Fabricated foods

FABRICATED FOODS
Presented By
Gayathri Devi M K,
M.Tech Dairy Technology,
CFDT, TANUVAS, Chennai-52.
gdkrishnan97@gmail.com

INTRODUCTION
• Conceived for convenience and nurtured by necessity,
fabricated foods now stand at the threshold of their greatest
growth.
• Formulated foods/fabricated foods are foods designed
and built according to plan from individual components, to
yield products having specified physical, chemical, and
functional properties (Glicksman, 1971).
• Fabricated foods originated in the early 1940s during
World War II. The earliest known fabricated food is bread.

D
E
F
I
N
I
T
I
O
N
Foods that have been taken
apart and put together in a new
form.
Two Types: those designed to
simulate natural counterparts
currently referred to as
“analogs” and those prepared to
give variety and spice to
the diet.
The cost of certain fabricated
foods may be lower while
providing about the same
nutrition and satiety, E.g.
margarine. The nutrition of the
food may be enhanced.

INGREDIENTS
PROTEINS:
 Fabricated foods generally comprise a mixture of components made
up of lipids, proteins, simple and complex Carbohydrates.
 Major building blocks of fabricated food is protein. Blends of
proteins will be the key to good nutrition. For example, Soy protein
lacks methionine but has more lysine than is needed for proper
nutrition.

Soy Protein
• 35-40%
Protein, 15-
20% fat, 30%
carbohydrate
, 10-30%
moisture.
• Moisture and
flavor
retention.
• FDA
recommende
d 25 g/day,
lower
cholesterol.
Cottonseed
• Toxic
pigment
gossypol.
• Water
holding
capacity.
Used in
bakery
doughs for
anti-staling.
• 5%
replacement
levels in
dough
products
Peanut
• Peanut
protein
isolate
used in
liquid
milk.
• Defatted
peanut
flour as a
suppleme
nt at 6-
10% to
flour
(atta).

 Mycoprotein:
Mycoprotein is a form of single-cell protein, made
from Fusarium venenatum. High in fiber, amino
acids, low in sodium, sugar.

CARBOHYDATES:
Sucrose, dextrose and corn syrup, are used mainly as bodying and
sweetening agents.
Carbohydrates polymers, more commonly known as gums and
starches (hydrocolloids), are used. All gums will dissolve or disperse
in water to give a thickening or bodying effect.
FATS:
Soybean oil has been major component for margarine.
Other sources such as cotton seed, pea nut, sesame, safflower,
sunflower, palm, coconut, etc.
Hydrogenation, fractionation, interestrification, etc. to suit to
specific requirement.

T Y P E S
Meat and Dairy Analogue
Soft Moist Foods
Special Purpose Dietary Foods
Infant and Geriatric Foods
Convenience and Snack Foods

•History- In the 1980s, meat analogues
and fabricated meat chunks were first
successfully developed by R.A. Boyer.
•Global market is expected
to swell to $5.8 billion by
2022.
•Meat substitute, Mock meat,
Faux meat, or Imitation meat.
•Meat analog is the food
product, which structurally
similar to meat but differs in
composition.
MEAT ANALOGS

Water: Ingredient distribution
Emulsification, juiciness.
50-80%
01
Textured vegetable proteins:
Protein fortification/nutrition
Source of insoluble fiber.
10-25%
02
Binding agents: wheat gluten,
egg whites, gum. 1- 5%.
03
Flavors/spices: 3-10 %
Coloring agents: 0-0.5%
04

TECHNOLOGY
Spin Process/ Fiber Spinning:
Assemble a heterogeneous structure comprising a certain
amount of protein fibers within a matrix of binding material.
Material should contain 90% protein isolate and molecular
weight should be 10-50 k dal.
Boyer process:
Solubilizing the
protein
Unfolding the
protein
chains
Reforming
muscle
protein fibers
Spinning
fibers

Protein
concentration(10-
40%) solubilised
by alkali(pH-10)
Unfolding of
individual
polypeptide chain
Pressed through
a die-plate
containing holes
with diameter of
5-150 µm
Enters a
coagulation bath
at pH 2-3, and
contains 10%
NaCl.
Rollers- Fibers
get stretched and
increase
chewiness.
Bundles are
placed in a bath
at pH 5.5-6
Optional:
Addition of
additives, binders
and lipids.
Finally bundles are
heated, cut, assembled
and compressed.
Boyer Process:

Extrusion:
Transform plant-based materials into fibrous
products. During extrusion, proteins undergo
thermal and mechanical stresses by heating of the
barrel and shearing of the screws.

