CEREAL BAR WITH PURPLE MUSCADINE                                                                                            

   

 

  1. Objective: To develop breakfast cereal bar using an industrial byproduct Muscadine pomace (muscadine skins and seeds) which a nutraceutical value.

 

  1. WHY Cereal Bar: more than 40 % of baked good launched world wide in 2001 had a health positioning. Within bakery categories cereal bars have the highest positioning with functional and light products accounting for 75 % new launches. The bar market is growing explosively in US, which accounts for 70 % of global sales (Markets & trends). In this category trend has gone beyond simply listing vitamin and mineral fortification. Consumer is looking for the claims concerning lowering of cholesterol, reducing heart disease, and sometimes even fighting free radicals and removing toxins.e.g Kellogg’s (Battle Creek, Mich.)not only has fortified its complete Oat Bran flakes with 11 vitamin and minerals , but claims that fortification helps support the immune and digestive systems.Abott laboratories introduced bar with functional fortification including Ginseng , Ginkgo biloba, rose hips and antioxidants. In today’s fast paced world breakfast cereals and cereal bar offers great vehicle to deliver health benefits of functional foods. Category is just addressing the Breakfast opportunity of consumers.

 

  1. Based on above market feel of Cereal bar and Muscadine skin and seed extract as functional ingredient , efforts are made to design  a product with  functional benefit along with  by product utilization.

 

 

Ref-Market and trends

4.     WHY : Muscadine skins and seeds

 

a.      Muscadine grapes are a major commodity in the Southeastern U.S  marketed as Juice , jellies ,preserves,etc.In processes sing , about 900-100 lb of waste is generated  from each ton .Muscadines have tough and thick skins and yield less juice than other grapes. Thus during processing operations like juice, wine approximately half of the fruit is lost as press fraction. (Woodroof et al., 1956).

b.      Recently reported that most phenolics in grapes are located in the skins and seeds. The seeds were found to have highest antioxidant  capacity compared to the other fruit parts due to presence of phenolic compounds (Pastrana-Bonilla et al,2003)Muscadines are also found significant sources of several phytochemicals that have been associated with disease prevention in human.High concentration of gallic acid , catechin , epicaechin,ellagic acid and reseratrol found in the skins and seeds give muscadines a high antioxidant capacity (Ector et at.,1996;Striegler et al.,2004) .This encourages use of muscadine skin and seed extract in various food products with nutracuetical function.Today beverages and wines are already developed using this, however usage of same is yet to come  in the area of baked goods ready to eat cereals , meal replacers , snack bars, etc. These development of additional value added products  will have an important economic impact on the muscadine industry both by increasing the market value per tone of fruit and decreasing or eliminating waste disposal problems.(Ector, 2001)

c.       Phytochemistry of MuscadineL(C.C.Akoh and E. Pastrana-Bonilla,2002)

 

                                                              i.      As a member of Vitis family it shares high content phenolic compounds.

                                                            ii.      Phenolics compounds

                                                          iii.      In seeds mg/100g of fresh weight.

1.      Gallic acid,                                          6.56

2.      (+)catechin                                          789

3.      epicatechin                                          1234

                                                           iv.      Muscadine skins major phenolics mg/100g are:

1.      ellagic acid                                          16.5

2.      myricetin                                              8.34

3.      quercetin                                             1.74

4.      kaempferol                                          0.64

5.      trans-resveratrol                                  0.14

 

                                                             v.      Average total phenolics:          Total anthocynin                      Antioxidant capacity

mg/g gallic acid equivalent                     mg/100g                       mM TEAC

 

SEED,                    21.78                                                   4.4                               285

SKIN                      3.75                             1.34(BRONZ) &118(PURPLE)                  11.4

PULP                     0.24                                                     1.0                               1.0

                                                          vi.      Seeds were high in phenolic content and antioxidant capacity

 

 

d.      Without question numerous studies have shown that the muscadine and its fractions are extremely high in antioxidant activity as assessed by ORAC (Oxygen radical acceptance capacity) values Yilmaz and Toledo, 2004).Due to its high fiber content it is associated with lowering of blood pressure, serum triglycerides and total and LDL Cholestrol.It also protect against Coronary heart diseases, gastrointestinal diseases and colon Cancer. (Ector)

e.       Muscadine seed and skin offers second top  ingredient opportunity with antioxidant properties in functional foods.

