Slide 1: Up-cycling Low Value Proteins Through Functional Food Technologies
Up-cycling Low Value Proteins Through the Use of Functional Food Technologies Promotes Sustainability While Enhancing Profitability C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 2: Starkey Laboratory: Processing Product Upcycling and Pet Food
Starkey Laboratory Processing Product Upcycling and Pet Food C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 3: Starkey Laboratory
Starkey Laboratory • 107 Undergraduate research assistants • 43 International visiting scholars • 22 Graduate students • Training in Food Science • Abstract generation ~80 • Publishable projects ~20 • 1 undergraduate Thesis • 4 Masters Thesis C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I
Slide 4: Introduction: Animal Co-Products
Introduction Animal Co-Products • Low-value Protein conversion co- products Often sold for rendering Co-products are often sold at 6-13¢ per kg. • Pet treats saveur.com Valuable product ($22 to ≥ 55 per kg) Pet food manufacturers already use animal co-products to manufacture pet treats rich
Slide 5: Introduction: Animal Co-Products
Introduction Animal Co-Products • Animal co-products (ACP) may be considered a delicacy, or an undesired material destined for purposes other than human consumption • They do not participate largely in American dish and are rarely found on menus Marti et al, 2012 • ACP are rich in protein, vitamin
Slide 6: Introduction: Animal Co-Products
Introduction Animal Co-Products • Processing is the conversion of live animals into smaller retail cuts for human consumption USDA, 2013 • Processing generates lower value co-products C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 7: Introduction: Animal Co-Products
Introduction Animal Co-Products • Combined value of production from broilers, eggs, turkeys, and the value of sales from chickens in 2020 was $35.5 billion, 61% from broilers USDA, 2020 • Total number of broilers Raw wing tips (WT) produced in 2020 was 9.22 billion USDA, 2020 C O L L E G E O F A
Slide 8: Introduction: Animal Co-Products
Introduction Animal Co-Products • Chicken co-products are the most common protein source used in dry dog treats Watson, 2006 • United States has a robust poultry industry, with an inventory of over 518 million chickens Shahbandeh, 2021 • For the last decade, the United States has exported 6 to 7
Slide 9: Introduction
Introduction Animal Co-Products • Parts of processed animal not included in dressed carcasses Galanakis, 2018 • Animal co-products (ACP) are often repurposed for other usages than human consumption Ockerman & Basu, 2014 • Co-products can represent up to 44% and 37% of cattle and poultry live wei
Slide 10: Introduction: Animal Co-Products
Introduction Animal Co-Products • Broiler wing tips (WT) are a low-value broiler processing co-product • WT are in abundant supply and can be repurposed into more marketable products Raw broiler WT saveur.com C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 11: Introduction: Animal Co-Products
Introduction Animal Co-Products • Broiler carcass frames and Wooden Breast (WB) meat are low-value broiler co-products • Both are in abundant supply and can be repurposed into more marketable products Broiler carcass frames Wooden Breast C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N
Slide 12: Introduction: Animal Co-Products
Introduction Animal Co-Products • Largest gland in animals and most consumed animal co- product • Contains a protein level close to lean meat • High levels of carbohydrates • Rich in Fe, Mg, Cu, vitamins A, B6, B12, C, niacin, and folacin C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N
Slide 13: Introduction: Animal Co-Products
Introduction Animal Co-Products • Represents 0.5% of cattle live weight Ockerman and Basu, 2014 • Rich in protein, niacin, riboflavin, Fe, Zn, Se, and P Marti et al, 2012 • Consumed as a deli and used in traditional gastronomy in some countries C O L L E G E O F A G R I C U LT U R E P O U LT R Y
Slide 14: Introduction: Animal Co-Products
Introduction Animal Co-Products • Processing co-products have additional opportunities to supply a valuable protein source to the pet food industry • Establishing quality parameters for certain processing products is useful for future product development Pet treats in packaging system C O L L E G E
Slide 15: Overview of the Pet Food Industry
Introduction Overview of the Pet Food Industry • Pet humanization and premiumization of pet foods have led to significant changes in animal co-product markets Mullen et al, 2017 • Pet owners seek new protein-based and healthy food products for their pets Mullen et al., 2017 • Pet food manufactur
Slide 16: Overview of the Pet Food Industry
