Gluten-Free Baking: Solving Formulation Challenges with Innovative Solutions

Gluten-free baking: Solving formulation challenges with innovative solutions

Elena De La Peña, Ph.D. Associate, Global Applications

1. Gluten-free formulation challenges

2. Gluten-free formulation solutions • Gluten-free flour and starch systems • Pulse flours and proteins • Gums

Key takeaways

Gluten is essential Removing gluten Selection of the right for the proper results in formulation combination of handling and challenges to build functional ingredients processing, taste, back the processability, can replace gluten and texture of texture and eating minimizing the baked goods. experience. processing challenges, eating quality, and shelf-life of baked goods.

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

• Dough cohesiveness • Dough resistance to extension • Dough • Dough elasticity extensibility Gliadin Glutenin

Gliadin + Glutenin + Water + Mixing = Gluten

• Viscoelastic and cohesive dough→ Good machinability • Able to retain gas during fermentation • Sets the dough during baking

Texture Nutritional Processing Taste Shelf-life Appearance profile

• Lack of viscosity • Reduced volume, • Shorter shelf-life/ • Lack of protein, or elasticity of the lack of an even cell Increased staling nutrients and fiber wheat-containing structure rates due to • Use of high levels dough leading to • Dry, crumbly, increased water of sugars and fats difficulties in grainy texture mobility to mask the processibility and • Poor crust color texture and flavor machinability and development challenges • Lack of structure • Grainy flavor during baking

• Safety, quality assurance, distribution • Ingredients sourcing and costing • Labelling

Hydrocolloids Gluten-free •Xanthan guam baked goods •Guar gum •HPMC, etc

Starch granules •Gluten-free flours Protein •Cookup starches •Egg •CWS starches •Whey •Pulses

Hard to control batter viscosity during processing Lack of viscosity or elasticity of the wheat-containing dough→ batter vs dough

Controlling the batter viscosity is essential for proper batter disposal during the manufacturing process of gluten-free baked goods

Batter viscosity has direct effect on the end product quality:

High batter Smaller Denser Higher crumb viscosity volume crumb firmness

Wrong batter Large holes Product viscosity in crumb collapse

Gluten-free products suffer changes upon storing: •Rubbery crust •Excessive crumbliness •Hard and dense crumb

Storage requirements: •Most gluten-free breads in the US are sold frozen: Important to maintain soft crumb texture for 2-3 months after freeze-thawing→ Freeze-thaw stability

•Most gluten-free breads in Europe are sold at room-temperature: – Shelf-stable: ≈8days Important to maintain soft crumb texture after storing at room – MAP: ≈6months temperature → Shelf-life stability

Regular bread Gluten-free bread • Good volume • Reduced volume • Even cell structure • Lack of an uneven cell structure • Moist and cohesive crumb • Dry, crumbly, grainy texture • Golden toasted crust color • Poor crust color and development • Hearthy flavor • Grainy flavor

Leading regular Leading white white bread gluten-free bread

Caloric content Total fat content

Protein and carbohydrate content

Mineral content

High caloric content High in fat Low in protein Low in minerals

Typical defects of Bread & pizza commercial products • Lack of volume • Lack of elasticity Cake/muffin • Dryness •Lack of volume • Gumminess •Crumbliness • Not homogeneous Biscuits/cookies •Dryness • Crumb •Grittiness •Gumminess • Taste •Sandiness •Taste • Nutritional profile •Lack of bite •Nutritional profile •Taste

Increased functionality of gluten

Type Examples Usage Level Function

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

Cook-up native functional Corn, tapioca, rice, potato 20-50% • Texture modifier: Body, elasticity & or modified starches chewiness, 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 Xanthan gum, guar gum, cellulose gum, -.5-3% • Dough viscosity control hydrocolloids/gums alginates, konjac, psyllium husk • Texture modifier • Prevent staling • Freeze-thaw stability

• Benchmarking wheat- containing & gluten-free products

• Identifying gaps using Descriptive Sensory Analysis

• Developing solutions to minimize the gaps

Cohesiveness of mass: The degree to which a chewed product forms a bolus/ball/holds together Gluten-free Wheat-containing market samples benchmark

LOOSE COMPACT

Roughness of mass: The amount of graininess as perceived on the surface of the product during its mastication

Gluten-free Wheat-containing market samples benchmark

HIGH LOW

Process Dispersibility, dough rheology, machinability, handling Descriptive Sensory Preliminary Optimization Final optimal Analysis screening DOE composition Cohesiveness, graininess, dissolvability, hardness, denseness, firmness, springiness, mouth coating Final product measurements Hardness via Texture Analyzer, yield, height, moisture, cost

A specialty flour solution, that enables the commercial production of gluten-free baked goods with texture and product quality that closely resembles that of gluten containing products.

