flour Yellow pea flour • Characteristic pulse Yellow pea protein flavor from convention pulse ingredients or ne flavor from clean-taste ingredients • Adjustable protein lev Applicable to a wide variety of baked goods such as tortillas, pasta, puffed snacks, etc.

Potato and corn starch based fibers: • Allows to create new high-fiber tortillas with taste and texture of regular “white f applications

• Similar water-holding capacity to wheat flour for ease of processing

• Clean and mild sensory properties with little or no impact on taste, texture and co products

• Process-stable fiber that enables savings through reduced cost-in-use

• Inherently reduce the calories in formulations when substituted for flour, starches o other fully caloric carbohydrates (0.47-0.60 kcal/g)

Copyright © 2017 by Ingredion Incorporated Use of fiber in gluten-free flat bread free tortillas with an enhanced nutrition hat deliver the taste and texture of PERCENT INGREDIENTS PROCEDURE based versions % 1. Using stand mixer fitted with paddle Modified tapioca starch 34.03 attachment, blend all of the dry ingre ed tapioca starch mimics the together in a stand mixer on lowest nality of wheat flour in gluten-free Chickpea flour 9.44 2. Dissolve honey in water (≈40˚F) and s Gradually add the water, honey, and Pregelatinized modified tapioca starch 3.10 mixing on low speed for 1 minute. pea flour is a gluten-free, pulse-based 3. Switch to medium speed and mix for dds color to the tortilla and and Corn starch 9.00 seconds or until a smooth, uniform d es nutrition created and begins to pull from the s Faba bean protein concentrate 1.74 bowl. 4. Cover bowl with plastic wrap and pr starch is an invisible source of gluten- Water 29.78 minutes on benchtop. tary fiber provides a good source of fiber Vegetable oil 8.52 5. Pre-heat convection oven with low fa ormulation 500°F. Salt 0.71 6. Divide dough into 50g rounds, using ed modified tapioca starch is a high- Sugar 0.92 BAKE GF as dusting flour. mance cold water swelling modified food 7. Dust surface with PRECISA BAKE G erived from tapioca; it exhibits many of Yeast, instant 0.83 dough to 0.15” thick and let rest cov minutes. perties of a modified cook-up starch and Distilled mono- and diglycerides 0.25 es a very bland flavor profile with good 8. Bake for 7 minutes, flipping flatbreads melt-away characteristics Xanthan gum 0.25 half way through baking (at 3.5 minut lightly browned. Olive oil 7.94 9. Remove from oven and place on rack ean protein concentrate helps with andling, adds color, improves elasticity Honey 2.93 10. Pack and freeze to store. tilla resilience TOTALS 100

PRODUCT FUNCTIONALITY

Xanthan gum Batter viscosity and cohesive texture

Guar gum Batter viscosity, freeze/thaw stability and moisture retention

CMC Structure and moisture retention

Psyllium husk Upfront dough viscosity, dough malleability and moisture retention

Let’s get started!

www.ingredion.us/glutenfree

Contact: Ricardo Rodriguez, Marketing Manager, Confectionery & Bakery, [email protected]