Creative Reformulation of Protein Foods: Five Steps Toward a Sustainable Protein Supply

Clyde DonCDC FoodPhysica Lab – The Netherlands

2019 Protein Trends & Technologies Seminar - May 21-22, 2019

OUTLINE – CREATIVE REFORMULATION

• FOODPHYSICA• INTRODUCTION & TRENDS• PROTEINS, SOURCES, QUALITY & SAFETY • PROTEIN QUALITY & FUNCTIONALITY• SHIFTING PROTEIN CONSUMPTION PATTERNS

• Re-Formulating and 5 steps to more sustainable sources• CONCLUSION

CDConsultancy

Cereal & Grains Technology

Circular Chemistry [ChemPhysica]

New Methods, Non-Routine Analyses & Validation

Ingredient Interactions

Meat & Protein Products

“Overall, however, although a number of countries –particularly in the Near East and North Africa and in South Asia – have reached or are about to reach the limits of their available land, at the global scale there are still sufficient land resources left to feed the world population for the foreseeable future.”

“Does this mean that all is well? Certainly not. – “

NOTE: ‘Feeding the world’ in terms of projected food calories / capita towards 2050.

Food Calorie = f (fat x carbs x proteins x ..)100 kcal product A ≠ 100 kcal product B

A focus on Protein

Plant protein market forecast for ‘5% growth a year’ in recent reportPosted By: News Desk on: March 30, 2016In: Food, Health, Industries, Ingredients

- June 2017 Retailers in Netherlands and Flanders report a 25% increase in ‘plant-meat’ sales- 2018 Unilever buys the Vegetarian Butcher- March 2019, Dutch Meat Industry announces ‘we’regoing plant-based!’

Animal proteins ->

The Balance – Animal / Plant Protein

Animal% Plant%

80 20

70 30

60 4050 5040 60

30 70

20 80

High Income

Low Income

IN SOME REGIONS CEREAL CONSUMPTION CAN PROVIDE ≥ 60% OF PROTEIN INTAKE

Animal / Plant – Just make the swap?AA OVB BLG Beef* WG CG SP

Histidine 1.8% 1.2% 2.7% 2.0% 1.1% 2.5%

Isoleucine 6.5% 6.2% 4.6% 3.5% 2.2% 4.6%

Leucine 8.3% 13.6% 7.9% 7.0% 8.7% 8.1%

Lysine 5.2% 9.3% 8.2% 1.8% 0.9% 6.7%

Methionine 4.4% 2.5% 2.4% 1.4% 1.3% 0.9%

Phenylalanine 5.2% 2.5% 4.0% 5.2% 3.3% 5.3%

Threonine 3.9% 4.9% 4.0% 2.5% 1.8% 4.1%

Tryptophan 0.8% 1.2% 1.1% 0.1% 0.3% 0.8%

Valine 8.0% 5.6% 5.5% 3.8% 2.4% 4.7%

*J. Biol. Chem. 1951, 193:23-28.

CASEIN set at 100

Common maize 32.1

Wheat 38.7

Rice 79.3

Animal / Plant – Just make the swap?

From another angleBLENDING on basis of AA

This is seen as a good way tocompensate e.g.:

Soy x WheatWheat x Rice x PeaOr even: A x B x C x D protein

We know a lot about single proteins, but complex proteinblends is something else!

AA CAS

Histidine 2.4%

Isoleucine 4.8%

Leucine 10.5%

Lysine 5.3%

Methionine 2.9%

Phenylalanine 4.3%

Threonine 4.3%

Tryptophan 0.5%

Valine 9.1%

?

Protein Quality ? In-Vitro In-Vivo

Lys

Trp

MetLeu

Thr

Val

Ile

Thr

Phe

Truncated PDCAAS values do not provide informationabout the potency of a protein to balance inferiorproteins; (and a solution for this problem should befound).

