Value chain vegetables summing up results in Cycle Trondheim

Transcription

1 Value chain vegetables summing up results in Cycle Trondheim Kaisu Honkapää and Riikka Juvonen, VTT Ekrem Misimi, SINTEF Jens Petter Wold, Nofima Steffen Adler and Randi Seljåsen, Nibio Henrik Egelyng, UC

2 Vegetable value chain in Cycle WP1: Automated quality differentiation and sorting of co-streams and waste Objective 1a) Develop VIS/NIR/(and/or)X-ray based sensor systems for optimal quality differentiation of raw materials, co-streams and waste; Objective 1b) Develop automated concepts for an efficient and precise sorting of raw materials, co-streams and waste. WP2: Resource-efficient bioprocessing technologies for food industry Objective 2.1: To develop knowledge, technology and processes for better utilization of co-streams in the vegetable industry with focus of food use WP3: Bio-processing of waste for feed, fertilizer and energy Objective 3. Convert waste not appropriate for utilization as human food to feed, feed ingredients or fertilizer, possibly in combination with energy production. WP4: Food safety and logistics Objective 4. To study the challenges of managing and controlling the complex logistics processes in the food chain from manufacturing until end of life. WP5: Socio-economy - market and consumer Objective 4: Study economic and institutional factors influencing production of costreams and waste in value chains for chicken, fish, and vegetable, investigate the role of consumers, in sustainable consumption and integrate natural and social sciences in demonstrating macroeconomic values and policy options with a view to sustainable solutions. 07/06/2016 2

3 Vegetable industry plants visited in Cycle Potato processing: Potato sorting and packaging, Produsentpakkeriet Trøndelag AS and Hvebergsmoen Potetpakkeri AS Sous-vide potato products: Potetpartner AS Potato chips production: Findus Tønsberg, Carrot processing: Carrot sorting and packaging: Produsentpakkeriet Trøndelag AS Processing of lettuce, vegetables, fruit and potatoes: Bama Lier Ref: Adler et al /06/2016 3

4 Smaller and larger plants Unit: 1,000 tonnes/year Ref: Adler et al /06/2016 4

5 WP1: Automated quality differentiation and sorting of co-streams and waste Case studies: On-line determination of dry matter in whole potatoes (Nofima) Sorting between ripe and unripe fruits/vegetables by CT and X-ray imaging (SINTEF) Weight estimation of cucumbers (ongoing) (SINTEF) Waste management hierarchy The waste management hierarchy of the EU (EC, 2008) 07/06/2016 5

6 On-line determination of dry matter in whole potatoes On-line determination of dry matter in potatoes has been developed based on NIR spectroscopy The method enables automatic sorting of potatoes into batches of low, medium and high dry matter content Can ensure optimal processing of e.g. fried potatoes: Stable quality and less loss. 07/06/2016 6

7 Automated classification by CT and X-ray imaging Goal: Sorting between ripe and unripe fruits/vegetables Results: High classification accuracy Less loss! 7 7

8 Ripeness of mango and avocados by CT imaging unripe Center CT scans ripe 8 8

9 Currently working: Weight estimation of cucumbers 9 9

10 WP2: Resource-efficient bioprocessing technologies for food industry Case studies: 1. Enzyme-aided peeling of potatoes and vegetables to lower the amount of peel co-stream -> due to lack of suitable suberinase enzyme the method can t be developed at the moment 2. Films from potato peels: potato peel containing waxy suberin has interesting film properties -> published in J. Appl. Polymer Sci. 3. Smoothie recipes based on vegetable co-streams developed by Bioforsk/Nibio 4. Fermentations with multifunctional starter cultures Microbial enrichment of vitamin B 12 in carrot matrix Fermentations with probiotic bacteria (ongoing) 5. Extruded snack product with vegetable co-stream and added protein (ongoing) 07/06/

