Food Technology Trends

Technology Trends &
Solutions for
Sustainable Value Chains
Beatrice Conde-Petit
Buhler AG
2015
Title | Author | 2005
Cereals are the cornerstone of our nutrition
Maize, Rice and Wheat sum up to 2’500 Mio MT pa.
1200
Production in Mio MT
1000
800
Maize
Rice, paddy
Wheat
600
Potatoes
Cassava
Soybeans
400
Barley
Sorghum
Oats
200
0
Source: FAO2015
2 | © Bühler | Bühler 2015 | Presentation GF1
What drives innovations in the Grains to Food value chain?
Grower
Trader
Agro-food
convertor
Food
Processor
Retailer
Solution/ Technology Providers
3 | © Bühler |
Consumer
The new consumer: a strong driver for innovation
Tasty
Safe
Grower
Trader
Agro-food
convertor
Food
Processor
Retailer
Consumer
Affordable
Convenient
Healthy
Natural
Solution/ Technology Providers
Regional
Free-off
….
4 | © Bühler |
Bread in Europe: the same product but changing value chains
Bake-off bread:
> 20 % of fresh
bread market
From Gira 2014
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In-store baking requires new food safety concepts
Traditional (industrial) baker
microbial kill-step
Grower
Trader
Miller
Baker
raw
Retailer
Consumer
baked
In-store baking
high hygiene for safety & shelf life
Grower
Trader
Miller
low microbial
flour
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Baker
par baked
Retailer
Consumer
baked
Salmonella in dry foods: the game changer for the food industry
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Salmonella in dry foods: the game changer for the food industry
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In-store baking requires new food safety concepts
Traditional (industrial) baker
microbial kill-step
Grower
Trader
Miller
Baker
raw
Retailer
Consumer
baked
In-store baking
high hygiene requirements
Grower
Trader
Miller
low microbial
flour
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Baker
parbaked
Retailer
Consumer
baked
Salmonella in dry foods: the game changer for the food industry
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Innovation on the raw material side
What comes beyond wholegrain?
Sprouted grains for good nutrition
Biotransformation for better taste, good
texture and more micronutrients
US Market expected to grow from
30 to 250 Mio USD by 2018
Bühler solution: Pargem
Biotranformation (Germination, possibly in combination with fermentation)
•
•
•
•
•
•
Natural increase of micronutrients (better bioavailabilty of minerals, more vitamins)
Natural flavor enhancing
Natural source of enzymes
Reduction of antinutrients (e.g. phytate)
Mild preservation
Solubilization of fibres
11 | © Bühler |
Wheat production Mio tones
It is worth looking at other regions of the world
Cereal production shows strong increase in growth regions
12 | © Bühler | B.Conde l 2015
150
CHINA
100
INDIA
INDIA:
Westernwheat
Europe
70 % whole
flour
North America
(Atta) for flat breads,
North America
India
China
50
Western Europe
0
1980
1990
2000
2010
2020
Atta is a traditional Indian wheat flour for flatbread
Processing is done by stone milling
The key Atta flour properties:
Stone
Chakki
-
whole grain flour (extraction 94-97 % )
-
high starch damage
-
overall fine granulation
The challenge
-
technology for industrial scale milling
-
safe, reliable, efficient, affordable
J. Reddy, S. Weinmann, D. Heine and B. Conde-Petit,
Quality Assurance and Safety of Crops & Foods, 4, 2012
13 | © Bühler | B.Conde l 2014
Max Force Toughness Rig [N]
The secret of good chapatti texture lies in its high starch damage
12.0
10 µm
10.0
8.0
6.0
4.0
2.0
0.0
55
60
65
70
75
80
Water absorption Farino 500, 14 % H2O [%]
5
10
Western-type flour
→Roller milling
15
20
% Starch
damage
Challenge: generate mechanical
modification of starch upon milling
Atta flour
J. Reddy, S. Weinmann, D. Heine and B. Conde-Petit,
Quality Assurance and Safety of Crops & Foods 4, 2012
14 | © Bühler | B.Conde l 2014
Traditional Atta flour
From traditional stone milling to a revolutionary new milling concept
Stone
Chakki
Bühler Pesa Mill
A new milling technology
- efficient
- affordable
- Fit-for-purpose
15 | © Bühler | B.Conde l 2015
Traditiona Atta flour
From traditional stone milling to a new milling concept
Stone
Chakki
A new milling technology
- efficient
- affordable
- Fit-for-purpose
16 | © Bühler | B.Conde l 2015
Sustainable protein is one of the biggest nutrition challenges
Animal protein is valuable, but less sustainable that plant protein
5-6 units
1 unit
70%
plant-based proteins
animal-based proteins
(e.g. grains, legumes, oil seeds, nuts)
(e.g. meat, dairy products, fish, eggs)
30%
17 | © Bühler | Proteins | 2015
70%
30%
Meat demand is increasing drastically
Alternatives to animal protein need to be found
400
meat production (mio t)
CAGR = 1.5%
350
300
10%
250
31%
200
150
36%
100
50
36%
beef
38%
0
1970
1980
1990
2000
year
18 | © Bühler | Proteins | 2015
21%
2010
2020
2030
What are the alternative protein sources today and tomorrow?
