Project : USDA ARS

ARS Home » Pacific West Area » Albany, California » Western Regional Research Center » Healthy Processed Foods Research » Research » Research Project #426044

Research Project: New Sustainable Processing Technologies to Produce Healthy, Value-Added Foods from Specialty Crops

Location: Healthy Processed Foods Research

2018 Annual Report

Objectives
The goal of this research is to continue the investigation, development and commercialization of several new infrared (IR) and ultraviolet (UV) based processing technologies including infrared drying, dry blanching, sequential infrared (IR) dry-blanching/dehydration and hot air-drying (SIRDBHAD), and combined IR and UV disinfection, and IR dry-peeling of specialty crops. Further goals of this research are to use new process technologies including microwave, solar thermal, vacuum forming, casting, extrusion, pasteurization, and homogenization, alone or in combination, to add value to specialty crops. Specific objectives are listed below: Objective 1: Enable new, efficient and sustainable commercial infrared and ultraviolet based methods for processing specialty crops to improve food quality, value and safety. Sub-objective 1.1 Investigate and commercially demonstrate an energy efficient drying technology for producing high quality nuts. Sub-objective 1.2 Investigate, demonstrate, and commercialize a novel IR technology for producing healthy crispy snacks. Sub-objective 1.3 Develop IR heating and ultraviolet (UV) technology for improved drying efficiency and safety of nuts. Sub-objective 1.4 Develop sustainable IR peeling technologies for fruits and vegetables. Objective 2: Enable economical, input-efficient and sustainable commercial microwave and solar thermal methods for processing specialty crops while improving product quality and value. Sub-objective 2.1. Develop microwave systems for drying and extracting high-value compounds from specialty crops and their co-products. Sub-objective 2.2 Develop a medium-scale solar thermal cabinet dryer with the capability to operate 24 hours a day during specialty crop harvest periods. Sub-objective 2.3 Develop solar thermal alternatives for heat-intensive specialty crop processing unit operations beyond cabinet drying. Objective 3: Enable novel, value-added commercial forming, casting and extrusion methods for processing fruits, vegetables and legumes with improved food safety and nutrition. Sub-objective 3.1 Develop vacuum forming technologies that can be implemented to increase utilization and consumption of specialty crops and their co-products in a variety of nutritious and value-added forms. Sub-objective 3.2 Apply the tools of nanoscience to the casting of edible films to improve safety, extend shelf-life and improve quality. Sub-objective 3.3 Develop healthy and sensory enhanced, ready-to-eat extruded healthy foods from legumes, specialty crops, cereals, fruits and vegetables and their fractions. Objective 4: Enable new, commercial methods of pasteurizing legumes and specialty crop-based beverages and yogurts, for improved flavor, bioactives and shelf life.

Approach
The research and development of new processing technologies can add value to specialty crops through the development of new foods containing up to 100% specialty crop based ingredients with enhanced healthfulness, convenience, and overall consumer appeal. Increased consumption of nutritious fruit, vegetable, nut, and legume based foods will improve the American diet and reduce the prevalence of obesity in our nation. This research will also improve profitability for U.S. growers and processors by increasing demand for specialty crops and by developing new value added products with high potential for export. Development of sustainable processing technologies which result in energy and water savings is another benefit of this research. Food safety will also be improved. Infrared, ultraviolet, microwave, solar thermal, forming, casting, extrusion, pasteurization and high pressure homogenization processing technologies will be explored, alone and in combination, to form novel value added food systems. Ultimately, effects of processing on final product properties will be characterized and processing methodologies optimized to maximize final product quality, safety, nutritional value, and sensory properties. An extensive network of collaborators from universities, research institutes in other countries, commodity organizations, medical research labs and the food industry, as well as sizable grants from Federal and State agencies and industry groups, will be used to support and insure a high degree of impact resulting from the research proposed in this project plan. Scientific impact will ultimately be achieved through scientific publications, patents, new mathematical models and transference of these technologies into commercialization.

Progress Report
Significant progress was made on all aspects of Objective 1. Researchers completed the two commercialization projects of the infrared drying technologies for walnuts and fruit- and vegetable-based healthy snacks with support from the California Energy Commission. The sequential infrared and hot air drying system was built, installed, tested, and optimized. Various fruit- and vegetable-based crispy healthy snacks were produced. The performance of the system was quantified. The product quality and energy use were also investigated and compared with the freeze-drying method. The patented technology has been licensed by a commercial Cooperative Research and Development Agreement (CRADA) partner. For infrared peeling, it was found that adding flame heating before infrared heating can significantly reduce the overall heating time needed for peeling tomatoes, which further improved the throughput of the process compared to infrared heating alone. A new pilot scale system has been designed to demonstrate the new approaches. In addition, researchers continued to make significant progress on solar thermal food processing research (Sub-objectives 2.2 and 2.3). The effects of sulfiting pretreatment and cabinet materials on the sun-drying performance of apricots were investigated, and other stone fruits were dried using a novel tray design that increases the phytosanitary quality of the product. Through a partnership, researchers are testing the potential of novel solar driers to dry fruit at a commercial farm in California. Significant progress was also made on all Objective 3 sub-objectives. The metabolic balance/obesity prevention bar that was developed with a CRADA partner was licensed, and a company is beginning to market it commercially. The USDA, NIFA funded project on blow spinning of nanofibers from food materials was completed and applications of nanoscience to improve the quality and safety of foods was completed. Toxicity tests on the nanofibers were performed and they were found to be safe. In addition, research concluded on the Binational Agricultural Research and Development Fund project with Israeli collaborators finding new uses for mushroom waste to improve foods. Research continued on a wide range of CRADA projects all of which support the objectives of the base funded research program. Research on legume-based snacks and beverages also progressed. Effects of particle size on flavor and functionality of legume-based flours were studied. In addition, drying processes were optimized to improve the flavor and functionality of legume-based beverages made from flours.

Accomplishments
1. Unique fruit-based bar for enhanced health. Most of the world’s population, even in developed countries, has inadequate intake of one or more nutrients. Damage to human health due to the lack of these nutrients is underestimated. ARS researchers in Albany, California, worked with Children’s Hospital Oakland Research Institute (CHORI) to develop a bar to provide all of these missing pieces to the diet and improve human health. Results have shown favorable shifts in measures for cardiovascular health, insulin resistance, inflammation, lung function and obesity in adults based on fifteen human clinical trials that have been performed, and the bar has been shown to simultaneously raise good-cholesterol and lower bad-cholesterol (lowering risk of heart disease) within two weeks of consumption. Additional surprising health benefits of the bar are its ability to reduce waist circumference (combating obesity) after two months of consumption and its unique benefits in improving lung function (combating asthma). A license for the patent has been issued to a commercial partner and they are working on commercializing the bars to provide a new means to improve the health of consumers worldwide.

2. Natural vitamin D supplement from mushroom powder made from mushroom waste. New process technologies are needed to add value to specialty crops and enhance their nutritional value. Currently, 60% of Americans are deficient in vitamin D, and there is a need for new food sources of this critical vitamin. ARS researchers in Albany, California, developed and optimized a novel ultraviolet (UV)-B light treatment for mushrooms to enhance their nutritional value. Recently the process was adapted to treat mushroom waste into a powdered ingredient that is high in vitamin D, providing a needed new vegetarian source of vitamin D. Human clinical trials proved the bioavailability of vitamin D in the processed mushrooms. Numerous commercial companies use the process and sell mushroom powders as a healthy source of vitamin D.

U.S. DEPARTMENT OF AGRICULTURE

Healthy Processed Foods Research: Albany, CA