The document discusses dry and wet fractionation processes for peas, lentils, and chickpeas to produce ingredients for gluten-free foods. Dry fractionation uses pin milling and air classification to separate proteins, starches, and fibers. Wet fractionation uses soaking and pH adjustment to solubilize proteins and starches, which are then separated. These processes produce pea hull fiber, protein-rich flour, and starch-rich flour. The fractions find uses in baked goods, pasta, meat analogs, and other gluten-free applications. Fractionation allows for tailored functional properties and offers opportunities for pulse crops in gluten-free markets.
The document discusses dry and wet fractionation processes for peas, lentils, and chickpeas to produce ingredients for gluten-free foods. Dry fractionation uses pin milling and air classification to separate proteins, starches, and fibers. Wet fractionation uses soaking and pH adjustment to solubilize proteins and starches, which are then separated. These processes produce pea hull fiber, protein-rich flour, and starch-rich flour. The fractions find uses in baked goods, pasta, meat analogs, and other gluten-free applications. Fractionation allows for tailored functional properties and offers opportunities for pulse crops in gluten-free markets.
The document discusses dry and wet fractionation processes for peas, lentils, and chickpeas to produce ingredients for gluten-free foods. Dry fractionation uses pin milling and air classification to separate proteins, starches, and fibers. Wet fractionation uses soaking and pH adjustment to solubilize proteins and starches, which are then separated. These processes produce pea hull fiber, protein-rich flour, and starch-rich flour. The fractions find uses in baked goods, pasta, meat analogs, and other gluten-free applications. Fractionation allows for tailored functional properties and offers opportunities for pulse crops in gluten-free markets.
applications of peas, lentils and chickpeas in gluten-free foods Mehmet C. Tulbek, Ph.D. Technical Director Northern Crops Institute Fargo, ND Institute of Food Technologists 2010 Annual Meeting Gluten-free foods: Opportunities and challenges DRY PEAS, LENTILS and CHICKPEAS Base ingredient in gluten free foods High protein & dietary fiber Non GMO Poor allergen Low glycemic index COMPOSITION OF PEAS, LENTILS & CHICKPEAS Dietaryfiber 2535 Connecting in the Global Marketplace WORLD DRY PEA PRODUCTION (MT) Source: FAOSTAT 2008 Connecting in the Global Marketplace Major Exporters WORLD LENTIL PRODUCTION (MT) Source: FAOSTAT 2008 Connecting in the Global Marketplace Major Exporters WORLD CHICKPEA PRODUCTION (MT) Source: FAOSTAT 2007 Connecting in the Global Marketplace Major Exporters Connecting in the Global Marketplace FEASIBLE TO FRACTIONATE ? Pin Milling, Air Classification and Fractionation Lentils and chickpeas Strong and growing market due to changing worldwide agricultural practices Dry peas (yellow) Price & functional advantages Connecting in the Global Marketplace GROWER PRICES JULY 16 th 2010 Lentils $ 25-32 / CWT Chickpeas - $25-30 / CWT Green peas 8-9.5 / CWT Yellow peas 6.25-8.00 / CWT CWT = 100 lbs = 44.5 kg Connecting in the Global Marketplace LITERATURE OVERVIEW Pin Milling & Air Classification Significant research conducted in 1980s Tyler (1982), Tyler (1984) and Tyler and Panchuk (1982). Connecting in the Global Marketplace LITERATURE OVERVIEW Air classification and protein-starch fractionation is similar in all pulses except chickpea (Han and Khan 1990). High fat content Based on variety 5-8% fat content Connecting in the Global Marketplace DRY FRACTIONATION PROCESS Fractionate protein, starch and fiber components in dry milling process Fractionation is conducted based on particle size. Dehuller Pin mill / jet mill Air classification REQUIRED EQUIPMENT Connecting in the Global Marketplace DRY FRACTIONATION