Production

VTT TECHNICAL RESEARCH CENTRE OF FINLAND LTD
Tulevaisuuden ruokaa
uusin raaka-ainein
Biotaloudesta viennin veturi – Kuuntele VTT:n
näkökulma, 30.11.2015
Kaisa Poutanen ja Emilia Nordlund
Trends and drivers in the food industry
Health and
wellness
Consolidation
Cost
efficiency GLOBALISATION
SHAPES THE
MARKET
Responsibility
02/12/2015
Safety
and
security
Sustainability
Natural
CONSUMER
NEEDS ARE
INCREASINGLY
DIVERSIFIED*
Free from
Rich in
Aging
population
The story
behind
*Top ten food trends for 2015, Innova market insights; 10 key trends in food, nutrition & health 2015, New Nutrition business
2
The value chain of food delivery is changing
Farm
Ingredient
factory
Food
factory
Retail
Horeca
Packaging
Digitalization
02/12/2015
3
The value chain of food delivery is changing
Farm
Future raw
materials come
from nature but
also factories
Ingredient
factory
Food
factory
Retail
Horeca
Rethinking the food
Food and story
processing chain;
behind; experiences,
Efficiency, safety,
convenience 24h/7,
new technologies
participation,
and conceptsPackaging personification and
knowledge sharing
Digitalization
02/12/2015
4
We should use raw materials more effectively
Tightening
landfilling
regulations
15% increase in
resource productivity
needed by 2030
1/3
of food
is wasted
Zero
waste
*Source: EU Commission communication
COM(2014) 398 Towards a circular
economy: A zero waste programme for
Europe
02/12/2015
5
Sources of new future food ingredients?
New plants
and
sidestreams
for protein
sources
02/12/2015
Novel
cell or plant
factory
concepts
Non-food
raw materials
and bystreams
6
Protein
7
Protein challenge is one of the
most urgent global food security challenges
45%
more
energy
2030
50%
more
food
30%
more
water
02/12/2015
8
Protein issue is multidimensional
Global
National
Personal
9
There is a lot to gain from agro sidestreams
Wheat bran
Brewers’ spent grains
Rape seed press cake
Production >100 M t/a
world-wide
Low in starch (9-13%)
High fibre (48-53%) High
protein (15-17%)
Production 30 M t/a
world-wide
Can be turned into more
valuable products using
mechanical, chemical and
enzymatic fractionation
Production 62 M t/a
world-wide
High proteins (34–37%)
High oil (10%)
02/12/2015
10
Plant proteins can satisfy* the daily
protein need of the EU-27 population
Production
(M tons/ a)
Protein
content in the
side stream
(g / 100 g)
Protein
amount
(M tons/a)
Rapeseed presscake/
meal (oil)
13
30-40
5
Wheat bran (flour)
37
Brewers’ spent grains (beer)
2
> 20
0.4
Soy (oil)
1
40-50
0.5
Potato cell sap (starch)
6
2
0.1
Sidestream (primary
product)
*calculated on the basis of the daily consumption of 50 g
02/12/2015
>10
6
Source: FAOSTAT and FEDIOL
11
Fractionation concepts and new products from
rapeseed press cake
Products
Intermediates
Fractionation
• Dry fractionation
• Enzyme-aided water
extraction
• Water-lean concepts
02/12/2015
• Protein
• Bioactive peptides
• Antioxidative
phenolics
• Smoothies, bakery
products, spreads
• Cosmetics
• Wound healings
• Natural preservatives
• Protein-rich feed
• VTT has developed simple fractionation concepts for production of protein
concentrates and antioxidative phenolic extracts from rapeseed oil pressing
residue
• VTT has demonstrated:
• Removal of hulls from the press cake by dry fractionation
• Enzyme-aided recovery in of protein-sugar concentrates and peptide fractions
at 20% solid content (250 g scale)
• Technological properties of the protein concentrates
12
• Techno-economic viability of production concepts
Examples of VTT approaches
Multifunctional ingredients from rapeseed
press cake
Brewer´s spent grain and fractions for
bread, yogurt and other applications
Use of bioprocessed bran as bakery
ingredient to deliver high-fibre foods rich in
protein
Concentration of bran proteins for food uses
(e.g. performance proteins)
Use of oat protein and legumes (fababean)
and fractions in bread, pasta and extruded
snacks
02/12/2015
13
Potential of oats
14
Finland – Oatland
How to add value to oats?