Principles:
 Raw materials are allowed into the extruder barrel.
 The screw kneads the material into a semi solid ,plasticized
mass.
 The food is then passed to the section of the barrel having the
smallest flights.
 Finally it is forced through one or more restricted openings (dies)
at the discharge end of the barrel.
Gelatinization of
starch
Modifications of
lipids
Inactivation of
enzymes

Basic Elements:
 Addition of starch/ amylase improve texture, up to 3% NaCl added.
 Moisture content is adjusted to 30-40%. The material should be pre
conditioned with steam at 80°C.
 Mixture fed to the extruder at 10,000-20,000 k pa.
 Over a period of 10-30 s, the dough is elevated to 115-200°C.
 Extruded through a small orifice.
Single screw extruders:
Feed- The function of the feed section is to assure sufficient material
moved down the screw.
Compression- The food is heated and worked into a continuous dough
mass.
Metering- Dough is further cooked and starch granules may be broken
down due to higher shear forces.

Shear Cell Technology:
 High-temperature conical shear cell.
 It has a volume of ~7 L and a 30 mm distance between the
two cylinders.
 Optimum process conditions 15 min, 30 RPM and 95°C.
1.Outer cylinder, 2.Inner cylinder, 3.Shaft, 4.Rheodrive unit, 5. Housing heating
jacket, 6.Inner cylinder heating jacket, 7.Shearing zone

TOFU
TEMPEH
SEITAN
TVP
•Produced in China.
•Coagulated Soy Milk.
•Absorb flavours well.
•Indonesia.
•Fermented soybean.
•Rhizopus oligosporus.
•Made from wheat gluten.
•Sticky dough.
•Soy Bean.
•Less cost.
•Formed into various shapes.
MEAT ALTERNATIVES

Commercial Products:
Beyond Meat- Pea,
Mung Bean, Brown
Rice, Cocoa Butter
,Coconut Oil, Ca, Fe,
Salt, KCl. Beet Juice
Extract, Apple Extract.
Burger from Nestlé and
sold in refrigerated. The
Awesome Burger is
made out of pea protein,
coconut oil, wheat gluten
and canola oil.
Quorn brand use
mycoprotein, low in
saturated fat and
calories, high in fiber
and protein, and with
zero cholesterol.

IMF FOODS
B A K E R Y
Intermediate moisture foods (IMF) are
shelf-stable products that have water
activities of 0.6-0.84, with a moisture
content ranging from
10-50%.
Preserving fruits and vegetables without
refrigeration

TECHNIQUES:
Drying: Remove water from those foods.
Microwave drying displays lower degree of lipid
oxidation and higher protein carbonyl content.
Vacuum microwave drying (VMD) can preserve
more color and reduce toughness of strawberries
after drying. The combination of microwave and
infrared drying has also been applied to improve the
quality parameters of cakes.
Water-activity-lowering agents: Adding
water-activity lowering agents such as salt,
organic acids can maintain relatively high water
contents with low aw, thus reducing much loss
of food flavor.

Partial Drying: Partial drying is employed for raw food that naturally
have a high amount of humectants such as raisins, apricots. Humectants are
solutes (such as sugar or salt) that immobilize water in food. The drying
process removes free water, and the humectants in the product bind the rest
of the water, not allowing it to be utilized for chemical reactions or for
microbial use.
Dry Infusion: Combination of partial dehydration and osmotic
dehydration using a humectant. The food product is first dehydrated and
then the resultant product is added to a humectant solution to reach the
desired water activity.
TECHNIQUES:

TECHNIQUES: Current salt reduction methods
follow 3 main approaches reduce, replace and
enhance. Use of high hydrostatic
pressure, replacement by potassium, natural
flavor enhancers and encapsulation of salt
crystals. KCl has a noticeable metallic flavour
and risk to people with kidney problems.
LOW SODIUM FOODS:
Sodium is an essential nutrient, the primary intracellular electrolyte.
Low sodium foods were developed for patients with hypertension.
• Sodium-free - < 5mg of sodium
• Very low-sodium - 35mg or less
• Low-sodium -140mg or less
SPECIAL PURPOSE DIETARY FOODS

Salt Replacers
KCLean- Blend of
KCl and NaCl.
50% reduction in
products.
AlsoSalt
KCl & L lysine.
Lactosalt-5
times less
sodium than
NaCl.
Mrs. Dash is a completely salt
free, all-natural seasoning
blend. Use a citrus component
that helps bring out the flavor
of dishes.