What’s unique about these products? Targeted performance • HOMECRAFT™ Create GF systems are especially designed to make high quality gluten-free baked goods • More functionality than competitive blends of regular products (flours, gums, starches, etc.)

Clean, simple flour label declaration • Brings unique options to manufacturers and consumers • Highly desired on ingredient statement by wholesome customers

Muffin: HOMECRAFT Create GF 10 Cookie: HOMECRAFT Create GF20

Commercial cookie benchmark: Commercial cookie benchmark: Gluten free Wheat containing Commercial muffin benchmark: Commercial muffin benchmark: Gluten-free Smooth Wheat containing

Dry Moist Crumbly Chewy

HOMECRAFT Create GF 10 and 20 flours Clean label solution rice, tapioca flour

Modified Clean Label Retail Gluten- Retail Wheat Solution Solution Free Containing

HOMECRAFT® Create GF 20 Flour

HOMECRAFT® Create GF 20

Gluten containing

A highly functional starch based solution, that enables the commercial production of gluten-free baked goods with texture and product quality that closely resembles that of gluten containing products at an affordable cost.

What’s Unique about this product? Targeted performance • PRECISA Bake GF is especially designed to make high quality gluten- free baked goods • Superior functionality to competitive blends of regular products (flours, gums, starches, etc.)

Label declaration: Modified tapioca starch, potato starch, corn starch • Brings unique options to manufacturers and consumers

Ingredients Bakers % PRECISA Bake GF starch 100.00 Psyllium HUSK 5.84 Granulated sugar 8.27 Egg white powder 3.74 Salt 2.04 HPMC K4M 4.06 High fructose corn syrup 5.09 Canola oil 12.19 Water 100.00 Yeast, instant 1.63

Procedure •Dissolve the syrup into lukewarm water (77°F), add yeast and psyllium husk to hydrate for 1.5 minutes. •Premix the dry ingredients. •Add dry ingredients to water solution. •Add oil on top of dry ingredients, mix for 2 min on slow to obtain firm dough. •Grease bread loaf pans; weigh dough at 520g; mould and place in the baking pans. •Proof for 60 min at 95°F (35°C)/85% RH. •Bake at 400°F (204°C), one steam injection at beginning of bake, for 30 - 33 minutes.

C1: Used to determine water absorption C2: Protein weakening due to mechanical work and Temp. C3: Starch gelatinization C4: Hot gel stability C5: Starch retrogradiation

C3 C5 C4 C1 C2

PRECISA® Bake GF system

Modified solution: Modified tapioca, potato & corn starch

Modified Clean Label Retail Gluten- Retail Wheat Solution Solution Free Containing

Retail GF Breads

Ingredion gluten-free samples scored closely Retail Wheat Breads

to wheat breads. Peak Force Average (g) Average Force Peak

Clean Modified Label Solution

Solution

PRECISA Bake GF breads stored in ambient conditions extended shelf-life up to 21 days, patent application

Peak Force Average (g) Average Force Peak Modified Solution Native Solutions

PRECISA® Bake GF System

PRECISA Bake GF Gluten containing

Science-based problem-solving from Ingredion Idea Labs

What are pulses?

