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Fractionation and Reconstitution of
Fractionation and Reconstitution of
AND
RECONSTITUTION
OF
WHEAT AND WHEAT FLOUR
TOPICS
1. Definitions
2. Aims and objectives of fractionation
and reconstitution
3. Components of wheat and wheat flour
separated in the fractionation process
4. Starting materials for fractionation
processes
5. Important steps in wheat and wheat
flour fractionation processes
6. Whole wheat kernel fractionation
processes
7. Wet fractionation of whole wheat
kernel
8. Dry fractionation of whole wheat
kernel
9. Factors affecting the wet fractionation
process of whole wheat kernel
10. Wheat flour fractionation processes
11. Factors affecting the fractionation of
wheat flour
12. Methods of reconstitution of wheat and
wheat flour
13. Effects of fractionation and
reconstitution of wheat and wheat
flour on food products
1. DEFINITIONS
1.1 DEFINITION OF
FRACTIONATION
Fractionation means separating wheat
or wheat flour into
Proteins
Starch
Damaged starch
NSP (non-starch polysaccharide)
Lipids
1.2 DEFINITION OF
RECONSTITUTION
Reconstitution means adding wheat
/flour fractions or components to form
new flour.
2. AIMS AND OBJECTIVES OF
FRACTIONATION AND
RECONSTITUTION
OBJECTIVE # 01
To separate
Starch
Gluten
Other components
GLOBAL STARCH MARKET
2000
48.5 Million Tons
2005
60 Million Tons
2010
70 Million Tons
INDUSTRIAL PRODUCTS USING
NATIVE STARCH
Chemicals
Acetic acid
Lactic acid
Cosmetics
Coatings (food and drug)
Dispersing agent
Industrial alcohol
Organic solvents
Surgical dressings
Paper and paper related products
Abrasive paper and cloth
Bookbinding
Labels
Papers
Straws
Adhesives
Binders
Glues
Gums
Pastes
Textile
Cord polishing
Dyes
Oil cloth
Printing
Sizing
Window shades
Fermentation
Fuel alcohol
Beer
Building materials
Cardboard
Ceramics
Coating (wood, metal)
Wallboard
Fiberboard
Ceiling tile
Wall paper
Cork products
Domestic products
Diapers
Typewriter ribbons
Trash bags
Cord, string
Misc. Industries
Explosives
Filters
Fireworks
Drilling fluids
Plastics
Rubbers
Tires
FOOD PRODUCTS USING
NATIVE STARCH
Baking snack foods
Baking powder
Biscuits
Breads and rolls
Cakes
Cookies
Crackers
Doughnuts
Pies
Canning
Berries
Fruits
Fruits fillings
Soups
Tomato sauce
Vegetables
Confectionary
Chewing gum
Chocolates
Dusting powders
Marshmallows
Condiments
Ketchup
Gravies
Mayonnaise
Mustard
Salad dressings
Sauce mixes
Fats and oils
Margarine
Pan coatings
Frozen desserts
Frozen puddings
Ice cream or milk
Powder mixes
Sherbets
Meat products
Sausage
Mincemeat
Surimi
Fish, sea food
Mixes
Cake
Coatings and breadings
Cookies, brownie
Dessert
Gravy
Instant breakfast foods
Pancake
Seasoning
Soups
APPLICATIONS OF
GLUTEN
Gluten is used as a stabilizing agent in
products like ice-cream and ketchup.
water or
other liquid like ethanol
Pre-treatments
Degerming
Debranning
Bran fractionation
Pre-treatments
Wheat grain can be subjected to
different pretreatments before milling or
grinding, in order
To modify its mechanical properties
To improve tissue dissociation and increase
or decrease the tissue fragmentation
To modify its biochemical properties
To influence the tissue composition
To influence tissue biological activity
To have an effect on the properties of the
grain and bran
To influence the organoleptic properties of
the final product, such as flour and bread
To influence the functional properties of the
final product, such as flour and bread
Physical Pretreatments includes
Changes in the moisture content of grain
and bran
Decrease or increase in the conditioning
temperature
Exposure to ultraviolet radiation
Biochemical pretreatments includes
Adding chemical agents in the tempering
water
Adding enzymes in the tempering water
Degerming
Wheat germ is a source of highly
concentrated nutrients and is one of the
richest sources of tocopherols of plant
origin.
It is a valuable ingredient and a good
way of fortifying food products.
“Beall Degerminator” process can be
used for Degerming.
In beall degerminator process,
the grains are forced between a stationary
casing and a rotating conical rotor, and the
germ is dislodged from the endosperm by
impact and bending stress.
Debranning
Debranning of wheat is adapted from a
process widely used for rice.
This technique is based on sequential and
controlled removal of grain layers prior to
milling.
Debranning of grains can be carried out by
Friction (peeling)
Abrasion/scraping (pearling)
Combination of friction and abrasion
Bran fractionation
Wheat bran was considered to be a
milling by-product and mostly used in
animal feed.
It is a source of compounds which have
high value for human nutrition, like
fiber
micronutrients
antioxidant
Wheat bran nutritional value may be
enhances
By new fractionation processes
By separating the interesting parts of the
bran from the undesirable ones
By making bioactive compounds more
accessible
Most bran fractionation processes comprise
two steps.
