IMPROVED UTILIZATION OF FRUITS AND VEGETABLES AS FORMED AND RESTRUCTURED PRODUCTS

Knowledge Area (KA)	Subject of Investigation (SOI)	Field of Science (FOS)	Percent
502	1010	2020	10%
502	1040	2020	10%
502	1110	2000	10%
502	1112	2020	10%
502	1114	2000	10%
502	1115	2000	10%
502	1122	2000	10%
502	1440	2000	10%
502	1452	2000	10%
502	1460	2020	10%

Progress 11/05/00 to 01/28/05

Outputs
1. What major problem or issue is being resolved and how are you resolving it (summarize project aims and objectives)? How serious is the problem? What does it matter? This project addresses issues involving consumer health, agricultural product utilization, rural employment, competition in international markets and processing waste. The goal is to develop processing technologies to produce convenient, healthy, value-added restructured fruits and vegetables, thereby increasing the contribution of fruits and vegetables to the diet. Processing technologies investigated include casting, extrusion, starch molding, drying, dehydrofreezing, dehydrocanning and vacuum forming. Potential health benefits include higher levels of phytochemicals and other nutrients through the use of pureed fruits and vegetables. These new value-added foods will facilitate extension of the processing season because the fruits and vegetables are first processed during the harvest season into a stable aseptically packaged puree, and then the puree is further processed during the remainder of the year into convenient, healthy restructured fruits and vegetables. Year-round processing reduces irregular and seasonal rural employment and increases overall utilization of processing equipment. By using fruit purees, more complete utilization and consequently less waste of harvested fruits and vegetables can be achieved. New markets for the fruit and vegetable harvest, beyond traditional canned and frozen foods, are needed to maintain and improve the economic vitality of the fruit and vegetable production industries in both national and international markets. Obesity is becoming the number one health issue in America due in large part to over consumption of unhealthful processed foods. The USDA Nutrition Pyramid recommends the consumption of 5-6 servings of fruits and vegetables per day, but surveys show that most Americans consume only half of that amount. Convenience is necessary to increase consumption of healthful fruit and vegetable foods. The markets for fruits and vegetables are limited because traditional, economic processing technologies are restricted to relatively few forms or styles. Seasonal hiring in the farm industry is costly as rural employers are required to pay benefits year round even for seasonal employees. Seasonal processing is costly because the processing equipment is used only during the harvest and is idle during the remainder of the year. All of the above listed problems are serious agricultural issues that are being addressed by this project. In these ways this work has a significant impact on the public, the food industry, rural communities, commodity organizations and farmers. This research has been assigned to National Program 306, Quality and Utilization of Agricultural Products. By providing new outlets for underutilized fruit and vegetable materials, the value-added processes researched through this project can enhance long-term viability and competitiveness of U.S. farmers within the global economy. Through research on new food processing technologies for fruits and vegetables the economic base for agricultural foods can be diversified and farmer income streams can be stabilized. 2. List the milestones (indicators of progress) from your Project Plan. Year 1 (FY 2000) Research the potential of twin screw extrusion to form expanded, restructured fruit products. Investigate potential of starch molding as a means to form highly concentrated fruit and vegetable snack products. Develop novel high-moisture fruit gels exploiting the synergistic relationships that alginates and fruit purees exhibit. Study use of drum-dried fruit purees as sucrose alternatives in confectionery products. Further develop and characterize fruit and vegetable films. Year 2 (FY 2001) Characterize the rheological properties of fruit purees during extrusion. Evaluate sensory acceptability and commercial potential of molded, extruded, formed and cast fruit and vegetable products made in our laboratory. Investigate use of extrusion to manufacture 100% vegetable snacks in expanded and nonexpanded forms. Work with Pacific Basin Agricultural Research Center to increase utilization of tropical fruits. Year 3 (FY 2002) Research use of vacuum forming technology to manufacture both high moisture and shelf-stable fruit bars and sticks. Begin to research ways to scale up commercial production of 100% fruit and/or vegetable edible films. Year 4 (FY 2003) Scale up vacuum forming process to enable commercial production of shelf- stable fruit bars. Work with an industrial partner to evaluate the shelf-life of 100% fruit bars and commercialize the product. Optimize production conditions for the casting of fruit and vegetable- based edible films. Year 5 (FY 2004) Research use of coextrusion forming technology to manufacture two component fruit and/or vegetable bars and sticks. Develop technologies to process novel vegetable-based bars. Scale-up commercial manufacturing of fruit and vegetable-based edible films using casting technologies and work with cooperators to commercialize products. Research unique product applications for the fruit and vegetable edible films, testing final product shelf-life characteristics and sensory appeal. Begin collaboration with ARS laboratory in Fairbanks, Alaska developing new food uses for fish processing co-products. 