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

High in High in protein dietary fiber

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

Food 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 Whole soy flour 35.0 20.0 25.6 9.6 Whole wheat flour 13.2 2.5 61.3 10.0 Dry pea 23.7 1.3 45.5 16.6 Lentil 26.3 1.1 45.0 13.6 Chickpea 24.4 5.9 41.1 8.7 Dry bean 24.5 1.5 41.5 22.5

High in protein (high in lysine), dietary fiber, Exceptional micro nutrients (iron, zinc, selenium, -Carotene) nutritional value Low-glycemic index (GI=40-55)

Discover HOMECRAFT® Pulse flours and VITESSENCE™ Pulse proteins

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 with • Certified as Gluten-Free by Intertek other gluten-free • Certified as Non-GMO Project Verified • Water-holding flours • GRAS status: • Adhesion • Increase protein ⎼ HOMECRAFT® Pulse flours considered • Film forming • Eliminate other traditional food ingredients proteins, such as • Blending egg whites ⎼ VITESSENCE™ Pulse proteins: self-affirmed GRAS

Ingredient Baker's % PRECISA Bake GF starch 50.00

HOMECRAFT Pulse 3103 Faba 50.00 Bean flour (10 % Protein)

Shortening 15.0

Sugar 10.5

Salt 1.8 • Good synergy with other gluten-free flours Instant yeast 1.7 • Enhance texture and provide moist mouthfeel HPMC 3.3 • Good volume and open cell structure Psyllium husk 6.1 • Increase protein in the formula Xanthan 1.3 • Eliminate other protein sources in the formula Water (warm ~75°F) 146.0 i.e. egg-whites, whey concentrate

Ingredients Bakers % Ingredients Bakers % PRECISA Bake GF starch 60.00 PRECISA Bake GF starch 80.00 HOMECRAFT Create 860 Rice flour 40.00 HOMECRAFT Pulse 4101 Chickpea flour 20.00 Flaxseed meal 5.00 Flaxseed meal 5.00 Psyllium HUSK 6.25 Psyllium HUSK 6.25 Egg white powder 3.74 HPMC 2.00 HPMC 2.00 Salt 2.04 Salt 2.04 Sugar 5.09 Sugar 5.09 Yeast, instant 1.63 Yeast, instant 1.63 Bread crust flavor 1.17 Bread crust flavor 1.17 Olive oil 12.19 Olive oil 12.19 Water 99.98 Water 97.00

• Texture impact-delivers chewy texture • More open cell structure • Open cell structure • Balances chewiness, with crispy crust • Remove egg whites in the formula: formula cost reduction

Copyright © 2016 by Ingredion Incorporated 32 Gluten free hummus cracker ® HOMECRAFT Express 390 pre-gelatinized tapioca Procedure flour provides a crunchy texture while helping with 1.Preheat convection oven to dough handling and sheeting. 375°F. 2.Combine dill, parsley, water, and HFCS in bowl allowing herbs to HOMECRAFT® Pulse 4101 chickpea flour and hydrate for 30 minutes. ® HOMECRAFT Create GF 20 tapioca, rice flour are 3.Combine remaining dry gluten-free flours used in the formula to replace wheat flour. ingredients in mixing bowl with paddle at speed 1 for 90 seconds. GLOBE® 63 DE Glucose Syrup, Non-GMO ingredient 4.Add shortening and continue primarily contributes to sweetness and binding. mixing for 90 seconds. 5.Slowly add the hydrated herb mixture to bowl and mix with Ingredients Percent (%) paddle for 1 minute. HOMECRAFT® Pulse 4101 chickpea flour 25.48 6.Switch to dough hook and HOMECRAFT® Create GF 20 flour 25.48 continue mixing at speed 1 for HOMECRAFT® Express 390 flour 7.39 another 3 minutes. Monocalcium phosphate 0.76 7.Sheet dough to about 1.5 mm Baking soda 0.76 thickness. Cut and dock with Salt 0.81 cracker cutter. 8.Place crackers on perforated Buttermilk powder 2.15 sheet tray and bake for 3-6 minutes Dill, Freeze dried 0.35 depending on thickness. Vinegar powder 0.71 9.Remove crackers and let cool on Garlic powder 0.27 sheet tray. Onion powder 0.27 10.If applying a topical seasoning or Parsley, freeze dried 0.16 salt, coat the crackers evenly with it Granulated sugar 1.40 before they cool. Pepper, ground black 0.11 Palm shortening 7.90 Water 23.76 Globe® 63 DE Glucose Syrup, Non-GMO 2.24 Total: 100.00