In the fragmentation step, bran tissues are broken
down by grinding. Various types of stresses are
imposed on the bran, like
Impact
Shearing
Compression
Crushing
In the separation step, the bran particles
are sorted out according to certain
properties, such as
Size
Shape
Mass
Density
Dielectric properties
9. FACTORS AFFECTING THE WET
FRACTIONATION PROCESS OF
WHOLE WHEAT
Steeping
Processing aids
Enzymes
10. WHEAT FLOUR FRACTIONATION
PROCESSES
Processes for wheat flour
fractionation
Dough process
Dough – batter process
Batter process
Other batter based processes
Alkaline process
10.1. DOUGH PROCESS
It is also called as Martin process.
It is the traditional method for obtaining
gluten from wheat flour.
It has been widely used since 1835.
In this process,
A stiff dough with approximately 40 – 60%
water is allowed to rest and fully hydrate,
producing a centimeter to meter sized
gluten matrix.
The dough is then washed in a continuous
kneader with additional water to remove
starch and the WEF (water extractable
fraction) from the gluten.
The starch containing washings (starch
milk, starch suspension) are centrifuged,
the WEF removed and the lighter squeegee
starch separated from the heavier prime
starch which is subsequently dried.
10.2 DOUGH – BATTER
PROCESS
In this process,
The first step is the formation of a stiff
dough.
The gluten matrix is partially dispersed by
addition of extra water and mixing.
This results in a batter which is then sieved
or centrifuged to obtain starch and gluten.
10.3 BATTER PROCESS
This process is a variation of the Martin
process.
It was developed during World War II.
This process, also known as the batter/
Slurry or screening process has been
adapted for continuous processing.
In this process,
A slack dough or batter is formed by mixing
approximately equal amounts of flour and water.
The batter is mechanically broken up in the
presence of additional water to produce
suspended curds of gluten particles containing low
levels of residual starch.
Millimeter sized gluten particles are produced.
Typically, temperatures of 40 – 55 °C are
used.
The gluten curds are recovered the sieves
while the starch milk and WEF (water
extractable fraction) pass through.
The starch is recovered by centrifugation
or tabling and subsequently dried.
10.4 OTHER BATTER –
BASED PROCESSES
FESCA OR DIRECT CENTRIFUGATION
PROCESS
RAISIO PROCESS
FESCA OR DIRECT CENTRIFUGATION
PROCESS
In this process,
Wheat flour is rapidly mixed with water to
form a thin batter in which gluten protein
agglomeration is minimized by additional
shear and a lower slurry temperature (30
°C) compared to the batter process.
The centrifugal process produces
micrometer – sized gluten agglomerates.
The starch is removed from the suspension
by centrifugation while the protein remains
suspended.
The centrifugation yields essentially three
layers:
Prime starch
Squeegee starch
Semi-clear supernatant which contain proteins
and WEF (water extractable fraction)
RAISIO PROCESS
In this process,
Flour and water are combined into a batter
which is homogenized to give a uniform
suspension without gluten protein
agglomeration.
Continuous centrifugation of the
suspension separates the heavy prime
starch from a protein rich fraction.
Protein agglomeration and gluten
development then takes place during pin
mixing.
Gluten is separated by passing over
vibrating screens and is then washed,
dewatered, and dried.
10.5 ALKALINE PROCESS
In this process,
The wheat flour is dispersed and partly
dissolved in 0.03 M sodium hydroxide or
ammonia.
The dispersion is tabled or centrifuged to
give a non-vital gluten fraction.
A significant portion (70 – 80 %) of total
starch is recovered as prime starch.
11. FACTORS AFFECTING THE
FRACTIONATION OF WHEAT
FLOUR
Flour composition
Protein
Starch
NSP (non-starch polysaccharide)
Lipids
Mixing water
Amount
Temperature
Mineral content
Mixing time
Mixing speed
Washing
Processing aids
Ascorbic acid
Enzymes
Pearling (prior to the milling)
12. METHODS OF RECONSTITUTION
OF WHEAT AND WHEAT FLOUR
Add flour fractions or components to a
native flour.
Flour is separated into fractions or
components and then add the fractions
to form a reconstituted flour.
13. EFFECTS OF FRACTIONATION
AND RECONSTITUTION OF WHEAT
AND WHEAT FLOUR ON FOOD
PRODUCTS
BAKED PRODUCTS
POSITIVE EFFECT
Baking volume is proportional to the
increase of the total protein content of
the reconstituted flour.
BAKED PRODUCTS
NEGATIVE EFFECT
The baking volume of the reconstituted
flour decreased.
The dough and gluten prepared with
reconstituted flour had higher resistance
than the native flours.
BREAD
POSITIVE EFFECT
Loaf volume of petroleum ether defatted
flour is increased after addition of
shortening.
BREAD
NEGATIVE EFFECT
Mixing time increased as the shortening
level increased in the defatted and
reconstituted wheat flour.
Water absorption decreased as the
shortening level increased in defatted and
reconstituted wheat flours.
NOODLES
NEGATIVE EFFECT
Quality score is decreased when noodles
are made from reconstituted flour.