3a List the milestones that were scheduled to be addressed in FY 2005. For each milestone, indicate the status: fully met, substantially met, or not met. If not met, why. 1. Research use of coextrusion forming technology to manufacture two component fruit and/or vegetable bars and sticks. Milestone Fully Met 2. Develop technologies to process novel vegetable-based bars. Milestone Fully Met 3. Scale-up commercial manufacturing of fruit and vegetable-based edible films using continuous casting technologies and work with cooperators to commercialize products. Milestone Fully Met 4. Research unique product applications for the fruit and vegetable edible films, testing final product shelf-life characteristics and sensory appeal. Milestone Fully Met 5. Begin collaboration with ARS laboratory in Fairbanks, Alaska developing new food uses for fish processing co-products. Milestone Fully Met 3b List the milestones that you expect to address over the next 3 years (FY 2006, 2007, and 2008). What do you expect to accomplish, year by year, over the next 3 years under each milestone? This project has ended and has been replaced by a new project entitled "New Technologies to Process Value-Added, Healthy Foods from Fruits and Vegetables". Future milestones are outlined in this new CRIS project, 5325-41000-060-00D. 4a What was the single most significant accomplishment this past year? New processing technologies are needed to increase utilization and consumption of fruits by American consumers. In FY05, researchers in the Processed Foods Research Unit at WRRC developed and patented a novel continuous casting technology to produce 75% to 100% fruit and vegetable wraps and entered into a CRADA with an industrial partner to commercialize the films for a variety of final product applications. One of these applications is the use of the films a healthy, colorful alterative to the seaweed wrap 'nori' for sushi products. This research has not only generated a good deal of national and international press interest in the past year, it has also generated interest from sushi chefs around the globe and commercial manufacturers of seven-day sushi. We anticipate that the films will be commercially available in the next year. Other applications for the fruit and vegetable films include wraps for meats, liquid delivery systems and strips. 4b List other significant accomplishments, if any. To meet the need for new processing technologies to increase utilization and consumption of fruits by American consumers, researchers in the Processed Foods Research Unit at WRRC, Albany, CA, developed and licensed a technology for forming 100% fruit health bars from pears and other fruits to add value and create new markets for pears and other fruits. Through a CRADA collaboration with ARS, the industrial partner is has now been commercially producing the bars in a plant in North Bonneville, WA, an area of high unemployment, and sixty new jobs have been created. This research resulted in numerous awards including this year's presentation of a Presidential Early Career Award in Science and Engineering. The impact of this grass roots effort of pear growers has recently expanded by the introduction of a line of apple-based bars. In addition, we continue to work with our industrial partner who has plans to introduce a new expanded line of bars nationally and in Canada within the next month. This research increased grower profits while assisting consumers around the globe in meeting their daily requirements for fruits through the development of healthy, convenient 100% fruit bars. New processing technologies are needed to increase utilization and consumption of fruits and vegetables by consumers in the U.S. Researchers in the Processed Foods Research Unit at WRRC, Albany, CA, developed and patented forming technologies to produce 100% vegetable and vegetable/fruit bars and scaled up the production process to manufacture these bars through a CRADA. During the past year, several 100% vegetable and 100% vegetable/fruit bars have been developed and numerous producers of vegetables and fruits are considering licensing this technology from ARS. In addition, a new process was developed to enable the formation of coextruded bars, for example bars with a tomato center and a potato exterior. This will result in increased utilization and consumption of fruits and vegetables, not only improving the American diet, but also adding value to the growers. American consumers do not consume enough fruit. In an effort to increase consumption, researchers in the Processed Foods Research Unit at Albany, CA completed a CRADA with a grower owned industrial partner on the development of a soft, shelf-stable, healthy and convenient fruit snack. A novel hurdle technology, consisting of a combination of direct steam injection cooking and forming, was developed to produce this unique 75% fruit snack. Consumer acceptability of strawberry, apricot and peach snacks is underway and it is hoped that the product will be introduced into the marketplace in the next year. The grower owned partner hopes that this technology will provide a new, value added outlet for their fruit. New efficient processes for blanching and dehydrating fruits and vegetables are needed to expand markets and add value to these healthy foods. A novel infrared dry blanching technology that does not require addition of steam or water in the blanching process was invented by researchers in the Processed Foods Research Unit at WRRC, Albany, CA. A patent was filed on this invention which can be used to produce many kinds of value-added dried, refrigerated, frozen and dehydrofrozen fruit and vegetable products in an energy efficient method which preserves the nutrition and quality of the final products. Ultimately these novel products can assist consumers in meeting the USDA dietary guidelines for fruit and vegetable consumption. In FY05, we entered into a CRADA with an industrial partner to test this technology's potential as an alternative to freeze drying for dehydrated and partially dehydrated strawberries and bananas for inclusion in breakfast cereals and snacks. 