Protected Ingredients for Better Process · 6/13/2019 · Microencapsulation 101 To Control,...

Protected Ingredients for Better Process Control in Companion Animal Nutrition

Functional Benefits of Encapsulation: An Enabling Technology

Robert Mason, Senior Applications Scientist Eric K. Altom, PhD, Technical Nutritionist *

13 June 2019Cologne, Germany

Rules of Engagement

•Everyone has a stake in the discussion today

•This is a discussion, not a formal presentation

•We WILL generate more questions than answer

today

Benefits of Encapsulation, June 2019

This is a very exciting time to be a Pet Food Technologist !!!!

“If you don’t know where you are going, any road will do.”From Alice in Wonderland

New Technology

and/or Ingredient

Reapplication of

Existing Technology

Reapplication into

Alternate Platform

Paths for Product Development

Presented by EK Altom. Product Qualifications for a Successful Commercial Launch. Pet Food Forum China. Shanghai. 2016


Microencapsulation 101

Why Do I Need an Microencapsulated Ingredient?

• Because of the Ingredient itself• Control release and maintain functionality

• Improve stability

• Improve handling characteristics

(hygroscopicity, dusting)

• For reasons related to Process operations• An “Enabling Technology”

• Work around manufacturing tolerances

• To improve a finished product• Increase viable shelf life

• Fortify without overage or off-flavors


Microencapsulation 101

To Control, Protect and Deliver

SubstrateCore

Active

Raw

CoatingShell

Wall

Capsule

Microencapsulation separates an ingredient

from its environment until release is desired.


Shapes & SizesEncaps come in all shapes & sizes, and have very different characteristics


Single Coating Multiple

Coatings

Irregular Shape

Matrix Particle Multiple Actives Plated Liquid

Application FactorsThe release of a lipid-coated encapsulate is affected by application factors:

MOISTURE

TEMPERATURE

FORCE

Lipid melts and disperses

Water migrates inside,

substrate leaches out

Shear from processing,

mastication, etc.

&


Control Release Profile

• Type of encapsulation material• Lipid, carbohydrate, polymer, protein

• Thickness of encapsulation

• Encapsulation Method• Coacervation, spray drying, spray chilling, freeze drying, fluidized bed,

extrusion

• Raw Material Particle Size• Surface area to volume ratio


Core TechnologyAn established, proprietary process

• Better protection & improved stability

• Minimal residual surface actives

Microencapsulation of dry granular actives

• 90-1,000 microns

• Water-soluble & water-insoluble

• Regular & irregular shapes

• 50-95% activity

Microencapsulation of plated liquid actives

• Water soluble & oil soluble

• 20-35% activity (> than spray drying)


Porosity and Texture Management

Chemical Leavening

Sodium Bicarbonate (Baking Soda)+ Acid(s) → CO2 + Salt + Water

• Reaction is sensitive to:• Temperature

• Moisture content and water activity

• pH

• Reactivity controlled by contact of bicarbonate with acid

• Used alone or in conjunction with yeast

Baking Powder


Encapsulated Chemical Leavening

• Prevent premature reaction of sodium bicarbonate with naturally acidic ingredients• Fruit pieces/juices

• Protein Meals

• Acids, pH controllers, preservatives

• Molasses

• Buttermilk

• Provide process flexibility (pre-baking)• Extend refrigerated storage time of batters/doughs

• Improve tolerance to extended floor time


Increase Holding Times for Doughs and Batters


0

20

40

60

80

100

120

0 5 10 15 20 25 30

cum

ula

tive

CO

2ge

ne

rate

d a

t 3

8 o

C (m

L)

time (min)

85% active 70% active Raw #2

Release and reaction

of sodium bicarbonate

can be manipulated

by microencapsulate

design and

manufacture.

Fast generation

of CO2

Slower generation

of CO2

108 117.596 1230

20

40

60

80

100

120

140

Unprotected Citric Acid BakeShure Citric Acid

Avera

ge D

onut

Volu

me (

cm

3)

After Mixing Mixing + 4 hour Hold

Increase Holding Times for Dough and Batters

Controlled release of active ingredients prevents loss of leavening power over time.

