Grain-Based Ingredients

Comedian Robin Williams once said, The first time I ate organic whole-grain bread, I swear it tasted like roofing material.

Hes not the only one who recalls the industrys early, dense products. But grain-based products continue to innovate and aerate. The results are lighter and increasingly palatable to mainstream consumers.

In the marketplace

The USDAs food pyramid stresses the importance of grains in the diet. Specifically, it states that consumers should eat at least 3 oz. of whole grains daily, or roughly half of their grain intake. The message seems to be reaching consumers.

FDA allows foods containing at least 51% whole grains by weight of reference amounts customarily consumed (RACC) that are low in total fat, saturated fat and cholesterol to carry a health claim linking them to a reduced risk of heart disease and certain cancers. FDA uses the amount of fiber within the grain to calculate the 51% whole-grain minimum. Whole wheat contains 11 grams of dietary fiber per 100 grams; thus, the qualifying amount of dietary fiber required for a food to bear the prospective claim may be determined by the following formula: 11 grams X 51% X RACC/100, according to FDA.

A stamp provided to members by the Whole Grains Council, Boston, offers consumers an easy way of knowing the types of grains they are consuming. If a product bears the 100% stamp, all of its grain ingredients are whole grains and it contains 16 grams of whole grain per labeled serving. Products that bear the basic stamp contain half as much whole grain, or at least 8 grams, and may contain some refined grain. As of April 2008, a Whole Grain Stamp appears on more than 1,800 products.

Understanding grains

FDA is specific in defining whole grains as cereal grains that consist of the intact, ground, cracked or flaked caryopsis, whose principal anatomical componentsthe starchy endosperm, germ and branare present in the same relative proportions as they exist in the intact caryopsis. Cereal grains may include amaranth, barley, buckwheat, bulgur, corn (including popcorn), millet, quinoa, rice, rye, oats, sorghum, teff, triticale, wheat and wild rice.

Although these products are often included in grain-based foods, the FDA does not consider products derived from legumes (soybeans), oilseeds (sunflower seeds) and roots (arrowroot) as grains.

Whole grains are the entire seed, or kernel, of the plant. The bran is the outer skin of the kernel. The bran contains 50% to 80% of the minerals in grains (including iron, copper, zinc and magnesium), as well as protein, fiber, B vitamins and phytochemicals. The endosperm, or middle layer, is the germs food supply. The largest portion of the kernel, it contains most of the protein and carbohydrates. The germ is the embryo. It contains trace minerals, unsaturated fats, B vitamins, antioxidants and phytochemicals. Together, the bran and germ contain 25% of the grains protein.

Refined grains are milled to remove the bran and the germ. Although many of the nutrients are lost, they are often enriched with B vitamins such as thiamin, riboflavin, niacin and folic acid. Enriched grains do not have fiber added. No doubt, refined grains grew in popularity because, in addition to a finer texture, they also have a longer shelf life.

Perennially popular wheat

Wheat remains the favorite bread for luncheon sandwiches among American consumers. The International Dairy, Deli and Bakery Association, Madison, WI, ranked wheat No. 1 in a 2007 report.

While wheat may be a generic term to consumers, food developers know certain classes of wheat are more suitable for certain applications. The classes are based on the endosperm hardness (hard or soft), color (red or white) and season grown (spring or winter). Hard wheat has a harder physical texture and is not milled as easily. Hard wheat flour has more protein (12% to 14%) than soft flour (7% to 8% protein). It also has more gluten. Hard spring wheat flour has slightly more protein than hard winter wheat flour.

Hard red winter wheat is used in breads, tortillas and pizza crust. Hard red spring wheat is a good choice for hearth breads and bagels. Hard white wheat is most often used in white breads.

Soft red winter wheat and soft white wheat are used in cookies, cakes and pastries. Durum wheat contains the highest protein levels and is used to make pastas. The ideal protein level for pasta flour should be between 12% and 16%, at 14% moisture content. Using less than an 11% protein will result in poor-quality pasta, as will protein levels greater than 16%.

Careful selection of white wheat varieties and improved milling processes have led to the development of finer-granulation, whole-grain, white wheat flours. According to Joni Huffman, director of business development, ConAgra Mills, Omaha, NE, the companys whole-grain white wheat flour is appropriate in any application where the natural nutrition of whole grains and the taste, texture and appearance of refined white flour products are desired. Its lighter color, fine texture and milder flavor have consistently met the expectations of consumers who like the taste and texture of white flour products and who recognize they need more whole grains in their diets. The flour is available in both hard and soft wheat varieties. The hard wheat variety has 12% minimum protein; the soft variety has 9% minimum. Both can be used in a range of applications, including breads, baked goods, bars, snacks, batters, breadings and pastas.

Adding other wheat-based ingredients can help the developer achieve optimum functionality in certain products. Wheat protein isolates, such as those produced by MGP Ingredients, Atchison, KS, contain 90% protein and are available in varying levels of extensibility and elasticity. Extensibility is important for products such as tortillas, pizza crust or flatbread. These protein isolates can also add strength to suspend particulates in whole-grain products. Typical usage is 1% to 3%.