Introduction Overview of the Pet Food Industry • Nearly 82% of pet owners buy some type of treats with some regularity Simmons National Consumer Survey, 2014 • Pet owners frequently provide treats to cats and dogs as a demonstration of affection and reward or a way to motivate them during training
Slide 17: Overview of the Pet Food Industry
Introduction Overview of the Pet Food Industry • Pet treats success in the market is influenced by several factors such as price, packaging, marketing claims, and sensory properties Koppel, 2014 • Treats’ sensory attributes such as appearance, color, texture, and flavor can contribute to their acc
Slide 18: Overview of the Pet Food Industry
Introduction Overview of the Pet Food Industry • Pet industry expenditures Of the $103.6 billion spent on pets, $42 billion were for pet food and pet treats in 2020 Out of 90.5 million households with a pet there are 69 million with at least one dog Dog food and treats market was valued at $66
Slide 19: Overview of the Pet Food Industry
Introduction Overview of the Pet Food Industry C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 20: Global Pet Product Growth Projections by Category 2012-2017
Global Pet Product Growth Projections by Category 2012-2017
Slide 21: Overview of the Pet Food Industry
Introduction Overview of the Pet Food Industry • Co-products are the most common protein source used in dry dog treats Watson, 2006 Dog treats Chicken liver and heart (Mullins, 2021) pet treats C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 22: Restructured Pet Treats from ACP
Restructured Pet Treats from ACP • Animal co-products (ACP) can be processed into restructured pet treats by using hydrocolloids as functional ingredients Challen and Moorhouse, 2011 • Hydrocolloids are high molecular weight polymers used to improve the rheological and textural properties of food
Slide 23: Economics
Economics Input Costs/lb Costs/week Paws $0.76 $76,000 ALGIN $2.77 $16,346.65 Packaging $0.64 $65,184 Labor $0.75 $75,000 Total $4.92 $232,530.65 C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 24: Hydrocolloids in Product Development: Sodium Alginate
Hydrocolloids in Product Development Sodium Alginate • Alginate is a type of hydrocolloid used in product development as a structure- forming ingredient Qin et al., 2018 • Alginate can provide mechanical strength and flexibility to restructured meat products, such as pet treats C O L L E G E O F A
Slide 25: Hydrocolloids in Product Development: Sodium Alginate
Hydrocolloids in Product Development Sodium Alginate • Alginate is produced from marine brown algae Goh et al, 2012 • Alginate is extracted from algal tissue and brought into solution by neutralization with an alkali, such as sodium carbonate • Soluble sodium alginate is precipitated and converted
Slide 26: Hydrocolloids in Product Development
Hydrocolloids in Product Development • Hydrocolloids are high- molecular-weight, hydrophilic molecules • Used as functional ingredients in food Ching et al., 2017 formulation • Increases food consistency, improves gelling effect, and controls the microstructure, texture, flavor, and shelf life of fo
Slide 27: Hydrocolloids in Product Development: Sodium Alginate
Hydrocolloids in Product Development Sodium Alginate • Sodium alginate is a hydrocolloid with gelling and stabilizing properties that could improve textural characteristics of meat products Edley, 2007 • Divalent metal ions, such as calcium, line up alginate chains to form a stable gel Egg-box str
Slide 28: Hydrocolloids in Product Development: Alginate Gelation
Hydrocolloids in Product Development Alginate Gelation • Calcium salts can be totally soluble, sparingly soluble, and insoluble • Calcium lactate is a totally soluble calcium salt with a rapid gelation rate and poorly controlled Challen and Moorhouse, 2011 • Because of the fast gelation rate, mixt
Slide 29: Hydrocolloids in Product Development: Alginate Gelation
Hydrocolloids in Product Development Alginate Gelation • Calcium lactate may be encapsulated to control release of calcium ions into a soluble alginate solution for gel formation and development of restructured products Challen and Moorhouse, 2011 Sodium alginate Ca 2+ C O L L E G E O F A G R I C
Slide 30: Introduction: Restructured pet treats
Introduction Restructured pet treats • ALGIN= sodium alginate + encapsulated calcium lactate • ALGIN can enhance the quality and add stability to mixtures of minced protein components through a gelation process • Co-products may be processed into pet treats by using ALGIN as Sodium alginate a struct
Slide 31: The process
The process Chicken liver and heart Chicken carcass frames Chicken paws Raw product Mixtures Final product C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 32: The process
The process C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 33: The products
The products C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 34: The products