Unprotected Citric Acid Encapsulated Citric Acid


Added Porosity from Control

• Control with no leavening

• PetShure Porosity Medium added with citric acid

• 12.3% increase in cross-section height

• 20.1% increase in volume

• This technology could be used to reduce density of current treats for lower calories or to increase size of treats without increase to calorie count


Pet Application: Porosity & Texture


pH Control Systems

Benefits of Encapsulates for pH Control

• Precise dose-response control of pH • Lowering the pH provides a hurdle to unwanted microbial growth

• Improve production• More flexibility in hold times

• Reduce processing time

• Maintain higher quality texture in cooked meat

• Consistent & reliable control of flavor profile


Why Do We Need Microencapsulation?

• Microencapsulation controls reactivity of water soluble ingredients• Can be directly mixed into meat emulsion

• Prevents protein denaturation & extraction

• Reduces syneresis (purge)

• Active ingredient is released by combined effects of heat, force, and moisture after stuffing

• Improve processing• Flexibility in hold times

• Minimize handling issues

• Increased product throughput


• Starting pH, Target pH

• Cook cycle

• Process time (Hold time/delays)

• Manufacturing tolerance

Variables to Consider

• Type of meat, Meat fat content

• Acidulant properties

• Citric, Lactic, Glucono-Delta-

Lactone (GDL),

• pKa

• Flavor impact

• Acid blends

Using Microencapsulated Acids


Microencapsulated Acids Promote Better Yield


Virtually no loss from purge

Significant loss from purge

Application of pH Control Systems

• Browning and protein denaturation after only 30 minutes

• Meat becomes hard, brittle, and at risk for rapid microbial growth

Application(s):

• Stabilize fresh meat prior and during shipping

• Stabilize fresh meat prior to processing at plant

• Help provide a valid method for commercializing “safe raw foods and BARF diets”


Protein breakdown after only 30 minutes

Raw Protected

Structure and Forming

Microencapsulated calcium lactate provides control of alginate gelation in restructured meat products.

Microencapsulated Calcium Lactate + Alginate for Meat Binding


Calcium Alginate GelAlginate Suspension

+ Encap Calcium Source

Meat Pieces

Add meat to tumbler

Add water, mix until absorbed

Add sodium alginate to meat while mixing

Add MeatShure Encapsulated

Ealcium Lactate to meat while

mixing

Transfer to stuffer/former

Refrigerate or freeze overnight

Binding Process


Mix 5-15 min

Mix

Final Product has Excellent Binding Characteristics


Microencapsulated Calcium Lactate + Alginate for Meat Binding

• Neither salt nor phosphate required• Both will impede the bind

• Standard meat processing equipment can be used

• Can binding both raw and uncooked meat

• Raw finished products can be distributed refrigerated or frozen

• Bound meat pieces are freeze thaw stable


Application Benefits

• Maximizes the value of meat trimmings

• Can bind all types of lean meat (max 20% fat) • beef, pork, lamb

• chicken, turkey

• some varieties of fish

• Mixtures of skeletal muscle and organ meats

• No specific requirement for size of meat pieces•From chunked, trimmed meat, to emulsified mixtures

• Appearance, cooking and cooking losses similar to that of unbound processed meat

• Permits accurate portion control


Application: Prototype Meat Jerky Treats



Is this for Humans?? Or Pets??


Who are our customers?


Questions?


Thank You!

1.800.819.9233 | [email protected] | petshure.com

Robert Mason, BSSr. Applications Scientist –

PetShure and Ingredient Solutions

[email protected]

P: 314.702.2074

M: 845.421.7119

Eric K. Altom, MS, PhDTechnical Nutritionist

Monogastric Nutrition

[email protected]

P: 937.472.3322

M: 937.620.1795

mailto:[email protected]

mailto:[email protected]

Protected Ingredients for Better Process · 6/13/2019 · Microencapsulation 101 To Control,...

Documents

Transcript of Protected Ingredients for Better Process · 6/13/2019 · Microencapsulation 101 To Control,...