11 Ref. P+Ce+Cu P+Ce Cu P=Pectinex Ultra SP-L (pectinase) Ce=Econase CE (Cellulase) Cu=Optimyze 525 (Cutinase) Enzymatic peeling of vegetables In an earlier study pectinases and cellulases were shown to improve peeling of carrots and onions, but with no effect on peeling of potatoes New cutinases have become commercially available possibly capable of degrading the outernmost layer of peel containing suberin The effect of pectinases, cellulases and cutinase was studied on peeling of potatoes and carrots Conclusions: The commercial cutinase did not improve enzymatic peeling of potato or carrot Commercial pectinase and cellulase enabled peeling of a carrot when the surface was slightly scratched prior to enzyme treatment Further work won t be conducted on the topic development of commercial enzymes required Enzymatic peeling would have great potential in increasing yield of peeled potatoes, but new enzymes are needed before the process can be developed. 07/06/

12 Films from potato peels Potato peeling co-streams may be used without fractionation to prepare films with similar barrier properties to pure starch films High-pressure homogenization (HPH) + heat treatment was the optimal treatment to produce homogeneous films from wet-milled potato peel mass Film-forming ability retained also after enzymatic starch removal à resulted in films with better mechanical properties compared to the other films Possible product applications: Edible film -> hygienic quality of peels hindering Effective mineral oil barrier coating in recycled cardboard packaging, e.g. in disposable plates ( potato chips packed in potato peel ) Mulch film protecting plants from weeds etc. Higher Lower Value 07/06/

13 Smoothies from vegetable co-streams Aim: to utilize vegetable co-streams as innovative food products Case application: smoothie Materials tested: carrot, lettuce, Swedish turnip, red beets and spinach Results: mixtures developed varied in sensory properties and how they were liked by the consumers. Some of the mixture were very promising. Continuation: real vegetable co-streams fermented with probiotic bacteria to enhance nutritional value of the smoothies. Fermentations ongoing at VTT. Ongoing publications: One combined scientific publication of purees is planned by NIBIO and VTT (lead by VTT) One publication (popular scientific) on smoothies. Effect on the resource utilisation in the Norwegian food chain: The results from the studies has stimulated industry to investigate raw material utilization and product development of fermented products. 07/06/

14 Fortification of carrot co-streams with vitamin B12 by fermentation with propionibacteria Potential B12 vitamin propionibacteria isolated from cereal samples for use in CYCLE The feasibility to use propionibacteria for biofortification of B12 vitamin into carrot raw material was tentatively shown In non-optimized conditions up to 34 µg/kg B12 RDI for adults µg / day The produced chemical form of B12 may not be physiologically active characterization CFU/g ug B12 vitamin / kg Growth in carrot medium 1,0E+10 1,0E+08 1,0E+06 1,0E+04 1,0E+02 1,0E+00 B12 in carrot medium 50,0 40,0 30,0 20,0 10,0 0 h 72 h 144 h 0 h 72 h 144 h 0,0 07/06/

15 Potential of various types of functional bacteria for valorisation of vegetable co-streams Carrot compared as a growth medium for antifungal, texturizing and probiotic lactic acid bacteria Promising results with a probiotic strain Enrichment of probiotic bacteria in co-streams On-going MSc Study article in 2016 Most co-streams suitable for enrichment of L. rhamnosus, B. animalis more demanding High cell numbers reached after 1-day fermentation Good growth and sensory properties with both strains in cabbage and turnip Optimization of fermentation conditions with selected co-streams is on-going Maximum cell numbers in h Sugar addition did not improve growth Dry weight content of the medium did not affect growth Food application studies with liquid and dried materials 07/06/

16 Development of snacks with vegetable and protein addition (ongoing) Development of carrot or potato co-stream based snack products Extruded snacks with (carrot co-stream and) protein addition (VTT) Cereal base material e.g. oat, rye or rice flour Protein from plant or animal / fish sources (Cycle hydrolysates?) Refined research topic: the comparison of the level of hydrolysis of the added protein on the expansion of an extruded product. The theory: smaller protein particles which are more hydrolysed would interfere less on the formation of the starch network in the buffed product and thus allow more expansion The basis of the model snack needs to be as simple as possible -> no carrots Pre-test with rye base and different glutens -> promising results -> actual fish and/or poultry proteins from Sintef? -> New application for co-streams, better quality with smaller molecular size of added proteins 07/06/