The Method - in 2000

Presented at the symposium “Criteria and Significance of Dietary ProteinSources in Humans,” held in San Francisco, CA, on October 4, 1999.

Journal of Nutrition - 2000

Quality of Protein Blends

PROTEINS AND SOURCES FOR HUMAN CONSUMPTION

Continents and meat productionMeat production, tonnesTotal meat production, measured in tonnes. Meat includes cattle, poultry, sheep/mutton, goat, pigmeat, and wildgame. Figures are given in terms of dressed carcass weight, excluding offal and slaughter fats.

1961 1970 1980 1990 2000 2010 2014t0

million t50

million t100

million t150

million t200

million t250

million t300 Central America

Northern America

Caribbean

South America

Oceania

Europe

Asia

Africa

Source: UN Food and Agricultural Organization (FAO) OurWorldInData.org/meat-and-seafood-production-consumption/ • CC BY-SA

Meat and Seafood Production & Consumption

by Hannah Ritchie and Max Roser[cite]

World Champions of Meat

1961 North America and Europe

2013Asia

FAO (2012). Food and Agriculture Organization of the United Nations. http://faostat.fao.org/

US and Europe more focus on beef andpork as meat supply, but in generaldemand not growing much

THE CHALLENGE SINCE ~2000: REPLACE MEAT

PROTEINS AND SOURCES FOR HUMAN CONSUMPTION

Comments:

Fake Meat

Rubbery

No taste

Dry

1st Generation of Meat-replacers

2013 – 2018 meat analogue tasting in NLSeveral tests show a majority of products scoring lower than 5 on a 1 – 10 scale

Negatives • Lacks Juiciness• Too much salt• No meat taste• RubberyPositive Some judges do see texture

improvements

UNRAVELLING MEAT

Chop

Wash 0.6% NaCl

Centrifuge

Connective tissue Sarcoplasmic and myofibrillar proteins

Cook the three protein fractions at 85°C

50% Cook Loss Small aggregates 5% cook loss

Steak ~70% water – low fat

Meat: a multiple phases aggregation system • Myofibrillar soluble in ≥ 2% aqeous NaCl • Connective tissue – base/acid/T soluble• Sarcoplasmic – soluble in water (0.6% NaCl)• Fat – oil soluble / Tmelt / intramuscular• Water – bound, low pressed juice, but syneresis ‘drip’

Cooking:• Myofibrillar protein – viscoelastic gel + WHC

• Synergy between actin x myosine• Connective tissue – ‘shrink/swell’ and expels water• Sarcoplasmic proteins - small aggregates low WHC • Fat – melting, part of compressed juice• Water - cook loss, less bound, higher pressed juice

MULTIPLE PROTEIN PHASES APPROACH FOR BETTER UNDERSTANDING MEAT PRODUCT QUALITY - UNRAVELLING KEY INTERACTIONS BY USING A MULTIPLE PHASE AGGREGATION MODEL C. Don, R.P. Happe, T.J. Verkleij and G. Wijngaards 52nd ICoMST 2006

Length scale / concentration

effect Lean beef steak

F1 cooked / F1 raw = 0.61CHcook / CHraw = 1.23

Pressed Juice released

Raw 3 mg /g Cooked 15 mg/g

The “50/50” Burger

C. Don – Cereal Foods World – July-Aug, 2017

Protein Functionality

Look for synergy!

C. Don – Cereal Foods World – July-Aug, 2017

Protein Processing

Blend Gluten & Soja

Blending is important to reach structural and textural features of a good meat analog

A variety of plant-meat creations by blending

Courtesy: Mr Henk Schouten

Au bain-marie cooking in hot water (not boiling)

1400

1131

1261

TEST-CASE – THE VEGGIE SMOKEDSAUSAGE

Vegetarianformulation

Meat-basedformulation

Vegetarianformulation

Meat-basedformulation

Mimicking Meat• Single protein based meat analogues, where the protein has been

selected on basis of gelling capacity, tend to remain rubbery anddry

• Major steps forward have been made in formulating meat-like textures by using a blending strategy

• There is a better response to the new formulations than 20 yrs ago• The texture challenge has almost been cracked, we are close and

are already seeing much better products ‘now’• Challenges that remain:

– 1) creating the proper juiciness– 2) find suffcient protein sources!