PROCESS Dehulling Key process for the removal of 97-98% of the fiber portion Dry fractionation Protein & starch separation Pin mill OR jet milling Air classification Connecting in the Global Marketplace FLOWCHART Dehulling wholepeas Pinmilling split(dehulled) peas Airclassification split (dehulled)peaflour Packaging Connecting in the Global Marketplace DEHULLING Removal of outer kernel Easier to conduct in peas and lentils Much difficult process in edible beans and chickpeas due to crop characteristics Connecting in the Global Marketplace DEHULLING Impact dehulling Stone dehulling Connecting in the Global Marketplace DEHULLING 1000 kg Dry Pea (%9 Hulls) 90 kg pea hulls removed 910 kg dehulled or split peas Pea hulls are rich in terms of insoluble fiber. %85 Insoluble fiber %15 Soluble fiber Connecting in the Global Marketplace Connecting in the Global Marketplace DRY FRACTIONATION 910 kg dehulled or split peas Pin milled High speed pulverizer %100 under 350 mesh (60 micron) Very fine material Connecting in the Global Marketplace Pinmill CourtesyofParticle ControlLLC Connecting in the Global Marketplace AIR CLASSIFICATION Fluidized tower system Particles in vacuum Separation based on particle size 2-20 micron - Protein concentrate 20-40 micron Starch concentrate Connecting in the Global Marketplace Air Classification System CourtesyofParticle ControlLLC Connecting in the Global Marketplace Air Classification System Towerand DustBag CourtesyofParticle ControlLLC Connecting in the Global Marketplace Heavy Fraction Starchrich Flour CourtesyofParticle ControlLLC Connecting in the Global Marketplace Connecting in the Global Marketplace Light Fraction Proteinrich Flour CourtesyofParticle ControlLLC Connecting in the Global Marketplace Connecting in the Global Marketplace PROCESS OUTCOME 1 MT = 1000 kg 90 kg pea hulls 546 kg starch concentrate 364 kg protein concentrate Without any moisture loss (theoretical) Connecting in the Global Marketplace PROCESS OUTCOME 1 MT = 1000 kg 6% moisture loss 940 kg pea flour 84.6 kg pea hulls 513.24 kg starch concentrate 342.16 kg protein concentrate Connecting in the Global Marketplace Moisture Ash Protein Starch Fiber Lipid APC Mold Yeast (%) (%) (% dm) (% dm) (%) (%) (CFU/g) (CFU/g) (CFU/g) Pea hulls 8.2 2.1 2.0 <1.0 >85 0.1 1200 50 20 Split Peas 12.1 2.5 26.5 50.5 1.0 2.2 1000 200 50 Pea Flour 7.2 2.5 26.3 50.1 0.9 2.2 6200 70 30 Starch Concentrate 9.2 1.7 12.4 73.1 0.8 0.7 820 30 10 Protein Concentrate 8.7 4.6 53.5 8.0 1.0 2.2 500 200 40 DRY FRACTIONATION INGREDIENT SPECIFICATIONS Connecting in the Global Marketplace WET FRACTIONATION PROCESSES Fractionate protein, starch and fiber components in dry & wet milling process Dehuller Hammer mill Soaking tanks REQUIRED EQUIPMENT Decanter Spray / drum drier Connecting in the Global Marketplace WET FRACTIONATION PROCESSES Dehulling Key process for the removal of 97-98% of the fiber portion / same as dry fractionation Wet fractionation Protein & starch separation high purity Hammer milling Soaking and acid-base treatment Decanter filtration - spray or drum drying Dehulling wholepeas Hammermilling split (dehulled)peas Soaking split(dehulled) peaflour(pH=10) Removalofstarch &protein Precipitate solubilizedprotein (pH=4.5) Drying Starch & Protein Drying Protein Packaging #I #2 Connecting in the Global Marketplace WET FRACTIONATION 1000 kg peas Dehulling remove 90 kg hulls 910 kg dehulled or split peas Milling High speed pulverizer, or hammer mill %100 under 100 mesh Fine material Connecting in the Global Marketplace DEHULLING Impact dehulling Stone dehulling Connecting in the Global Marketplace Connecting in the Global Marketplace WET FRACTIONATION Solubilization of pea proteins, sugars and lipids by base solution (NaOH solution, pH=10.5-11.0 for 1h. extraction) Removal of starch & protein by decanter or ultrafiltration Protein can also be held at pH=4.5 for precipitation