4c List any significant activities that support special target populations. The first accomplishment in 4B has impact on rural employment in that the plant was built in an area where there is 34% unemployment. Sixty jobs have been created. All of these accomplishments also impact children's nutritional status by providing alternatives to increase consumption of fruits and vegetables. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. Invention of a novel combined process to produce up to 100% fruit and vegetable bars and snacks. The patent on this process was licensed to an industrial partner in late 2002 who worked with us on a CRADA to scale up the process to commercially manufacture 100% fruit, pear bars. The plant used to manufacture these bars is located in North Bonneville, WA, an area of high unemployment and has been in operation now over two years. Sixty new jobs have been created. This research has resulted in numerous awards including a Presidential Early Career Award in Science and Engineering, a Federal Laboratory Consortium Award for Excellence in Technology Transfer and a USDA Secretary's Honors Award. This grass roots effort of pear growers has recently expanded beyond pears and into other fruits, such as apples, from the Western States to enhance grower profitability and assist Americans in meeting their daily requirements for fruits through the development of healthy, convenient 100% fruit bars. The bars are now being exported, thus providing value-added export opportunities to U.S. growers and impacting consumer health around the globe. They are also distributed in school lunch programs in several states. The patented process used to manufacture the 100% fruit bars has recently been expanded to manufacture 100% vegetable and 100% vegetable/fruit bars. Increasing vegetable consumption is also a goal of this project and this novel, shelf stable product promises to provide a novel means for consumers to increase their consumption of vegetables in the future. Coextrusion technologies were also developed to form multicomponent vegetable and vegetable/fruit bars. Developed casting technologies for the formation of 100% fruit and vegetable wraps to increase shelf-life, quality and nutritional value of foods. Successful implementation of these technologies was achieved through two CRADAs to scale up the production process for these films. This research not only generated an extraordinary amount of national and international press interest in the past several years, including a story on ABC's World News Tonight with Peter Jennings, but also won a Best of What's New Award from Popular Science magazine. Presently we are involved in a CRADA with a cooperator who anticipates introducing these unique fruit and vegetable films into the marketplace shortly as healthy, colorful alternatives to the seaweed wrap, 'nori', that is used in sushi products. This research is expanding markets for growers, enhancing profits for farmers and improving consumer nutrition. Developed innovative starch molding technologies to manufacture novel, shelf-stable, nutritious fruit snacks and fruit/nut health bars. Discovered novel gel systems containing alginates and fruit purees without any additional pectin, calcium or sugar source and employed innovative vacuum forming technologies to manufacture final foods which could be used as condiments, snacks or ingredients in salads and baked goods. Characterized the rheological properties of fruit purees during extrusion to expand use of fruit in processed foods. Invented a novel infrared dry blanching technology to process fruits and vegetables into value-added products to increase consumption of these commodities. 6. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? Invented a novel combined process to produce up to 100% fruit and vegetable bars and snacks. The patent on this process was licensed to an industrial partner in late 2002 who worked on a CRADA with ARS to scale up the process to commercially manufacture the 100% fruit, pear bars. The plant used to manufacture these bars is located in North Bonneville, WA, an area of high unemployment and has been in operation over two years. Sixty new jobs have been created. This research has resulted in numerous awards including a Presidential Early Career Award in Science and Engineering, a Federal Laboratory Consortium Award for Excellence in Technology Transfer and a USDA Secretary's Honors Award. This grass roots effort of pear growers has recently expanded beyond pears and into other fruits from the Western States to enhance grower profitability and assist Americans in meeting their daily requirements for fruits through the development of healthy, convenient 100% fruit bars. The bars are now being exported, thus providing value-added export opportunities to U.S. growers and impacting consumer health around the globe. The bars are also available through the school lunch program in several states. Developed casting technologies for the formation of 100% fruit and vegetable wraps to increase shelf-life, quality and nutritional value of foods. Successful implementation of these technologies was accomplished through two CRADAs to scale up the production process for these films. This research not only generated an extraordinary amount of national and international press interest in the past several years, including a story on ABC's World News Tonight with Peter Jennings, but also won a Best of What's New Award from Popular Science magazine. Presently we are involved in a CRADA with a cooperator who anticipates introducing these unique fruit and vegetable films into the marketplace shortly as healthy, colorful alternatives to the seaweed wrap, 'nori', that is used in sushi products. This research is expanding markets for growers, enhancing profits for farmers and improving consumer nutrition. 7. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: List your peer reviewed publications below). Refer to publications listed in new project "New Technologies to Process Value-Added, Healthy Foods from Fruits and Vegetables", 5325-41000-060- 00D.

