Selected foods processing technology and fortification

Cereals
 Monocotyledonous plants that belong to the grass family
 Based on botanists’ approximation,
350,000 plant species, of which about
195,000 species are economically important.
 The cereal grains such as
 wheat
 rice
 corn Provide 50% of the food energy and 50%
 Barley of the protein consumed on earth.
 oat
 rye  Cereals are a versatile and reliable
 Sorghum source of food so dominant in the
 millet food sector
 Cereal grains, especially rice and wheat, provide the bulk of energy
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Wheat
 Middle East origin
 Grown in temperate zones around the world
 Major producing countries:
 China (18%)
 India (12%)
 USA (9%)
 Russian Federation (8%)
 35‐50 mg / kernel
Not covered
 Bran (14%)
 Endosperm (83%)
 Germ (3%)

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Two kinds of starch granules:

 small, spherical (5μ)
 large, lenticular (25μ)
 Gluten protein: allows leavened fermented products

 Grown primarily for human consumption

 Major part of harvested wheat is milled into wheat flour and
processed: bread, pastry, pasta, soft wheat products, ...
 Wheat as breakfast cereal:
 Ready‐to‐eat (shredded wheat, flaked wheat, puffed
wheat)
 For cooking (farina: prime middlings from hard wheat)

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Cereals processing
Forms a large and important part of the food production chain

Grain Cleaning
 There are two simple objectives in grain cleaning
 Remove non‐grain (e.g. non‐wheat) material
 Remove grain not fit for milling

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Preparing Grain to Mill

Conditioning
 To prepare the cleaned grain for milling, we begin with the
conditioning process.
 Defined as the application of water, steam, or heat to the grain
Tempering
 After water is applied in the conditioning step, the grain requires a
rest period called tempering. The tempering step allows water to
penetrate the inner endosperm.
 Tempering can last up to 24 hrs before milling
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Grain Conditioning
 Mellowing of the endosperm
 Flour extraction can be increased
 Power consumption / noise level of the Roller mills
reduced and
 Flour ash content reduced
 Toughening of the bran
 Bran tends to break up less and remains in bigger pieces
 Large bran flakes can effectively be cleaned by the
corrugated rolls
 Less small bran specks in the flour
 Adjustment of the Flour moisture content
 Constant moisture level = constant milling conditions
 Constant moisture level = constant baking conditions
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Milling
 Is a process of transforming cereals into more‐palatable, more‐
desirable food ingredients
Roller Milling
 Flour is extracted from grain in a series of steps called the gradual
reduction process
 Each step involves grinding the stock, followed by a sifting step

Stock is ground between two rolls of a roller mill

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SIEVES
 After each grinding step, the ground stock is separated on sieves
 Classified as bran
 Further grinding or
 Saved as flour
Flour Production
 Flour is collected from each milling step
 Based on its ash and protein content the miller must decide which
finished product it will become
 Multiple flour streams must be blended to create a finished
product that meets the customers specifications
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Production of wheat-based bread

 Bread is undoubtedly the most popular bakery product in
the western world
 The consumers’ bread preference is mainly dictated by tradition.
 Practical elements, such as availability and freshness of bread, also
have to be taken into consideration.
Essential ingredients
 Flour, yeast, salt and water are essential ingredients in a bread
formula
Non‐essential ingredients
 Fat, sugar, milk or milk powder, oxidants, enzyme preparations,
surface active compounds and additives against fungal development
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Different processes
 The processes involve basic operations: mixing or dough formation,
fermentation and baking.
 Bread can be produced in a variety of ways.
 Straight dough process
 Sponge-and-dough process
 Chorleywood-process
Straight dough process
 The simplest bread making procedure
 Commonly used in many parts of Europe
 All ingredients are brought together at the start of the kneading
 Dough is kneaded to obtain an optimally developed dough
 The dough is then allowed to ferment for 2 to 4 hours
 The dough is punched (re‐kneaded)
 Then the dough is divided in dough pieces of the appropriate size
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 Again the dough is fermented,

to obtain a leavened product.
 When the dough has risen
sufficiently, it is baked.

