Processing concepts towards a sustainable food industry

Stefan Töpfl Deutsches Institut für Lebensmitteltechnik e.V.

Louis de Funes (acting: Charles Duchemin) in L’aile ou la cuisse

Future Food Production (1976)

Homo sapiens

DIL support in LCSA

Consumer benefits

Basis

Results Impact Categories

• Climate Change

• Human Health

• Resource Depletion

• Ecosystem Quality

• Land Use

• Water Use

• Acidification

• Eutrophication

• Minerals Use

• Fossil Fuel Use

• Carcinogens …

ISO DN 14040-14044

Sustainable Degree of Product, Pt

Life Cycle Estimation

Inventory and Analysis

Estimate sustainability degree of technologies and products in environmental perspective Main Objective

55 9 26 6

1 t of Meat/Fish

Technologies and Products

Comparative Possibilities

Raw Materials

Equipment and Components Production

Waste and Pollution Flows

More Sustainable Equipment Selection

Product Sustainability Determination

Environmental Labeling

Technologies Improvement

Food Innovation

More efficient, less harmful

and less resource consuming

products

Quantified Data

1

annual

1 kPt

=

Life Cycle Assessment

DIL App V 2.0

LCA Tool – Input

DIL App V 2.0

LCA Tool – Output

LCA examples: Food

Meier, T., O. Christen (2012)

Energy and Environment

Agriculture of the 20th century

Do consumers want innovation?

Lebensmittelwirtschaft, 2016

The changing chain

ZukunftsInstitut, 2016

Bulk

trading

Food industry

Retail Food service and

cantines Restaurants

Gross

trader

Artisanal food

production

Tech-

driven

delivery

services

Agriculture

Consumer

New players Traditional players

Curated Food

Superfluence and Abundancy of Choices

Zukunftsinstitut Kochhaus, WholeFoods, Try Foods, 2016

Beyond Food

Technology likers and vegetarians

drive work on emulating food

products –replacement products are

getting mainstream

Rügenwalder, SpaceFood, De Vegetarische Slager. Just Mayo, Follow Your Heart, 2016

Convenience 3.0

Lebensmittelwirtschaft, Home Mate, 2016

Minimal processing

Options

• Heating

• Advanced Thermal Processing

• Smoking, Curing, Salt

• Preservatives

• HPP

• Pulsed Electric Fields

• Microfiltration Lebensmittelwirtschaft, 2016

Hiperbaric, Innova Market Insights, 2016

Minimal processing

Fermentation is

seen as a

trustworthy, healthy

alternative

Innova Market Insights, 2016

Minimal processing

Nonthermal Preservation Sustainability impact

FU 1 l of processed juice, scope - from farm to gate; zero values of aquatic acidification and

eutrophication excluded; 1 kPt = impact of 1 European per year

~50%

Nonthermal Preservation Life cycle analysis

Aganovic, K., Smetana, S., Grauwet, T., Toepfl, S., Mathys, A., Van Loey, A., Heinz, V. Pilot scale thermal and alternative pasteurization of tomato and watermelon juice: an energy comparison and life cycle assessment. Journal of cleaner production (submitted)

Pulsed Electric Fields Alternative technologies for structure modification

Approx 50 machines worldwide for tissue softening at 50 t/h

Example: French Fries Industry

Structuring Structure destruction

Standard pretreatment 60°C, 30 min

0 20 40 60 80

60°C 30min

MEF

PEF

Energy kJ/kg

Energy comparison Commercial scale potato processing

Short-time continuous

process

Volumetric treatment

Enanced cutting quality,

less breakage and

increased length of strips

LCA study Commercial scale potato processing

Organic, Regional, Local and Neo-ecology

Lebensmittelwirtschaft 2016

Driven to the max

ZukunftsÍnstitut, The Third Plate, Icon 2016

Organic, Regional, Local and Neo-ecology

Distribution

BBSR 2014

Food Production sites

Smart Food Production gets back to Town: Small-Scale Production Concepts Example: Micro-Breweries in New York

Decentralization

Factory in a container

Life cycle assessment

Processing concepts for decentralisation

Protein deficit

The European protein deficit (UNIP)

Contribution of cereals and soybean

Land use in m2 for the production different protein sources

Minimum 0.1 m2/kg

Maximum 1-2 m2/kg

Algae/Insects

(Nijdam et al. 2012) (Weyer et al., 2010) (Muys & Roffeis, 2014)

Proteins

Per Capita Consumption in Germany (in kg)

Source: AMI, BMEL

Dairy, butter, chees

Meat

Bread

Vegetables, salad

Potatos

Citrus fruits

Oils, fats

Fish

Eggs

Fruits

355.4

47.0

139.2

61.5

43.4

271.1

1.9

3.2

6.2

403.0

88.2

82.0

96.3

101.9

58,7

35.2

19.7

13.4

(1900) (2013)

214 pieces 90 pieces

Flexitarians

Innova Market Insights, 2016

High Moisture Extrusion / Texturization

Products with a meat like structure

Extrusion After Treatment

High Moisture Extrusion / Texturization

Process

Feeding

Raw material Mixing of protein powders and water

Processing T 170 °C Heating up to get a protein melt

HEATING JACKET Water

PRESSURE ZONE

Motor Screws

Cooling Formation of fibers and layers during cooling Temperature T 70 °C

COOLING DIE

High Moisture Extrusion / Texturization

Flexible Production Line at DIL

High Moisture Extrusion / Texturization

Determination of structure by recipe and process parameters

Meat vs. meat analogous

Meat Extruded soy protein

Generating a characteristic fibrous matrix down to scale of

microstructure Vegetable protein source: soy, pea, lupine, (wheat)

Products on the market

Based on soy protein

Based on pea and

lupine protein

Based on

pea protein

Based on insect protein

Insects, Algae and Co

Hermetia Soj

a

Soy Spirulina

Bug Foundation, 2016

Meat

Meat Substitutes, 1 kg of ready to eat product

(Smetana, Mathys, Knoch, Heinz, 2014)

Extrusion High moisture extrusion

Today´s Food Production (2016)

Food Production (2016)

Innovations and Sustainability Conclusions

• Replacing existing processing technologies can result in savings of energy, water, costs…

• LCA allows to characterize the potential or identify action points

• Significant changes require change of mode of operation