A novel high-performance BREAD TEXturizer and gluten substitute

Through its production of potato starch, HOFF SA generates significant amounts of by-products. In the BreadTex project, it has been investigated whether it is possible to refine side streams of by-products that now are regarded as waste into high-quality products. The side streams consist, among other things, of a large proportion of potato pulp which contains a considerable amount of cellulose fiber. In the BreadTex project, HOFF SA wanted to develop a high-quality product for the bakery industry and the home baking market based on cellulose fiber extracted from potato pulp. RISE PFI has leading expertise in the processing of lignocellulose and has participated as a research partner in the project. RISE PFI's research task consisted in developing a process for extracting cellulose fiber from potato pulp, as well as characterizing the processed cellulose product. Mesterbakeren AS, a large bread producer in Norway, also participated as a project partner. Mesterbakeren contributed with recipe development, baking experiments and analysis of dough and bread where the processed cellulose fiber from potato pulp was added. By designing a new process for the extraction of cellulose fiber from by-products in starch production, the project wanted to develop a high-quality product that can be added as an ingredient in foodstuffs. There are several examples of similar uses of vegetable fiber in foods. RISE PFI developed a process (laboratory scale) in which cellulose fiber from potato pulp was prepared (suspension). Mesterbakeren has performed several baking experiments, where processed cellulose fiber from potato pulp was added as an ingredient. Both coarse and fine bread, as well as gluten-free bread were baked. Effect of adding cellulose fibers was assessed; both during baking and finished products. On the basis of the baking experiments, the bread recipes were evaluated and optimized during the project. The fiber has also been tested in lump baking and as a consistency sensor in potato products at HOFF. The addition of the fibers in this case also gave positive results with regard to the quality of the dough and the finished products. The project has carried out a preliminary profitability analysis for an industrial production of cellulose fibers. A principle sketch has been prepared for a large-scale process line. The potential for cellulosic fibers in the market for baked goods and possible uses in other types of food has been analyzed and considered to be very promising. Product development should result in a product that is in accordance with current regulations on food safety and which is safe for consumers. The results from the BreadTex project were promising, and HOFF has decided to go ahead with several studies to determine if there may be opportunities for future commercialization. This work will be continued in a new IN-funded project.

Prosjektet har avdekket at cellulosefiber framstilt fra rasp har potensielle anvendelsesområder som tilsetning i næringsmiddelindustrien, og som tidligere nevnt er det avgjørende for HOFF SA å finne anvendelse for de store mengdene med biprodukter. Etter endt prosjektperiode ser vi at det er mulig å optimalisere fremstillingsprosessen med tanke på å øke utbytte, samt at vi ønsker å kartlegge markedet og markedspotensialet. Med dette som utgangspunkt bestemte HOFF SA å søke om midler fra Innovasjon Norge til et forprosjekt for å jobbe videre med denne tematikken. Søknaden ble innvilget og prosjektet starter formelt 1. oktober 2019. RISE PFI er med som samarbeidspartner i dette forprosjektet.

With the BreadTex-project, Hoff SA aims at developing a novel bread texturizer and gluten substitute based on cellulose nanofibrils (CNF) produced from potato processing residuals, including developing a novel process for such production of CNF. The underlying idea is to develop and produce a novel high value-added bread texturizer and gluten substitute based on low cost potato residues from Hoff?s potato processing units, aiming for the industrial bread baking market and for the home baking market. The main component of the new bread texturizer will be CNF, to be produced from the cellulose-containing residual streams from potato processing. In this project Hoff SA has joined forces with Mesterbakeren AS, a large Norwegian bread producer, who will perform early-phase testing of the new bread-improving ingredient and develop new recipes utilizing the new ingredient?s potential. Paper and Fibre Research Institute (PFI) has leading expertise in production of CNF and processing of lignocellulose, and will be the research partner in this project. The innovation involves: Developing a completely new process for production of high value-added cellulose nanofibrils utilizing an existing low value side stream (potato residues) as raw material. Focus will initially be on application as texturiser and gluten substitute in bread. Developing a completely new bread texturiser and gluten substitute with the potato-based CNF as main component Developing new breads with superior consumer satisfaction, including both gluten-free breads and non-gluten-free breads The project shall give the necessary knowledge basis to decide on further investments on implementation of the project results. A process for production of CNF from potato processing residuals shall be demonstrated in laboratory scale, both for CNF in suspension as well as dried CNF. The potential for the CNF-based bread ingredient shall be explored, through testing in various bread recipes.