Impacts
(N/A)

Publications

Sorthornvit, R., Olsen, C., McHugh, T.H., Krochta, J.M. Formation conditions, water-vapor permeability, and solubility of compression-molded whey protein films. Journal of Food Science. 2003. v. 68. p. 1985-1989.
Huxsoll, C.C., McHugh, T.H., Olson, D.A. Intermediate-moisture formed food products made from partially dehydrated fruit and/or vegetables and novel methods of packaging thereof. 2003. Docket No. 0039.00. Serial No. 09/774, 810 (Patent Pending).
McHugh, T.H., Olsen, C.W., Senesi, E. Fruit and Vegetable Wraps: Application to Partially Dehydrated Apple Pieces. Shahidi, F., Spanier, C- T.H. and Braggins, T. editors. Kluwer Academics/Plenum Publishing, New York, NY. Quality of Fresh and Processed Foods. 2003. p. 289-299.
Senesi, E., McHugh, T.H. Film e coperture eduli con matrici a base di frutta. Industrie alimentari. 2002. v. XLI dicembre. p. 1289-1294.

Progress 10/01/02 to 09/30/03

Outputs
1. What major problem or issue is being resolved and how are you resolving it? This project addresses issues involving consumer health, agricultural product utilization, rural employment, and competition in international markets and processing waste. The goal is to develop processing technologies to produce convenient, healthy, value-added restructured fruits and vegetables, thereby increasing the contribution of fruits and vegetables to the diet. Processing technologies investigated include casting, extrusion, starch molding, drying, dehydrofreezing, dehydrocanning and vacuum forming. Potential health benefits include higher levels of phytochemicals and other nutrients because of the use of pureed fruits and vegetables. These new value-added foods will facilitate extension of the processing season because the fruits and vegetables are first processed during the harvest season into a stable aseptically packaged puree, and then the puree is further processed during the remainder of the year into convenient, healthy restructured fruits and vegetables. Year-round processing reduces irregular and seasonal rural employment and increases overall utilization of processing equipment. By using fruit purees, more complete utilization and consequently less waste of harvested fruits and vegetables can be achieved. New markets for the fruit and vegetable harvest, beyond traditional canned and frozen foods, are needed to maintain and improve the economic vitality of the fruit and vegetable production industries in both national and international markets. 2. How serious is the problem? Why does it matter? Obesity is becoming the number one health issue in America due in large part to over consumption of unhealthful processed foods. The USDA Nutrition Pyramid recommends the consumption of 5-6 servings of fruits and vegetables per day, but surveys show that most Americans consume only half of that amount. Convenience is necessary to increase consumption of healthful processed fruit and vegetable foods. The markets for fruits and vegetables are limited because traditional, economic processing technologies are restricted to relatively few forms or styles. Seasonal hiring in the farm industry is costly as rural employers are required to pay benefits year round even for seasonal employees. Seasonal processing is costly because the processing equipment is used only during the harvest and is idle during the remainder of the year. Due in part to the Food Quality and Protection Act, there is an increased need for technologies that reduce levels of pesticides in foods. All of the above listed problems are serious agricultural issues that are being addressed by this project. In these ways this work has a significant impact on the public, the food industry, rural communities, commodity organizations and farmers. 3. How does it relate to the National Program(s) and National Program Component(s) to which it has been assigned? This research has been assigned to National Program 306 (100%), Quality and Utilization of Agricultural Products. By providing new outlets for underutilized fruit and vegetable materials, the value-added processes researched through this project can enhance long-term viability and competitiveness of U.S. farmers within the global economy. Through research on new food processing technologies for fruits and vegetables the economic base for agricultural foods can be diversified and farmer income streams can be stabilized. 4. What were the most significant accomplishments this past year? A. To meet the need for new processing technologies to increase utilization and consumption of fruits by American consumers, researchers in the Processed Foods Research Unit at WRRC developed and licensed a technology for forming 100% fruit health bars from pears and other fruits to add value and create new markets for pears and other fruits. Through a CRADA collaboration with ARS, the industrial partner is now commercially producing the bars in a plant in North Bonneville, WA, an area of high unemployment, and ninety new jobs have been created. This research resulted in numerous awards including a Federal Laboratory Consortium Award for Excellence in Technology Transfer and a Secretary's Honors Award from USDA. This grass roots effort of pear growers has recently expanded beyond pears and into other fruits and vegetables from the Western states and is expected to help growers' profits while