The products C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 35: The products
The products C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 36: The products
The products C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 37: Materials and methods: Cooking
Materials and methods Cooking • WT were cooked in a GoWise electric pressure cooker (n = 4) with 7% added water At 55 kPa for 90 min Average cooking moisture loss was 18.57% Raw WT Draining pressure Pressure cooked, cooked WT drained WT C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E
Slide 38: Materials and methods: Grinding
Materials and methods Grinding • Cooked WT were ground twice First grind: kidney grinder plate Second grind: 4.8-mm grinder plate Kidney grinder WT after first grind plate 4.8-mm grinder plate WT after second grind C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 39: Materials and methods: ALGIN inclusion
Materials and methods ALGIN inclusion Sodium alginate and encapsulated ALGIN addition calcium lactate ALGIN 0x 0.5x 1x 2x Sodium alginate, % 0.000 0.500 1.000 2.000 Encapsulated calcium lactate, % 0.000 0.425 0.850 1.700 C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 40: Materials and methods: Sample preparation
Materials and methods Sample preparation • Each mixture was stuffed into 63.5-mm-diameter casings, and secured with hog rings • Chubs were stored at 4 °C for 12 h to facilitate gelation, and then frozen at -20 °C for 3 h prior to slicing into 5-mm-thick slices • For data collection, samples were sto
Slide 41: Materials and methods: Sample Preparation
Materials and methods Sample Preparation • Oven was set at 93 °C until samples’ internal temperature reached 74 °C • Smokehouse temperature was dropped to 66°C until treats’ water activity (aw) reached 0.80 • Expressible moisture and cooking loss were measured on raw samples • Color variation and te
Slide 42: Quality Parameters of Pet Treats: Physico-chemical Characteristics
Quality Parameters of Pet Treats Physico-chemical Characteristics • Water Activity (aw) Important attribute that assesses food stability with respect to microbial growth, chemical, and biological reactions Park, 2008 • pH Quality parameter that affects color, water holding capacity, tenderness
Slide 43: Quality Parameters of Pet Treats: Physico-chemical Characteristics
Quality Parameters of Pet Treats Physico-chemical Characteristics • Expressible moisture Amount of liquid squeezed from products’ protein system by the application of external forces Pearce et al., 2011 • Cooking loss Loss of sample weight in percentage during cooking, caused by heat-induced p
Slide 44: Quality Parameters of Pet Treats: Textural Characteristics
Quality Parameters of Pet Treats Textural Characteristics • Rheological and structural properties of foods perceived by senses of sound, sight, and touch Chen and Opara, 2013 • Textural properties of pet foods may affect their palatability and provide pleasant sensations that stimulate pets to eat
Slide 45: Textural characteristics Measurements: Texture Profile Analysis
Quality Parameters of Pet Treats Textural characteristics Measurements • Texture Profile Analysis (TPA) • Double compression type test that mimics first two bites of the mastication process of foods in the mouth • Assesses Hardness, Adhesiveness, Cohesiveness, Springiness, and Chewiness of pet treat
Slide 46: Textural Characteristics Measurements
Quality Parameters of Pet Treats Textural Characteristics Measurements Adapted from Centre for Industrial Rheology C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 47: Textural Characteristics Measurements: Shear Force Test
Quality Parameters of Pet Treats Textural Characteristics Measurements • Shear Force Test • Measures degree of tenderness of meat products • Evaluates Firmness and Firmness Toughness of pet treats Stable Micro Systems C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 48: Textural Characteristics Measurements: Three-point Bending Test
Quality Parameters of Pet Treats Textural Characteristics Measurements • Three-point Bending Test • Measures break strength or flexibility by bending samples Peak force • Assesses Peak force and Flexibility of pet treats Stable Micro Systems C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I
Slide 49: Materials and methods: Texture analysis 3PB
Materials and methods Texture analysis: 3-point bend (3PB) • Hardness, flexibility, and stiffness were analyzed applying the 3PB bend test to 10 samples per treatment (TA-HDplusC with a TA-43R probe) Hardness, g Flexibility, mm Stiffness, g per mm • Blade speed was 1 mm per s for 10 mm C O L L
Slide 50: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Consumers rely heavily on fresh meat color as an indicator of wholesomeness at the point of sale Suman and Joseph, 2014 • Pet owners rely on pet treats characteristics such as color to make judgments on their quality and purchase decisions Guy,