5.     In view of above functional benefits of Muscadine , it is taken as an ingredient for the Cereal Bar.

 

  1. Entire product development is taken through following stages.Product
    1. Formulation
    2. Process development
    3. Suitable packaging
    4. Sensory evaluation
    5. Self-life studies
    6. Process validation
    7. Consumer research with prototype product
    8. Clinical trials to confirm the claims.
    9. Nutritional labeling

 

  1. Formulation: meal replacement bar with health claims of high phenols from muscadine skin powder.40% of calories derived from carbohydrate and 30 % each from protein and fat.

 

    1. Isolated soy protein                             10.5 %
    2. Calcium caseinate                               8.5 %
    3. Whey protein concentrate                   7.0 %
    4. Cocoa powder                                     6.0 %
    5. Rolled  oats                                         10.5
    6. Salt                                                      0.8 %
    7. High Fructose Corn Syrup                  23.0 %
    8. High maltose corn syrup                     10.0 %
    9. Honey                                                  5.0 %
    10. Vitamin and mineral premix               1.5 %
    11. Unsweetened chocolate                      1.0 %
    12. Muscadine skin powder                      4.0 %
    13. Muscadine seed powder                       4.0 %
    14. soy lecithin                                            0.5 %
    15. Cargill's Barley Betafiber                       2.7 %
    16. Flavor                                     0.5 %
    17. Water                                                  5.0

 

                                                               i.      Cargill's Barley Beta fiber offers the food product developer a new option for fiber fortification, viscosity building, texture development, moisture management, fat reduction, and a number of other technical challenges in a variety of food systems including breads, breakfast cereals, extruded snacks, juice drinks, soups, and more.

                                                             ii.      Nutragone natural products: http://www.nutragonstore.com Muscadine Plus Powder is sealed in three (3) gram foil packets with thirty (30) packets per box. Muscadine Plus Powder is an all natural fruit powder containing a high concentration of resveratrol and a blend of phytochemicals which enable it to have a high oxygen radical absorbing capacity (ORAC).

1.      Muscadine skin powder and Muscadine seed powder: m/s Muscadine products corp. This is used @ of 5.0 % in the formulation as at present no data available regarding the appropriate use of phenolic compounds .Data required for absorption pattern of phenolic compounds. However research was carried using 100 μg / ml.

2.      Total phenolic compounds in seeds /skin        approx.2 g/ 100 of fresh fruit(15°B)

3.      In dried form with moisture 5 %                     approx.12.6 g/100 g

4.      In purple powder (with 60 % additives           approx.5.0 g/100 g

                Like emulsifiers/bulking agents)

5.      With production and handling losses(40%)    approx.3.0 g/100 g

6.      In bar addition @ 8 %                                    approx.0.024 g/100 g of bar

Or per Bar of 50 g                                                 1.2 mg

 

  1. PROCESS:
    1. There are two methods of cereal cooking; both cooking systems can be used to process all types of Cereal, including corn, bran rice wheat barley and Oat

 

    1. Traditional rotator pressure Cookers

                                                               i.      Granola bar method: In this cereal is mixed with nuts and fruits. The mixture is then formed into a bar using a syrup or other binding matrix. A variety of grains and extruded grains can be used, including oats, barley, rice, rye, corn and wheat. Nuts and fruit pieces can then be added grains used: specialty grains, such as buckwheat, millet, quinoa, spelt or triticale may be used. Generally whole kernel with outer coating removed, milled such as grit, meal or flour may used. In general the larger more intact the grain the more visual attributes it contributes to finished product more finely ground grain higher will be its water binding capacity. Grain may also be heat treated to deactivate it enzymes or oils.

