Short Term Problem #1: Gravy Mix Proposed Causes and Suggested Solutions

PROBLEM STATEMENT

Gravy mix produced after December 2001 yields a gravy that is gelling overnight in the refrigerator, resulting in a non-pour able product the next day.  Re-heating the product results in a chunky gravy.  The chunks can be smoothed out with stirring, but the customer does not want to add an extra step to the preparation.  Gravy mix produced prior to December 2001 maintained a smooth consistency if refrigerated overnight.

PROPOSED CAUSES

 After presentation by the teams, the team Captains met and determined the consensus view of most probable causes.  They believed that  the major causes of the clumpy gravy are: 

1)      Cake flour

a.       a starch granules have been damaged by milling (higher water absorption)

b.      there is no specification for degree of starch damage or cultivar of wheat

2)      Cooling time is important prior to refrigeration

a.       uneven cooling may be occurring in the “quickie cooler”

Proposed causes suggested by the different teams  were:

·                                                                          problem appears to be related primarily to cake flour

·                                                                          retrogradation of starch due to high amylose

·                                                                          corn syrup is picking up moisture

·                                                                          protein content is too low in the cake flour

·                                                                          protein is gelling into clumps

·                                                                          the fat content is too low due to the lower fat content of the non-dairy creamer

·                                                                          starch/flour specs are not up to date

·                                                                          mono- and diglycerides are too low

·                                                                          water activity is fluctuating

SUGGESTED SOLUTIONS

The best solutions developed by the Team Captains  for the problem are:

1)      Explore the cake flour source in more detail.

a.       Has the farm source changed?

b.      What cultivar is used?

c.       What is the milling process?

d.      What is the protein content?

2)      Check the starch granules for damage caused by milling.

3)      Change the flour supplier and see if the problem persists.

a.       Get samples according to specifications from several suppliers and compare performance (i.e. gel performance)

4)      Set a new performance specification that takes into account milling damage to starch granules and wheat cultivar.

The suggested solutions presented by all teams  included:

·        Use low amylose cornstarch

·        Change the cooking method – cook longer

·        Use waxy (high amylopectin) starch

·        Add emulsifier/surfactant

·        Add hydrocolloids (propylene glycol, guar gum)

·        Increase protein content

·        Add a modified cornstarch – probably acetylated

·        Use more hygroscopic corn syrup

·        Use WPC in the place of starch

·        Add more water than specified in the directions

·        Substitute WPC for cake flour

·        Analyze incoming ingredients

·        Increase NDC and lower starch

·        Stir to remove clumps

·        Switch back to a higher fat NDC