Protein and starch are dried by fluidized bed drier or spray drier. Connecting in the Global Marketplace Decanters Starch & protein removal Connecting in the Global Marketplace Decanters Starch & protein removal Connecting in the Global Marketplace Separation decanters 16 level 99.9% starch and 85%protein purity Connecting in the Global Marketplace Spray drier Protein dehydration - drying Connecting in the Global Marketplace Connecting in the Global Marketplace Drum drier Starch dehydration - drying Connecting in the Global Marketplace Connecting in the Global Marketplace Moisture Ash Protein Starch Fiber Lipid APC Mold Yeast (%) (%) (% dm) (% dm) (%) (%) (CFU/g) (CFU/g) (CFU/g) Pea hulls 8.2 2.1 2.0 <1.0 >85 0.1 1200 50 20 Split Peas 12.1 2.5 26.5 50.5 1.0 2.2 1000 200 50 Pea fiber 10.0 2.2 2.1 <1.0 >85 0.2 6200 70 30 Pea starch isolate 11.0 0.1 0.4 >98.0 0.1 0.1 820 30 10 Pea protein isolate 11.2 4.2 >85.0 <1.0 1.1 2.1 500 200 40 WET FRACTIONATION INGREDIENT SPECIFICATIONS Connecting in the Global Marketplace CHINESE VERMICELLI NOODLE MAKING Traditional & long process Mung bean or dry pea Soaking in tap water Then acid addition Connecting in the Global Marketplace CHINESE VERMICELLI NOODLE MAKING Connecting in the Global Marketplace CHINESE VERMICELLI NOODLE MAKING Connecting in the Global Marketplace CHINESE VERMICELLI NOODLE MAKING Liquid starch sent directly to starch noodle process Extrusion Connecting in the Global Marketplace CHINESE VERMICELLI NOODLE MAKING Starch is gelatinized Connecting in the Global Marketplace CHINESE VERMICELLI NOODLE MAKING Drying vermicelli noodles Connecting in the Global Marketplace PEA HULLS (PEA FIBER ISOLATE) GLUTEN FREE END USE High water binding capacity Modifies texture Veggie burges, hamburgers, sausages, nutritional bars, sauces, fillings, baked products Connecting in the Global Marketplace PEA PROTEIN RICH FLOUR (PEA PROTEIN CONCENTRATE) High level of functionality, bioavailability and lysine content. Bland taste Good alternative to soy flour/protein concentrate (Non GMO and non allergen) Connecting in the Global Marketplace PEA PROTEIN CONCENTRATE Beverages Granola bars Baby foods Pasta TVPs Meat products - sausages Veggie burgers Baked goods Connecting in the Global Marketplace PEA STARCH RICH FLOUR (PEA STARCH CONCENTRATE) Rich source of starch (>%72) Good source of protein (%12) Acid, retort and shear stable similar to many modified starches Improves texture in gluten free baked products Increases volume/expansion in extruded products Connecting in the Global Marketplace PEA STARCH CONCENTRATE Pasta Baked products Batters and coatings Extruded snacks Fillings and dressings Soups, sauces Connecting in the Global Marketplace PEA PROTEIN ISOLATE High level of functionality, bioavailability and lysine content. >%85 Protein, %3 Fat, %4 Ash Good alternative to soy protein isolate (Non GMO and non allergen) TVPs, beverages, granola bars, baby foods, pasta, baked products, dressings, meat products, veggie burgers Connecting in the Global Marketplace PEA STARCH ISOLATE Excellent gel strength and bland taste >%98 purity Gelling and film forming properties Vermicelli noodle Excellent acid, retort and shear stable similar to many modified starches Improves crispness in baked products Increases volume/expansion in extruded products Connecting in the Global Marketplace CONCLUSION Pin milling, air classification and wet fractionation processes can be used in dry pea, lentil and chickpea processing. Raw material availability, sustainability and price Dry yellow peas can be utilized based on market needs Vermicelli noodles, TVPs Connecting in the Global Marketplace THANK YOU Mehmet Caglar Tulbek, Ph.D. Technical Director Northern Crops Institute North Dakota State University 1240 Bolley Dr. Fargo, ND 58102 Phone: 701-231-5493 Fax: 701-231-7235 Email: mehmet.tulbek@ndsu.edu http://www.northern-crops.com