17 WP3: Bio-processing of waste for feed, fertilizer and energy Case studies: Ensiling of cut potatoes in roundbales (Nibio, SINTEF) (Potato soil management [WP5]) 07/06/

18 Ensiling of cut potatoes in roundbales Material processed: rest raw material at vegetable packing facilities. Objective: To test ensiling of cut potatoes together with beet pulp and some grass silage in roundbales. Main results and conclusions: The ensiling of two roundbales was successful. At 20% dry matter run off was observed but not at 30%. Content of organic acids, ph and smell were acceptable for both roundbales. Publications and new projects: Norwegian language Potetball i stort volum. A qualification support project started in January 2016: From loss to feed with added value (SoCaPro) Ensiling discarded potatoes and carrots. Effect on the resource utilisation in the Norwegian food chain: In CYCLE only a preliminary test was done. The new project on potato/carrot ensiling and possible follow-up projects may initiate upcycling of discarded potatoes/carrots from starch/alcohol production and cheap unprocessed feed to a feed additive with the potential to improve gut health of pigs, chicken or calves by adding specific strains of lactic acid bacteria. 07/06/

19 WP4: Food safety and logistics Case studies? 07/06/

20 WP5: Socio-economy - market and consumer Case study: Harvesting Soil with Potatoes from Current Losses to Co-streams and Product Innovation Manuscript - Harvesting Soil with Potatoes from Current Losses to Co-streams and Product Innovation in preparation for Agronomy for Sustainable Development This paper investigates an emerging imperative for innovative use of soil co-extracted with potato crops. Based on case studies of potato processing plant practices in Denmark and Norway and of European regulations, the paper contrast the two country cases of potato sector soil loss due to crop harvesting, with a view to gain and provide insights on innovative options for sustainable potato soil management. The paper analyses and discusses volumes and costs involved aggregated to national levels, and institutional, economic and technological factors, determining options for sustainable use of the potato soil resource. The analysis includes exploring how European Union regulation affects utilization of potato soil. Economic factors are identified at the level of processing plants in terms of costs of soil loss and environmental or phytosanitary measures. The result of the analysis of current practices forms basis for a discussion of the demand for innovating new methods for residual soil treatments. Options for collection and utilization of residuals for different purposes are discussed. Finally, the paper discusses some concrete technology options that could allow for the soil to be recycled back to productive use, while maintaining requirements needed to prevent spread of potato diseases. Potato soil deposited for 40 years in Norway 07/06/

21 Challenges in developing new uses for vegetable co-streams (some thoughts) Currently used mainly as feed -> good use from the sustainability view point (no material is wasted, stays in the food chain), but of no or low economic value to vegetable industry Low protein content in most of the co-streams -> less ambition / need to take it into direct food use 2 nd class vegetables and many other co-streams are food grade raw materials, but: more sophisticated identification, quality differentiation and sorting procedures needed to direct the co-streams efficiently to food uses logistic challenge to use them as raw material in other food factories (as raw materials for ready-to-eat products, alcohol, potato flour, etc.) microbiological safety needs to be ensured Interest to extract/enrich valuable components like flavonoids, carotenoids, sugars, starch, protein, fiber, from vegetables? Lot of research already done and technologies developed Investments in production facilities needed To make investments feasible, large amounts of co-streams is needed Norwegian vegetable industry is located in relatively small units around the country, which makes the profitability of co-stream valorization uncertain 07/06/

22 07/06/ Vegetable and potato processes CYCLE cases Better sorting, less loss! Peels (potato) to packaging material Farming and raw material production Washing Sorting Peeling Processing Packaging Primary product Soil (potato) 2nd class Peels (potato) To higher value feed Deposit Feed Co-streams like cauliflower outer leaves *)Enzyme-aided peeling would incrace yield too To added value food products, like fermented smoothies Energy Fertilizer

23 Value pyramid for biomass applications Added value food products, like fermented smoothies Better sorting, less loss! Peels (potato) to packaging material Fermented feed additive Potato soil to fertilizer Ref. Chances for biomass - Integrated valorisation of biomass resources. Wageningen UR, /06/