growth = 9%
in-vitro
agricultural waste
synthetic biology
2%
8%
insects
14%
18% algae
moringa, quinoa, chia
pulses, rice, canola
soy
19 | © Bühler | Proteins | 2015
Solutions to cover meat demand.
meat alternatives
animal
protein meals
live animals
meat consumption
alternative sources
cultured meat
- soy
- maize
- ….
Conventional sources
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Raw material sources for protein
cereal seeds
pulse seeds
insects
cereal bran
oilseed extraction meal
algae
short-term
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long-term
Pulses, the underexploited opportunity
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Pulses, the underexploited opportunity
FORAGE LEGUMES
INDUSTRIAL LEGUMES
LEGUMES
Global pulse production
GRAIN LEGUMES
ex: green beans/peas
soybeans
peanuts
PULSES
(dry seeds)
60 million metric tons (MT) pa
FAO recognizes 11 primary pulses
1. Dry beans
(34%)
2. Dry peas
(16%)
3. Chickpea
(14%)
4. Dry cowpea
(9%)
5. Pigeon pea
(7%)
6. Dry broad beans
(6%)
7. Lentil
(6%)
8. Vetch
(2%)
9. Lupins
(1%)
10. Bambara groundnut (0.1%)
11. Minor pulses
23 | © Bühler | Innovation Day 2011 | S. Bellaio GP71 | 2011
(2%)
Why pulses?
pulses
15% – 35%
cereals
protein content
7% – 15%
but:
taste issues
War on wheat (gluten!)
digestive disconfort
Gluten-free cereals low protein
unterutilized in modern food
24 | © Bühler | Protein Summit | 2013
Pulses for product innovation
Established technologies for new applications
Tailor made
conversion into
food ingredients
Productivity
New varieties
New product with
established
technologies
Global supply
Grading
Farmers
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Traders
Miller
Food
processors
Innovative
products
Retailer
Caterer
Consumer
Why algae?
sunlight
for energy
fast growth
high yields
light
organic matter
CO2 gas
valorization
wastewater
purification
CO2
•
polysaccharides
•
lipids
•
proteins
•
others
H2O
N, P
lignocellulosic material
primary crops
no competition
for land/water
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higher
nutritive value
Algae classification
algae
macroalgae
microalgae
multicellular
unicellular
in littoral zones of aquatic habits
in all zones of aquatic habits
also called seaweed
also called phytoplankton
27 | © Bühler | Proteins | 2015
VALORIE: Technology for extracting value from algae
See Valorie film
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And how about insects as new protein source?
• They grow on organic waste,
• have high nutritional value (13-80% protein, 9-54% fat, minerals, vitamins),
• low environmental footprint (lower water & land use, less GHG),
• high feed conversion rate (beef 8:1, pig 3:1, chicken 2:1, insects 1.3:1),
• and are more than protein (lipids, chitin, etc).
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Protein structuring technologies for food will become key
Example: cooking extusion
barrel with screws
die
knife
Bühler ECO twin
cooking
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structuring
cutting
A step change in process monitoring, control & automation
From new sensors to new business models
Online Sensors
Real time monitoring of product properties
Process control
Expert systems
Self-learning automation systems
Predictive models
Statistical process control
Value chain intelligence
Big data analytics
Big data business (Industria 4.0)
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Hype Cycle for Emerging Technologies
relevant for breakthrough
innovation in intelligent food
process control
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www.buhlergroup.com
Bühler en España
33 | © Bühler |
Nov 2013
Key technological developments
Preservation & packaging technologies
Mild preservation, non-thermal inactivation technologies
Dry processing as alternative to wet processing
Smart sensors and advanced process control
Plant-based meat alternatives
Mild separation technologies, functional fractionation
Improvements in resource valorization (by-products, zero waste)
34 | © Bühler | Food Technology Trends | 2015