When added to lower-protein durum semolina or flour, wheat protein isolates can add textural firmness to pasta, and can replace egg whites in pasta formulations. This can be beneficial when developing frozen, retorted or other pastas subjected to stress.

A-maizing ingredients

Corn has been cultivated for more than 7,000 years, yet today its finding new life as people rediscover healthful dishes like polenta, grits and corn cakes.

A mature corn kernel has four parts, according to FDA: the hull or bran (also referred to as the pericarp and seed coat), germ, endosperm, and the tip cap. The tip cap, which attaches the kernel to the cob, is not considered an integral part of the caryopsis. The bran, germ and endosperm should be present in relative proportions as found in the kernel to be labeled a whole grain. Simply put, avoid degerminated or bolted corn meal or corn flour when looking for a whole grain.

Quali Tech, Inc., Chaska, MN, offers a 100% all-natural grain-based product line consisting of a grain fraction derived from corn. The line is a great tool for developers in any grain-based product-development project. It can contribute to a whole grain claim in corn-based or multigrain applications, explains Jeff Ploen, vice president of food sales, Quali Tech. The ingredient has 18% protein and 23% fiber and is typically used at small percentages ranging from 1% to 8% in formulations.

The company takes the germ portion of the corn kernel immediately after it is separated at the mill and heat-treats it to deactivate the active enzymes that typically cause the fat in the germ to oxidize and go rancid. Once this process is completed, the product is then toasted to two different levels, says Ploen. This results in a finished product that is simply 100% full-fat corn germ that is shelf stable. Because the majority of corns flavor components come from the germ portion of the kernel, stabilizing that flavor and enhancing it through the toasting process results in a wonderful grain-based flavor ingredient that delivers a wide range of flavor profiles in many different finished products.

According to Ploen, off flavors can occur when trying to incorporate high fiber levels into a finished product. Quali Techs full-fat corn germ has a natural masking property that is helpful when working with preservative systems or high-fiber ingredients. This is due to the naturally occurring fat content of the product. When consuming a finished product, the fat portion is the lingering component that is last to leave the palate, masking any preservative flavors or green notes left by high-fiber formulations. The product is offered in two different toast levels. The light toast level provides a concentrated corn flavor profile, while the dark toast level provides a nutty profile. This profile can contribute nutty flavors and nut-meal textures at a reduced cost without the allergen concerns.

Triple threat

Barley, oats and rice form a trifecta of health-claim carrying ingredients. The key, of course, is including them in low-fat, low-saturated fat and low-cholesterol foods.

In its whole-grain state, barley is difficult to digest, due to its tough hull. Pearling can remove the inedible hull, but the process removes some of the bran. Dehulled barley is considered a whole grain, because only the hull is removed and the bran is left intact.

ConAgra Mills offers barley flour derived from selective plant breeding. With its 30% fiber level, this is the highest-fiber whole grain offered commercially, says Huffman. Since Americans fall far short on their fiber intake, the inclusion of this natural non-GMO ingredient can help remedy that shortfall at even low levels of inclusion. Adding 4 grams to a product increases fiber content by a gram, she notes. It is also high in beta-glucan (15% soluble fiber), and use can enable an FDA-approved heart-health claim. With about half the starch of conventional grain, it is appropriate for low-glycemic products.

Cargill, Inc., Minneapolis, offers a concentrated beta-glucan soluble fiber derived from whole-grain barley. It can be used at levels up to 3% in baked goods, cereals, snacks, beverages and soups. To qualify for an FDA heart-health claim, foods must contain a minimum of 0.75 grams beta-glucan soluble fiber per serving.

Oats also contain beta-glucan and were the original bearer of the heart-health claim. They contain 14% protein and 10% fiber, of which 4% is soluble and 6% is insoluble. Oats are cut, flattened to produce rolled oats, or steamed and flattened to produce quick oats. These processes render whole grain ingredients. Cooking times depend on the cut. Steel cut, or Scottish-type meal, requires 20 minutes to an hour to make. Old-fashioned oats (made from the whole piece) take 5 minutes to prepare. Quick oats have a 1 minute cook time, and instant requires simply the addition of hot water.

Rice is typically classified by the size of the grain. Long grain, such as basmati, Texmati, jasmine and Louisiana pecan, is milled so that it is at least three times as long as it is wide. Medium-grain, such as Arborio, Bhutanese Red and Japonica, is slightly less than three times as long as it is wide, and is sometimes called short-grain rice. Technically, short-grain rice is less than twice as long as it is wide. Sushi, Balinese black and Balinese purple are short-grain rices.

Wild rice is a misnomer. Its not rice at all, but is instead a long-grain marsh-grass seed. Still, its flavor and texture make it compatible with rice dishes.

Rice might be processed in various ways. White rice might be polished to remove the bran and germ. Rice that is soaked, pressure steamed or boiled, and then dried before it is milled, is parboiled. This infuses some of the brans nutrients in the kernel and gelatinizes the starch, which results in a fluffy cooked texture. Converted rice is parboiled, but is further cooked, shortening prep time. Instant or quick rice is precooked, dehydrated rice.