Finland is the 5th largest oat producer
globally
The annual oat harvest is 1.2 million tons
Due to our latitude Finnish oat is of
excellent quality
However, domestic use of oats is mainly
as animal feed
Oats are also exported, but mainly as low
value added products like grains or
flakes
02/12/2015
15
Slide 15
PK8
tähän minulla on olemassa kaunis kaurakuva VTT:n (vanhan)tiedotteen kannesta kunhan joudan kaivaa
Poutanen Kaisa; 26.11.2015
Traditional use of oats
Whole grain
oats
Animal feed
• Hulls for ruminants
• Whole oats for horses
Dehulling
Hulls
Flaking
Oat flakes
Energy uses
• Heat
• Electricity
Food uses
• Bread, biscuits
• Porridge, muesli
02/12/2015
16
Opportunities by new oat fractionation
Foods and supplements
Fibre
-glucan)
Dehulled
grains
Oil
Fraction
-ation
Protein
• Lowering of cholesterol, fibre-rich products
with -glucan
• Oat protein, suitable also for celiac persons
• Fat-free oat starch for various applications
Starch
Cosmetics
• Skin care
• Hair care
02/12/2015
17
From wood
to food
18
Food and health
Eating patterns are a key lifestyle factor associated with health and well-being
Health and well-being are megatrends at food market
Foods should provide both nutrients and health-protective components
Food producers should provide alternative options for balanced intake and
controlled bioavailability of nutrients and non-nutrients
This calls for new bulking and texturizing agents
02/12/2015
19
Processed foods also in the bottom of pyramid
- stucturizing agents and water binding
important
Increasing welfare has generated foods with
refined macronutrients and high energy
The
plantthat
foods
high
density
areat
onthe
thebottom
top of have
the diet
pyramid
nutrient and low energy density –
andfuture:
a complex
cellular
structure
In the
Generate
palatable
processed
with good
retention
foods suitable
forwater
the base
of the pyramid
02/12/2015
20
Biomimetic structures using new ingredients
How to pack water in solid food structure using dietary fibre
polymers? This would make processed foods healthier and less
energy dense.
At the welfare world there is need for eating with less calories.
Use of dietary fibre polymers which are the backbone of healthy eating
– and also of natural plant food matrix.
APPLE COMPOSITION
Water = 85%
Sugars = 10%
Fibre = 2.4%
02/12/2015
21
Traditional pulping concept
By-products
Pulp
Paper
Energy
02/12/2015
22
Future biorefineries
Paper
Pulp
Other fibre
products
Polymers
Low MW
components
Fractionation
Energy
02/12/2015
Sugars
23
Wood and edible plant cell wall
components are similar
HEMISELLULOSES
- XYLAN
- MANNAN
LIGNIN
CELLULOSE
Could we use wood polymers as structurizing agents
and dietary fibre in foods?
02/12/2015
Graphic from the B.S. thesis of Renee Whippee, UMaine, 2006
24
New types of cellulose micro- and nanofibrils
Bacterial cellulose
Size/Dimensions/Branching
Scale bar: 20 m
Chain or rodlike structure
Nanocrystals
Nanofibres
All dimensions in
nanoscale
6
Nanofibrillated
Microfibrillated
5
Ribbonlike
structure
Overall
dimensions in
macroscale, fine
structure in
nanoscale
4
20
3
2
Branched
structure
15
1
Image area 1x1 m
Overall
dimensions in
macroscale,
fine structure
in nanoscale
10
0
Image area 2x2 m
5
0
Image area 2x2 m
Image area 2x2 m
Charge/Chemistry
Colloidal dispersion
Polyelectrolyte-like
Decreasing surface charge
02/12/2015
Woodfibre like
25
Eating experiences and health by new food
structures
Nanofibrillated celluloses
provide an array of
opportunities for new textures
and for increased stability
Gels with improved texture
Stabilized emulsions
Work by Marie Gestranius & Tekla Tammelin (VTT), et al.
02/12/2015
26
Birch xylan as yogurt ingredient
No xylan
+ 3% xylan
Technological properties:
More even and softer texture
Birch xylan
02/12/2015
Physiological properties as
dietary fibre:
Favourable (slow) fermentation rate
in vitro
27
Lignin as structure modifying ingredient
Lignin in muffins acts as an emulsifier
and coloring agent
Bile acid binding – cholesterol lowering
Lignin in mayonnaise forms a stable
emulsion
Lignin binds bile acid and can contribute
to reduction of blood cholesterol
Lignin is ampiphilic and interacts with
many food components with beneficial
potential as a structuring agent
02/12/2015
28
New ingredients
for new ways of
food delivery
29
New technologies and business models to
deliver healthy food for the future consumer
New plant food ingredients
New hybrid product concepts
New ways of food delivery
3D Printing
Prosumerism
Monitoring self
Increasing out-of-home eating
Food in digital world; social
media
Need for sustainability and
transparency of origin; safety
2.12.2015
Creative Dynamic
Energetic Beautiful
Happy Good looking
Healthy Independent
Functional Enjoying
Effective
30
3D-printers beside our coffee machines in 2020?
Existing concepts
Automation and speed - Push the button and go - 3D food
vending machines
Personalized diet by tuning portion size and composition
(e.g. for seniors by Biozoon Food Innovations)
Designer food – aesthetic values, structure forming, taste,
texture
Molecular gastronomy – involves physical and chemical
interaction
Sustainability: artificial raw meat by 3D bioprinter (Modern
Meadow)
Fun, healthy and educational food for kids - e.g. dinosaur
broccoli
Combining food and technology (e.g. Augmented
Reality) – monitoring and feedback
02/12/2015
Source: Sozer & Puukko, VTT
31
It is all about transformation new ingredients make the future foods
NEW SOURCES
New sources of
protein and fibre
ingredients
FUNCTIONALITY
FEASIBILITY
Chemical, physical
Up-scaling
properties,
physiological response
Functional
ingredients
designed
for specific
needs
NEW PROCESSES
Enrichment and
modification
technologies
02/12/2015
NEW FOODS
Applicability in
food products
COST
Techno-economical
evaluation of the
concept
32
TECHNOLOGY FOR BUSINESS