PROTEINS AND SOURCES FOR HUMAN CONSUMPTION

5 Steps toward a sustainableprotein supply

Today & Future: Meat is not center of the plate anymore

The Balance – Animal / Plant Protein

Animal% Plant%

80 20

70 30

60 40

50 50

40 60

30 7020 80

High Income

Low Income

By Andrew MT - Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=9643590

Worldwide rice production. Map of rice production across the world in the year 2000. Data compiled by the University of Minnesota Institute on the Environment with data from C. Monfreda, N. Ramankutty, and J.A. Foley. 2008. Image courtesy of Wikimedia Commons

Worldwide rice production. Map of rice production across the world in the year 2000. Data compiled by the University of Minnesota Institute on the Environment with data from C. Monfreda, N. Ramankutty, and J.A. Foley. 2008. Image courtesy of Wikimedia Commons

Step1. Protein Transition: Sausage of the FutureBlend existing ingredients:

- Meat/Muscle- Soy / beans- Cereals/Grains- Fruit & Vegetables- Insects- Nuts- ………………….

“The sausage is one of man-kind’s first ever designed food items”Carolien Niebling et al. Mix toward texture, taste and quality

Protein Transition 2. “Waste” (Animal) Protein Recovery

Soluble / Insoluble does it matter? – Egg Yolkvalorization project• Stomach

• Constant pH at 2.00 ± 0.10• Pepsin digestion for 2 hours

• Small intestine• Constant pH at 7.50 ± 0.50• Trypsin & α-chymotrypsin

digestion for 2 hours• TCA to stop digestion• Measure dissolved Protein digest

sample ProteinSolubility in

water

Solubility afterdigestion assay

Egg YolkProtein (Spray Dried)

96% 100%

Recovered EggYolk Protein 2% 98%

Casein 98% 100%

Recovered egg yolk protein has lower solubility, but in-vitro digestion is close to that of native egg yolk protein

Recovered egg yolk functionality

COOK LOSS %

Tests ongoing to enzymatically improve waste egg protein functionality in bakery products and dispersion quality in high protein beverages

improve yield with 1 % Collagen10% more product

Reduce cooking lossimprove texture

Collagens from by-products

Step 3. ‘New’ Sources

Insect Proteins

Step 3. Seaweed

Protein Solubility varies 10 – 80%Seaweed type and processing important! Applications in savoury products

Duckweed • Disperses but not soluble

• Good in bakery productssuch as pizza dough

• Success with a Tortilla andTortilla Chip Prototype

• Process optimization ongoing

A protein foods for a new generation

• More and more youngconsumers and young families enjoy a ‘meatless’ day

• More awareness aboutsustainability

• More creativity in cooking with‘plant-meat’

• Plant proteins in the mix ‘50/50’• Better understanding of where

protein comes from Courtesy: Henk Schouten

Step 4. Novel Proteins from the lab

Heme proteins from a bioreactorEgg proteins without chicken

Milk and Beef without a cowProf. Mark Post

‘Building off recent advances in their exploitation in agriculture, husbandry, and industrial fermentations, we envision that CRISPR-Cas technologies will drive research and development in many food products, and open new avenues for the future of food science.’

Clustered Regularly Interspaced Short Palindromic Repeats

Futuristic Technology to improve organisms that produce proteins and protein sequences ‘on demand’ – From high gelling Ovalbumin towards bread-making Gluten

STEP 5. Protein on demand

THANKS FOR YOUR ATTENTION

clyde.don@foodphysica.com