Gluten-free tortillas with an enhanced Ingredients Percent % nutritional profile that deliver the taste and PRECISA Bake GF 37.10 texture of wheat-based versions HOMECRAFT Pulse 4101 14.00 ULTRA-TEX 3 6.00 PRECISA® Bake GF modified starch Water 30.00 mimics the functionality of wheat flour in Vegetable oil 8.52 gluten-free products. VITESSENCE Pulse 3600 1.69 Salt 0.69 HOMECRAFT® Pulse 4101 chickpea Sugar 0.92 flour is a gluten-free, pulse-based flour with Glycerine 1.00 Xanthan gum 0.08 great functionality. TOTALS 100.00

ULTRA-TEX® 3 modified starch is a high Procedure performance cold water swelling modified 1. Preheat grittle to 400F and tortilla press at 130F 2. Combine dry ingredients in mixing bowl with food starch derived from tapioca. It exhibits paddle at speed 1 for 30 s. many of the properties of a modified cook-up 3. Add glycerine and combine at speed 1 for 30 s. starch and possesses a very bland flavor 4. Add slowly the water and the oil simultaneously profile with good mouth melt-away while mixing at speed 1 until a cohesive dough starts forming characteristics. 5. Switch to dough hook and continue mixing at speed 1 for another 1.5 min or until dough is VITESSENCE® Pulse 3600 faba bean properly mixed protein concentrate helps with dough 6. Cover dough with plastic wrap. Let dough rest for 5-10 min handling, adds color, improves elasticity 7. Divide dough into 58g balls 8. Lightly coat both tortilla press surfaces with spray oil and remove excess with a paper towel 9. Place dough ball in the center of the tortilla press and press down strongly 10. Cook tortilla in the grittle for 60 s each side 11. Let tortilla to cool down covered with towel

Product Functionality GUM NO GUM Xanthan Batter viscosity and cohesive texture

Batter viscosity, freeze/thaw stability Guar and moisture retention

CMC Cell structure and moisture retention A combination of potato starch, tapioca starch and guar gum Structure and set during baking due to provides a soft crumb structure, HPMC volume and moisture retention thermal gelling characteristics

Gum arabic Emulsification and film formation GUM NO GUM

Batter viscosity, cohesive texture, cell LBG structure and freeze/thaw stability

A combination of corn starch, gum arabic, xanthan gum and guar gum provides volume, uniform cell structure, suspension and moisture retention

Bulk Flour System Bulk Flour Component Texturizer (20-50%) (10-20%) (0.5-10%) Clean • HOMECRAFT® Create GF 10 • HOMECRAFT® Create 860 • VITESSENCE™ Pulse 3600 Label Flour (rice and tapioca flour) Flour (rice flour) Protein (faba bean protein) • HOMECRAFT® Create GF 20 • HOMECRAFT® Create 390 • HOMECRAFT® Express 390 Flour (tapioca and rice flour) Flour (tapioca flour) Flour (tapioca flour) • HOMECRAFT® Pulse Flours • NOVATION® 4600 Food (chickpea, lentil, faba bean, and yellow Starch (waxy corn) pea flour) • PENPURE® 60 Food Starch (potato starch) • PENPURE® 37 Food Starch (waxy rice starch) • HI-MAIZE® 260 Food starch (corn starch) Modified • PRECISA® BAKE GF Food • PURITY® Bake Modified Food • PENPLUS® 2140 Modified Starch (modified tapioca starch, Starch (modified tapioca starch) Food Starch (modified potato potato starch, corn starch) • PENBIND® 1040 Modified starch) • PENTECH® GF TTB Food Food Starch (modified potato • ULTRA-TEX® 2000 Modified Starch (tortilla blend) starch) Food Starch (modified waxy corn) • GUMPLETE™ Psyllium Husk 95% NT • GUMPLETE™ MC-0916 (hydroxypropyl methyl-cellulose) • GUMPLETE™ Xanthan Gum 80 Mesh SR-2

More consumers Gluten is Removing gluten Using the right than ever essential results in combination of switching to component of formulation key functional gluten-free diet taste and texture challenges to ingredients can of food products build back the replace gluten through its texture and without unique functional eating experience compromising properties the eating quality, processing and shelf-life

The window test — with only GF starch, GF flour and water….

…a reality!

Q&A

Science-based problem-solving from Ingredion Idea Labs