FORTIFICATION HANDBOOK VITAMIN AND MINERAL FORTIFICATION OF WHEAT FLOUR AND MAIZE MEAL Contributors Quentin Johnson Venkatesh Mannar Peter Ranum Editors Annie Wesley Peter Ranum This manual is based on current information as of June 2004. It will be periodically reviewed and updated to include new or revised data, costs, standards, QC methods, technologies and guidelines on fortification. Any suggestions for changes should be sent to The Micronutrient Initiative at the following email address: [email protected] Table of Contents Table of Contents ........................................................................................................................................... 2 Tables ............................................................................................................................................................. 6 Section 1 INTRODUCTION..................................................................................................................... 7 Micronutrient Malnutrition......................................................................................................................... 7 Milled cereal as a Vehicle for Delivering Deficient Micronutrients .......................................................... 8 Advantages of Flour and Maize Meal as Fortification Vehicles ................................................................ 8 The Flour Fortification Initiative................................................................................................................ 9 Fortification at Different Size Mills ........................................................................................................... 9 Scope of the Manual................................................................................................................................. 10 Micronutrients covered in the manual .................................................................................................. 11 Cereal fortification not covered in this manual .................................................................................... 11 Manual Sections ....................................................................................................................................... 12 Appendices and Additional Materials ...................................................................................................... 12 Section 3 CEREAL STAPLES.................................................................................................................. 15 Cereal Production and Consumption........................................................................................................ 15 Global Cereal Production and Trade ........................................................................................................ 15 Flour production and consumption by countries ...................................................................................... 17 Cereals as Food Staples ............................................................................................................................ 18 Fortification of Cereal Staples.................................................................................................................. 18 Grain Structure and Cereal Composition.................................................................................................. 21 Nutritional Composition of Cereals.......................................................................................................... 21 Phytic acid ................................................................................................................................................ 23 Section 4 MILLING AND PROCESSING ................................................................................................ 24 Wheat Milling............................................................................................................................................... 24 Brief History............................................................................................................................................. 24 Objectives of Rollermill Process .............................................................................................................. 24 Milling Process – Rollermills................................................................................................................... 24 Gradual Reduction Process................................................................................................................... 24 Break System........................................................................................................................................ 24 Reduction System................................................................................................................................. 24 Flour Collection System ....................................................................................................................... 25 Milling Process – Single Stage Milling.................................................................................................... 25 Stone mill ............................................................................................................................................. 25 Hammermill.......................................................................................................................................... 25 Plate mill............................................................................................................................................... 25 Pin mill ................................................................................................................................................. 25 Milling Products ....................................................................................................................................... 25 Production Capacity ................................................................................................................................. 25 Rollermills ............................................................................................................................................ 25 Single stage mills.................................................................................................................................. 26 Extraction Rate ..................................................................................................................................... 26 White and brown flours ........................................................................................................................ 26 Ash content........................................................................................................................................... 26 Wheat Based Foods ...................................................................................................................................... 27 Bread ........................................................................................................................................................ 27 Yeast raised (leavened) bread............................................................................................................... 27 Chemical leavened bread...................................................................................................................... 27 Unleavened bread ................................................................................................................................. 27 Noodles and Pasta..................................................................................................................................... 28 Maize (corn) Milling .................................................................................................................................... 28 2 Rollermilling of Maize ............................................................................................................................. 28 Single Stage Milling................................................................................................................................. 28 Maize Products and Food Uses ................................................................................................................ 29 Fortification Effects on Product Quality and Acceptance ............................................................................ 29 Colour and Appearance ............................................................................................................................ 29 Flavour and Aroma................................................................................................................................... 29 Shelf Life.................................................................................................................................................. 29 Taste and Mouthfeel................................................................................................................................. 30 Sensory Testing ........................................................................................................................................ 30 Reducing Phytic Acid............................................................................................................................... 30 Section 5 TYPES AND LEVELS OF MICRONUTRIENTS TO ADD ....................................................