Flavour Enhancers
The umami taste receptors are stimulated by glutamicacid,
iosinate and guanylate.
MSG:
Glutamic acid and Sodium.
Sodium content 12g/100g.
Yeast Extract:
Replacements for MSG.
Rich in glutamic acid, peptides,
nucleotides, glutathione.
Seagreens:
Hebridean Seaweed, Cornish Sea Salt.
This 50/50 mix of Ascophyllum nodosum
wrack seaweed and unrefined salt.

GLUTEN-FREE FOODS
 Gluten is a protein found in most grains, found in
wheat, barley.
Gives bread it’s elasticity and helps dough rise.
Required for people with Coeliac disease,Autism.
Decrease absorption of Ca, Fe, folate and B-
Vitamins.
Processing:
Chestnut flours have been successfully used in
gluten-free bread .
Dietary fiber, Hydrocolloids, Emulsifiers such as
diacetyl tartaric esters of monoglycerides.
Fermentation to produce gluten-free products.

DINNER SPECIAL
Rice flour, Corn starch
Buckwheat, sunflower
oil, flax seed, honey,
guar gum.
Cheese blend, tomato puree,
soybean oil,
dehydrated onion, garlic, soy
lecithin.
Sprouted brown rice,
organic coconut sugar,
Vitamin E.

SUGAR FREE FOODS:
Sugars are simple carbohydrates used as a food
ingredient for its sweet taste. Lower sugar intake can be linked
to: better brain function, increased energy, deeper sleep and
less bloating.
 Currently approved sweeteners are acesulfame-K,
aspartame, neotame, saccharin, and sucralose.
 Sugar alcohols (also called “polyols”) are bulk sweeteners
consists of ingredients that can substitute for both the physical
bulk and sweetness of sugar.

S
U
G
A
R
A
L
T
E
R
N
A
T
I
V
E
S
Glycemic index less than 50.
Refining cane sugar with
Fenugreek, Cinnamon,
Gooseberry, Black Pepper,
Ginger and Pomegranate.
Artificial sweeteners, contains
aspartame.
200 times sweeter.
3.6 calories per gram.
It contains sucralose.
600 times as sweeter.
3.3 calories per gram.

LOW FAT FOODS:
A high-fat diet with inadequate physical activity results in
overweight or Obesity.
Fat
Replacers
Fat
Substitutes
Emulsifiers Structured
lipids
Fat
Mimetics
Microparticulated
protein
Microparticulated
carbohydrate

Fat Replacers
Fat
Replacers
Olestra:
-Mixture of hepta,
octaesters.
-Vit A,D,E,K have been
added.
Caprenin:
-Glycerol, caprylic,
capric.
-Cannot be used for
frying foods.
Simplesse:
-Egg and Milk protein.
Use as a thickener.
Dairy Lo:
Modified WPC. 4
kcal/g.

Commercial Products
Quaker- Popped rice crisps, apple cinnamon
Contains whole grain brown rice, sugar,
corn, maltodextrin, cinnamon, soy lecithin,
acesulfame K, sucralose.
YQ Plain Yogurt
YQ is made with ultra-filtered milk,
retaining high levels of protein. 99% lactose free,
17 gm of protein and 1 gm of sugar.
Optifast
Replace all daily meals, the calorie intake
would be reduced to 800 kcal per day.

INFANT AND BABY FOODS
• Infancy is the period from birth of child till first year of life.
Infant formulae are composed of skimmed milk, demineralized
whey, a carbohydrate source, fat blend and vitamins, minerals.
Protein- 6%
Fat- 52%
Carbohydrate-
42%
Breast
milk Protein- 9%
Fat- 48%
Carbohydrate-
42%
Formula

ICMR (0-6 Months):
Iron-1mg/kg
vitamin A- 350
mcg
Protein-
2.05gm/
kg
Energy-
180 k
Cals

Ingredients:
Carbohydrates accounts for 35 to 42% of their daily energy
intake.
Emulsifiers are added to prevent the separation of the oil and
water.
Skim milk is commonly used as a diluents to create the liquid
bulkiness in infant formula. In contrast, purified water is used in
milk-free formulations.
Formulas not made with cow's milk must include biotin, choline,
and inositol.
Prebiotics are non-digestible carbohydrates that promote
the growth of probiotic bacteria in the gut.
Lysozyme is an enzyme that is responsible for protecting the
body by damaging bacterial cell walls. Lactoferrin is a globular,
multifunctional protein that has antimicrobial activity.