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Gluten on dough formation

 Gluten, the most‐studied cereal protein
 Believed to be mostly responsible for the bread making
capabilities of wheat flour
 Only wheat flour can form strong, cohesive dough that retains
gas and produces a light, aerated baked product
 Glutenin and gliadin, which together form gluten.
 Gluten is relatively easy to isolate from dough
insoluble in water
 Gliadin
 Extremely sticky when hydrated
 No resistance to extension
 Responsible for the dough's cohesiveness
 Glutenin:
 resilient and rubbery but prone to rupture
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 Gives dough its property of resistance to extension, i.e., its

elasticity

Physical properties of gluten (left) and its components: gliadin (center) and
glutenin (right)
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Baking

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Legumes
 Plants belonging to the family Leguminosae
 Have dicotyledonous seeds
 Next to cereals, they are the main food sources
especially for developing countries
 Fix atmospheric nitrogen into the soil thus increasing its fertility
 Good and inexpensive sources of proteins, fat, carbohydrates and
dietary fibers.
 Also rich in B‐group vitamins (thiamine, riboflavin and niacin) and
minerals such as K, Ca, Mg, Cu, Fe and Zn.
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 The word pulse is used to clarify legumes that have edible dry
seeds.
 ‘Pulses’ and ‘legumes’ should not be used interchangeably
 Not all legumes are considered as pulses but all pulses are legumes
 Pulses such as beans, peas and lentils have been consumed for
more than 10,000 years
 The most commonly grown legumes world over include soybean,
peanut, beans, peas, chickpeas and lentils
Limitations : the presence of several antinutritional factors
e.g. protein inhibitors trypsin and chymotrypsin inhibitors
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 The most common domestic methods for processing of legumes:

 Milling,
 Fermentation
 Dehulling
 Soaking
 Ordinary cooking
 Germination
 Pressure‐cooking
 Processing techniques cause important changes in the biochemical,
nutritional and sensory characteristics

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Roots and Tubers

 Important food crops and contribute significantly to sustainable
development, income generation and food security especially in
the tropical regions
 The perishable nature of roots and tubers demands appropriate
storage conditions
 Cassava, sweet potato, potato and yam are the most important
food crops in Africa.

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The Role of Roots and Tubers in Nutrition

 Second only in importance to cereals as a global source of
carbohydrates
 Also provide some minerals and essential vitamins

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Food fortification
 Refers to the addition of micronutrients to processed foods
 Basic principles
 Public health significance of MNM
 Selection of fortificants & vehicles
 Implementing effective programs

 Supplementation is the term used to describe the provision of

relatively large doses of micronutrients, usually in the form of
pills, capsules or syrups.
 The fastest way to control deficiency in individuals

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Types food fortification

 Commercial fortification (market driven)
 Home fortification
 Biofortification
Commercial fortification
 Most successful and cost‐effective approach for preventing MNM
 “No other technology offers as large an opportunity to improve
lives at such low cost and in such a short time.” (World Bank,
1994)

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Criteria for successful fortification

 Vehicle widely consumed by target population
 Low cost
 Vehicle processed centrally
 Nutrient does not change sensory properties
 Nutrient is stable in food matrix
 Appropriate government regulations in place
 Monitoring system in place

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Influencing factors of fortification

 Technology:
 Technologies relatively simple and well developed
 Trained workers essential
 Chemical analysis critical for quality control
 Bioavailability
 Stability of added nutrients

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Factors Affecting the Stability of Vitamins

 Heat
 Light
 pH
 Oxygen
 Metal ions (Fe2+, Cu2+)
 Food matrix
 Moisture content
 Form of the vitamin
 Protective coating and/or antioxidants
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Home fortification
 Practical ways of adding micronutrients to foods
at the household levels
 In particular to complementary foods for
young children

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Bio-fortification
Increasing the concentration and/or bioavailability of nutrients
through genetic selection or manipulation
– Conventional plant breeding
– Genetic engineering (e.g. golden rice)

Food Fortification Conclusions

 Technologies well developed
 Effective
 Benefit: cost ratio is very high
 Risks are low
 Over fortification may be a problem
 More effectiveness and toxicology studies are needed

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