Slide 51: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Color is brain perception of an object after its interaction with light • Perceived color is affected by three components: Lawless and Heymann, 2010 C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 52: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Color of meat products is mainly influenced by myoglobin and is also affected to smaller extents by other pigments such as hemoglobin and cytochrome c Bechtold et al., 2018 • When meat products are exposed to heat during cooking, myoglobin loses i
Slide 53: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Pet parents rely on pet treats’ physical characteristics such as color to make judgments on their quality and purchase decisions Guy, 2015 • Human color perception of foods is subjective and is affected by our visual characteristics and preference
Slide 54: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Instrumental color measurement simulates the ability of human eyes to perceive colors and can provide quantitative values Mancini and Hunt, 2005 • One of the most common methods to analyze instrumental color analysis is using a CIE L* a* b* www.hu
Slide 55: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Data on color was collected on d 0, 3, 5 and 7 post- production L* - Lightness o 0 to 100, black to white a* - Redness o -120 to 120, green to red b* - Yellowness o -120 to 120, blue to yellow Adapted from Cavanaugh, 2008 C O L L E G E O F A G
Slide 56: Results: Lightness (L*) of raw pet treats
Results Lightness (L*) of raw pet treats ALGIN INCLUSION × TIME 70 P < 0.0001 SEM ≤ 0.1370 68 66 64 a abc ab ab ab bc Lightness, L* d d c d d 62 e e f f 60 g 58 56 54 52 50 0 0.5 1 2 0 0.5 1 2 0 0.5 1 2 0 0.5 1 2 ALGIN inclusion, x 0 3 5 7 Time post-production, d C O L L E G E O F A G R I C U LT U R
Slide 57: Results: Redness (a*) of raw pet treats
Results Redness (a*) of raw pet treats ALGIN INCLUSION × TIME 30 P < 0.0001 SEM ≤ 0.1016 25 a c b d 20 Redness, a* 15 e g f h i k j 10 l n n n m 5 0 0 0.5 1 2 0 0.5 1 2 0 0.5 1 2 0 0.5 1 2 ALGIN inclusion, x 0 3 5 7 Time post-production, d C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E
Slide 58: Results: Yellowness (b*) of raw pet treats
Results Yellowness (b*) of raw pet treats ALGIN INCLUSION × TIME 26 P < 0.0001 SEM ≤ 0.0753 a 24 b c 22 d Yellowness, b* 20 e e gh gh f hi fg i j 18 k l l 16 14 12 10 0 0.5 1 2 0 0.5 1 2 0 0.5 1 2 0 0.5 1 2 ALGIN inclusion, x 0 3 5 7 Time post-production, d C O L L E G E O F A G R I C U LT U R E P O
Slide 59: Quality Parameters of Pet Treats: Color Variation
Quality Parameters of Pet Treats Color Variation • Regardless of ALGIN inclusion over time post-production, lightness decreased, redness and yellowness increased. • Delta-e (The measure of change in visual perception of two given colors) values indicate that the color differences among treatments du
Slide 60: Conclusions
Conclusions • Animal co-products combinations and ALGIN inclusions can be utilized to improve pet treats’ quality characteristics, enabling new product development opportunities for the pet food industry • Inclusion of ALGIN improved water retention of treats and allowed less water during cooking lo
Slide 61: Economics
Economics Input Costs/lb Costs/week Paws $0.76 $76,000 ALGIN $2.77 $16,346.65 Packaging $0.64 $65,184 Labor $0.75 $75,000 Total $4.92 $232,530.65 Sale price $18.20 $1,820,000 Difference $13.28 $1,587,469.35 C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 62: Summary
Summary • Demands for pet treats has increased in the last few decades • This trend has affected animal co-product markets which can be used to develop treats rich in protein, vitamins, and minerals • Hydrocolloids show potentials for adding values to animal co- products by improving sensory propert
Slide 63: Completed work
Completed work • Chicken liver / chicken hearts • Beef liver / beef hearts • Wooden breast carcass frames 1 • Wooden breast carcass frames 2 • Paws • Wing tips • Slice thickness • Food chemistry Texture Color Sensory C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 64: Future studies
Future studies • Conduct consumer sensory and pet palatability evaluations • Evaluate the ability of different processing co-product combinations to form various pet treat types sciencemeetsfood.org • Evaluate meat products combined with non-meat products to develop functional pet treats • Reconstit
Slide 65: Future work
Future work • Sensory • Oxidative chemistry • Complete and balanced • In home palatability • Field applications, soldier and dog co-nutrient delivery • Human nutrient supplementation C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E
Slide 66: Thank You
Thank You Charles Starkey cstarkey@auburn.edu +1-334-758-1750 C O L L E G E O F A G R I C U LT U R E P O U LT R Y S C I E N C E