 

                                                             ii.      Once the cereal is prepared it is put into coating drum where heated syrup is sprayed into the grain. .ideally the drum should be designed to minimize tumbling to reduce breakage of the pieces. The bars are dried to low moisture levels and individually wrapped. This will make the bar crisp and crunchy .The liquids and dry blends are mixed together in proper amounts and the wetted mass is then spread in a uniform layer on the band of a continuous dryer or oven. Baking takes place at temperatures in a range of 300-425 o F (149-218 o C) until mat is uniformly toasted into light brown and moisture reduced to 3 %.After toasting the mat is broken up into chunky pieces.

 

    1. Twin Screw Extruders.

                                                               i.      It can also be made with baked dough exterior surrounding a fruit paste filling. In this after the dough is mixed it is put through co extrusion process were it and the fruit pastes are combined

                                                             ii.      One of the key formulation challenges is to make sure that water activity go dough and filling are comparable. Moisture transfer from fruit paste is desirable after baking to ensure soft and tasty product and should not be so excessive that product becomes wet an unappetizing.

 

d.     Process DESCRIPTION

                                                               i.      Liquor and dry cereal ingredients (usually whole grain or grits are separately weighed and fed into rotator cereal cookers on an automated batch basis.)

                                                             ii.      The cereal is gelatinized by passing live steam under pressure through cooker.

                                                            iii.      The cooked grains are discharged into a belt coyer or screw conveyor.

                                                           iv.      A lump breaker is used to use to break up cereals which tend to agglomerate in the cooker.

                                                            v.      The cooked cereals are then dried and conditioned before forming in a flaking roll or shredding roll system, with final moisture removal and toasting achieved in the thermo glide toaster.

                                                          vi.      The thermo glide fluidized bed toaster/dryer provides very uniform heating of the product with minimum breakage and scrap.)

                                                          vii.      Mixing of above cereals and other wet and dry ingredients are mixed in a horizontal batch mixer or continuous mixer.

                                                      viii.      Forming: is done with the help of extruder, the extruder consists of two grooves rolls which feed the materials through a filler block and die plate. The die plate holds the individual dies sized to the product shape. Rows of product are continuously extruded onto a conveyor where they are cut to the desired bar length by a guillotine.

                                                          ix.      Feeder /spreader are used to form continuous sheet of product onto the in feed conveyor of an oven. The product passes through a compression roll assembly to control height and density.

                                                            x.      Final forming: Bar products are baked as sheet, a slitter cuts the product into continuous rows which spread apart using a spreading conveyor.

                                                          xi.      Process flow sheet

                                                        xii.     

 

  1. Machines used :courtesy APV

APV Baker - Breakfast Cereal Technology for the Production of Corn, Bran, Rice, Wheat, Barley and Oat Based Cereals

                                              Bar extrusion                  Dough Receiving hopper

http://www.apvbaker.com/cereal/index.php                                  

      


 

CEREAL BAR WITH PURPLE MUSCADINE

 

 

PRODUCT SPECIFICATIONS:

 

    1. PRODUCT DECRIPTION: Rich delicious  High Protein/Fiber Bar  with chocolate coating 50 g , Full of nutrients and grape flavor inside.
    2. Color:  light brown chocolate coating from outside, inside light purple colored bar with irregular surface due to Oat flakes.
    3. Packaging       Flexible laminate pouch with aluminum base to protect the product from moisture.
    4. Storage condition:      Keep the product under cool and dry place.

 

    1. Shelf-life                     Ambient           6 months

Refrigerated      12 months

 

 

 

 

10.                        Sensory evaluation:

 

a.      Affective methods: e.g. Preference tests. This mainly determines the response of large group of consumer regarding preference, liking sensory attributes, etc.Bench mark product in the market are Kellogs nutri Bar Or Abott nutri Bar

 

 

 

 

  1.   Stability studies : are required to evaluate following issues related to product shelf-life

 

    1. Behavior of phenolic compounds under baking conditions
    2. Interaction with other ingredients like, oat, High fructose corn syrup, emulsfiers, stabilizers and flavors.
    3. Interaction with packaging material
    4. Maximum shelf-life under ambient conditions.