White rices germ and bran is removed. Brown rice is a whole grain, as is some of the more-exotic rice, such as forbidden black rice or Bhutanese red rice. There are a number of varieties, including basmati and sushi rice.

FDA recently approved a whole-grain health claim for brown rice: Diets rich in whole-grain foods and other plant foods and low in total fat, saturated fat and cholesterol may reduce the risk of heart disease and some cancers.

Rice is the most easily digested of all the grains and is especially beneficial in formulating foods for those who cannot tolerate gluten.

An ancient revival

In recent years, ancient grains have continued to garner more consumer appeal.

Amaranth, a grain traced to the Aztecs in Mexico, is most noted for its peppery taste and 16% protein content. It can be combined with wheat to make leavened products such as breads and muffins. Crackers and cereals are other potential applications.

Hailing from the Incas in the Andes, quinoa is a quick-cooking grain that yields light, fluffy kernels. It can be used in soups, salads and baked goods.

Spelt is a variety of wheat that can be substituted for wheat in most recipes. It contains gluten, so is not appropriate for gluten-intolerant formulations.

Millet is common in India, where it is used as a cereal and in making flatbreads. Its flavor is very mild and its grains are tiny.

Ethiopians use teff to make flatbread. Its grains are miniscule compared to wheat, and the flavor is compared to slightly sweet molasses. It can be used in baked goods.

Although it is most commonly used to make syrups in the South, sorghum is a grain that can be used in baked goods, or brewed into beer.

With its exceptionally high fiber content, rye can add a healthy component to baked goods and other applications. Dark rye flour has 22.6 grams of fiber per 100 grams, as compared to 12.2 grams of fiber in 100 grams of whole-wheat flour.

Triticale is a hybrid of durum wheat and rye. It can be used in hot and cold cereals, and muffins.

The market for grains has grown since Robin Williams first tasted whole-grain bread, and no doubt the industry will continue to innovate and create new combinations and uses.

Cindy Hazen, a 20-year veteran of the food industry, is a freelance writer based in Memphis, TN. She can be reached at [email protected].

Market Snapshot

Great Grains

The Oct. 2007 report, Consumer Attitudes Toward Functional Foods/Foods for Health, from International Food Information Council, Washington, D.C., revealed that awareness of whole grains grew 25% from 2005 to 2007. Whole grains were listed in the top six functional foods. In addition, 72% of consumers associated whole grains with cardiovascular benefits, and 86% associated both fiber and whole grains with intestinal health.

Chicago-based Mintels Global New Products Database reports that, in 2007, nearly 15 times as many whole-grain products were introduced worldwide compared to 2000. In 2007, bakery constituted 798 new launches. Breakfast cereals followed with 708 launches. Snacks came in third with 408 launches.

In the Jan. 2006 Healthy Eating: Impact on the Consumer Packaged Goods Industry survey, conducted by Harris Interactive, Rochester, NY, 32% of those surveyed cited nutrition as the first reason for eating whole-grain products. Increased fiber was noted by 31% as their primary reason. Perhaps most revealing of the industrys success with whole grains is the 13% who cited better taste as their primary reason.

Market Snapshot

Just the flax

Although FDA does not consider flax or other oilseeds grains, these ingredients are infinitely well matched in whole-grain foods. Flaxseed is rich in omega-3s.

However, simply adding whole flaxseeds does not offer a nutritional benefit. Nam Fong Han, Ph.D., president, Natunola Health, Winchester, Ontario, explains that the whole flaxseed is not digestible by the human body. The company offers a shelled flaxseed and a hulled flaxseed.

Ground flaxseed releases oils from the kernel, resulting in an unstable product. Natunola has a unique processing technique: We take the shell off the whole flaxseed, providing the kernel, the meat, which is loaded with omega-3 and the shell, which is high in fiber and lignan, says Han. In the whole flaxseed, everything is intact. When they are ground up, everything is intact. When you are doing the shelling, you pull off the shell and then you have the kernel minus the shell. Thus, proportionally, the omega-3 content is increased substantially in the flax kernel. The omega-3 content in the shelled flax is much higher as compared to whole seed and ground. If you do a formulation using 3% to 6% of the whole flaxseed, you could use anywhere from 1% to 4% of the shelled flaxseed.

One version has 70% of the shell removed. Han notes that five grams of this shelled flax is equal to 1.5 grams of omega-3. An adult person needs 1.5 grams of omega-3 per day to stay healthy, he suggests.

According to Han, most customers use between 3% and 6% by weight of the whole flaxseed, the ground flaxseed or the shelled flaxseed in bread or cookie formulations. Because flax has a nutty flavor, it enhances the flavor of breads. If you are using the ground flax meal, or the flax hull, you may want to consider adding more water to your formulation, he says. The hull or the fiber from the powdered flax absorbs a lot more water and, thus, becomes more viscous in the formulation.