Cereal Based
Formula
Cereal is considered
very nutritious and good
for babies' health and
growth. It is easily
digested by infants.
Nestlé CERELAC Infant
Cereals are the only
infant cereals in
Australia to contain
probiotics.
Milk Based
Formula
Purified cow's milk whey and
casein as a protein source,
lactose as a carbohydrate source.
Comfort Proteins- 100 % gentle
whey proteins break into smaller
pieces to be easy to digest.
Nestle DHA & ARA, iron,
and Nestle's "Comfort
Proteins". The WHO
specification for DHA level
is 0.33-0.35% (Nestle-
0.32%) and the ARA level is
0.65-0.70% (Nestle-0.64%).

Processing:
Mixing
(Vacuum
mixer)
Prevents
oxidation
Evaporation
Increase TS%.
Remove occluded
air from the fluid.
Preheating to
75 to 85° C
Optional
Cavitation
High Pressure
Pumping and
Homogenization
Spray
Drying

SPX Flow’s Anhydro Triple -Spray dryer:
Incorporates an internal fluid bed, supports the formation of
strong powder agglomerates.
Both fluid beds are self emptying. This helps minimize
contamination.

ANDRITZ Gouda has developed a state of-the-art hydrolysis
process (cereal-based baby food). Hydrolysis is the cleaving of
a chemical compound into molecules by adding water.
• Shortening of the
starch chains.
• Results in a viscosity
reduction at 80-95°C.
First
Hydrolysis
• Different enzymes
• The enzyme for
saccharification is
active at around 60
°C.
Second
Hydrolysis • Slurry begins to
gelatinize when starch
heated to 51-65°C.
• Deactivate at 125 to
135 °C.
Deactivate
Enzyme

GERIATRIC FOODS
Geriatric nutrition applies nutrition principles to delay effects
of ageing, and disease to aid in the management of the
physical, physiological and psychosocial changes commonly
associated with growing old.
NUTRITIONAL REQUIREMENT:
 Whole diet should contain 1800 cal protein needs of
healthy older adult.
 Foods rich in Alpha lionolenic acid, Antioxidant vit A,C,E.
 Polyphenol about 1g/ day , which is about 10 times higher
than that of vit C and 100 times higher than those of vit E.

Supplementary Dietary Botanicals for Geriatrics:
Ginkgo biloba- Prevent Alzheimer’s disease, rich in
phytochemicals.
Cranberry, oregano- Possess multiple medicinal properties.
Green tea contains polyphenolic catechins that have been
reported to have a number of health benefits.
Needs more calcium and vitamin D.
Vitamin B12 deficiency has been associated with depression.

Commercial Products
MERITENE- NESTLE
Flavoured powder:
• Blend of Mg, K,Zn,
Vit A,E,K.
• Provide Less than100
kcal.
Danone Actimel-
Probiotic yogurt:
•0% fat, 0%
added sugar.
•VitB6 reduce
tiredness ,fatigue.
Ladder Whey
Protein:
•Provides 90% pure
digestible protein.
•Less than 1%
lactose.

Convenience food
is commercially
prepared food
designed for ease
of consumption.
Products can be sold
ready-to-eat dishes
at room temperature
and shelf-stable
products.
Two Types:
Self- stable
foods and
frozen foods
CONVENIENCE FOODS

RTE
• Does not require additional heat treatment.
• Chana masala, vegetable pulao.
RTC
• Require additional heat treatment.
• Instant Idli batter, Instant mix for cake, gulabjamun.
RTS
• Consists of beverages, Juices, Squashes, Purees and Soft
Drinks.
Frozen
• Foods that are kept below the freezing point of 0 °C.
• Frozen pizza, Meat pies (Mutton and Chicken), Chicken
nuggets.