 

  1. Based on this prototype sample process validation is required.

 

  1. Clinical trials as all data available in literature are based on animal studies and yet no maxima and minima are defined for phenols. Therefore clinical data has to be generated to get the for the claim. This will also help in getting the claim on the label.

 

  1. PACKAGING: Packing is done pillow pouch machine in flexible laminate with aluminum foil as one of the laminate. Care is taken that moisture and oxygen transmission rate is minimum through the film of packaging.

 

Final launch is done based on following product development module.

 

 

 

 

 

 

 

 

 

 

  1. COMMERCIAL ISSUES:

 

 

 

Approx 1 million gallon Juice will generate              $ 7 million gross sale

(ars.usda.gov/nov97)

Approx 3.8 million liter Juice will generate              $ 7 million gross sale

Approx 3.8 million kg Juice will generate                             $ 7 million gross sale

(Assuming density of juice approx. 1.0 g/cc)

Original fruit used: Approx                                                   6.3 million kg

(Assuming above Juice is generated 40 % waste)

Approx. waste                                                                        2.5 million kg

Assuming conversion of this into Purple powder                  1.25 Million kg

(Yield approx: 50 %)

Or 12,500 tons

Assuming 1/3 rd Industrial price of Nutragon                      approx.$13/.09 kg

Or                                                                                            approx. $ 14/ kg

 

 


Or approx. $ 17.5 million of waste can be utilized / 1 million gallon Juice

Exploding $2 billion market for food bars, including breakfast bars, snack bars, granola bars, sports bars, meal replacement bars, and diet bars. (www.packagedfacts.com/pub)This will provide major economic support to the muscadine industry with further clinical studies and data generation.

 

 

 

 

 

 

 

 

 

 

 

  1. REFERENCES

 

                                                              i.      Akoh,C.C and Pastrana-Bonilla,E.(2002) Polyphenols and antioxidant capacity of muscadine Grape Cultivars grown in South Georgia.Paper Presented in Annual Meeting of Institute of Food Technologist, Anaheim,California

                                                            ii.      Ector,B.J.,Magee,J.B.,Hegwood,C.P.,and Coign,M.J.1996.Reveratrol concentration in Muscadine berries. ,pomace,purees,seeds ,and wines ,juice.Amer.J.Enol.and Vitic,47(1):57

                                                          iii.      Ector,B.J.2001.Compositiona; amd nutritiona; characteristics .Chapt 16 in Muscadine Grapes,Basioouny,F.M. and Himelrick,D.G., eds.ASHS Crop Production Series ,ASHS Press , Alexandria,VA

                                                          iv.      Pastrana-Bonilla,E.,Akoh,C.C.,Sellappan,S.,and Krewer,G.2003.Phenolic  contnet and antioxidant capacity of muscadine grapes.J.Agric.Food Chem.51:5497-5503

                                                            v.      Prepared foods functions food blends Survey of 1998 food-2004

                                                          vi.      Woodroof,J.G.,Cecil,S.R., and Dupree,W.E.1956,Processing muscadine  grapes.GerogiaExp.Sta.Bull.AR 17

                                                        vii.      Yilmaz,Y,and Toledo,R.T.J.Agric.Food Chem., 52:255-260,2004

                                                      viii.      http://www.apvbaker.com/cereal/index.php        

                                                          ix.      http://www.ars.usda.gov/AR/archive      

                                                            x.      http://www.ars.usda.gov/is/AR/archive/nov97     

                                                          xi.      http://www.bakingbusiness.com/bs/channel.asp?ArticleID=37270  

                                                        xii.      http://www.kellogs co.u.k         

                                                      xiii.      http://www.nutragonstore.com/

                                                      xiv.      http://www.packagedfacts.com/pub/886177.html

                                                        xv.      http://www.roquette.fr/fr.qnewa/pub-market trends and products