TECHNOLOGY
Retort Technology:
Food is sterilized at 121°C/15
psi for 20 mins. ITC uses four-layered
pouches- PET/ polyester, Aluminium
foil, Nylon layer and polypropylene
layer.
High Pressure Processing:
Food subjects to a high level
of hydrostatic pressure upto 6000 bar.
Sandridge company using HPP to
process RTE salads.
Freezing :
Manufacturers freeze foods by
immersion in very cold liquids. Liquid
nitrogen is the preferred medium to use.
CMC is used as a stabilizer in frozen foods. It
damage muscle protein, to prevent such
changes, cryoprotectants such as glycerol
were added.
MATS (Microwave Assisted Thermal Sterilization):
Combination of pressurized hot water and
microwave technology. Uses long-wavelength
microwave energy together with heat and water
pressure to sterilize packaged food in a fraction of
time.

Wet Batter(3-6 Days):
• Rice, black gram soaked
overnight.
• Separately ground in a
grinder.
• Ground rice, dal and
fenugreek are then
combined.
• After fermentation
packets are filled. These
packets are then frozen.
Dry Batter (1 year):
• Rice and dal are
roasted, dried till
M.C 8%.
• It is then blended
with lactic acid,
sodium bicarbonate
and salt.
Instant Idli /Dosa Batter

Roasting Drying Blending
Instant Coconut Chutney
Coconut, chana dal, mustard seeds,
green chilly, curry leave and salt.
Packed in polyolefin plastic pouch of
37-75 µ thickness provides 5-6 months
shelf-life.

SNACK FOODS
Snack is defined as a little meal that is eaten between the main
meals of the day. Snack foods are designed to offer
convenience in eating, preparation, packaging and storage.
Generally comprises bakery products, RTE mixes and chips.
The snack food market in India is valued at Rs.1530 crore.

TYPES
First Generation Snacks (Simply Extruded Snacks)
• Use lowest cost raw material
• Three-dimensional snacks
Second Generation Snacks ( Expanded Snacks)
• Made on high-shear stress, also called as collet.
• Moisture level 7-12%. Corn curls, potato sticks.
• Fried and Baked Collets.
Third Generation Snacks (Pellets)
• Semi finished ingredient.
• Final moisture content 10% to form a glassy pellet.

Mixing/ kneading
Tank equipped with
blades
Extrusion
Homogenization and
cooking
Temperatures in cooking
zone 80 - 150°C . Barrel
temperature in forming
zone 65-90°C .
Conditioning, through hot
or cold air. In this phase
an effort is made to
stabilize the product and
obtain mechanical
resistance .
Pre-drying phase aimed at
a fast reduction of the
humidity, up to 26-28%.
Drying- To reduce
humidity values of about
10-12%, around 4-5
hours.
SNACKS PELLETS:

Expansion of Snack Pellets:
1st phase- Moisture loss occurs at the periphery of
pellets into the oil.
2nd phase- Moisture inside the pellet turns to steam.
3rd phase- Vapour quickly evaporates.

Novel Processing Technologies
Pulsed Electric Field: Food exposed to a high voltage
field for less than 1 sec. Better retention of carotenoids
flavonols.
Cold Plasma: Sanitisation of the surfaces of fresh
products, liquid products. Bacterial biofilms affect the
efficacy of cold plasma process.

CONCLUSION
The production of fabricated foods generally results from consumer
demands for convenience, nutritional composition. Fabricated food
improve the balance of a meal, they can increase palatability and finally
can provide satiety and other advantages. That upward trend will
continue in 2021.
Future of fabricated foods:
 Longevity- Fabricated foods might prove helpful in reducing lipid
peroxidation and thereby enhancing longevity.
 Mental activity- in future fabricated foods can be developed which will
enhance the mental activity.
 Freedom from disease; fabricated foods might find application in
pharmacy in the near future by encompassing drugs and antibiotics.
 Synthetic ingredients from bacteria and yeasts will be developed and
used in foods.

REFERENCE
1)Advances in Formulated Foods-2000 pdf, NDRI,
Karnal.
2) Fabricated foods: consumer demands for
convenience- QURAAZAHA.AMIN(2013).
3)Fabricated foods- Martin Glicksman a & Ralph E.
Sand, 1971.
4)Innovative Trends in Dairy and Food Products
Formulation, NDRI, Karnal.

THANK YOU
Email: gdkrishnan97@gmail.com

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