assisting Americans in meeting their daily requirements for fruits and vegetables through the development of healthy, convenient 100% fruit bars. B. New processing technologies are needed to increase utilization and consumption of fruits and vegetables by consumers in the U.S. In FY02, researchers in the Processed Foods Research Unit at WRRC developed casting technologies to produce 100% fruit and vegetable wraps and scaled up the production process to manufacture these films through a CRADA. This research has generated an extraordinary amount of national and international press interest in the past two years and it is anticipated that the 100% fruit and vegetable wraps will be commercially available in the near future. This will result in increased utilization and consumption of fruits and vegetables, improving not only the American diet but also the environment by reducing amounts of disposable packaging materials. C. The accomplishment 4A has impact on rural employment in that the plant was built in an area where there is 34% unemployment. Ninety jobs have been created. These accomplishments also impact children's nutritional status by providing alternatives to increase consumption of fruits and vegetables. D. Progress Report. Through a CRADA with an industrial cooperator, a process for scaling up production of fruit and vegetable wraps was successfully completed. One hundred percent fruit and vegetable wraps will be manufactured using a commercial casting processing system. These wraps can increase shelf life, improve quality and enhance the nutritional value of food systems. Numerous food companies are interested in the fruit and vegetable wraps and we hope to see them available in the marketplace within the next year. Effects of processing conditions on final food quality and shelf life are being researched. Through another CRADA collaboration with an industrial partner, patented ARS technology was licensed and a plant was built to commercially manufacture a 100% fruit health bar. This food bar offers a healthy alternative for consumers versus confectionery products. The plant was constructed through a grass roots effort of pear growers and is anticipated to add significant value to their pear crop in the years to come. Processing effects on final food properties, nutrition and shelf- life were researched. The bars are now being sold in 141 Albertson's stores, Rosaur's supermarkets, Thrifty stores and several other channels. Researchers continue to work on developing a novel liquid delivery system made from 100% fruit and are currently scaling up the process to manufacture this novel, healthful product. Completed a collaboration with the Pacific Basin Agricultural Research Center to increase utilization of tropical fruits through the development and commercialization of healthy, value-added fruits. Edible film and vacuum forming technologies are being explored through this collaborative effort to develop a variety of final products. 5. Describe the major accomplishments over the life of the project, including their predicted or actual impact. This is a continuation of project 5325-42000-032-00. Major accomplishments over the life of the project include: 1) Invention of a novel combined process utilizing drying in combination with twin screw extrusion was developed to produce up to 100% fruit and vegetable snacks. The patent on this process was recently licensed to an industrial partner who expects to introduce a 100% fruit bar into the marketplace this fall. 2) Innovative processing research on starch molding technologies was developed to manufacture novel, shelf-stable, nutritious fruit snacks and fruit/nut health bars. 3) Novel gel systems containing alginates and fruit purees without any additional pectin, calcium or sugar source were discovered and innovative vacuum forming technologies were employed to manufacture final foods which could be used as condiments, snacks or ingredients in salads and baked goods. A patent application is under review regarding this discovery. 4) Casting technologies for the formation of 100% fruit and vegetable wraps have been researched and continue to be investigated to increase shelf-life, quality and nutritional value of foods. Successful implementation of these technologies will lead to expanded markets for growers, enhanced profits for farmers and improved consumer nutrition. The technology used to manufacture the pear bars that are described in previous questions is the first to be implemented commercially under this project. 6. What do you expect to accomplish, year by year, over the next 3 years? In FY 2004, we expect to continue to support research relating to the forming technology used to manufacture the 100% fruit health bars and anticipate that the bars will be available in the school lunch program and the military rations program shortly. In addition, we plan to work toward implementing the casting technologies used to manufacture 100% fruit and vegetable edible films and through collaborations introduce this product into the marketplace during the upcoming year. Commercialization of 100% fruit liquid delivery systems is also anticipated. In FY 2005, we anticipate commencing research on extrusion processing of microwavable fruits and vegetables. Additional studies on hurdle technologies to enhance processing of dehydrofrozen and dehydrocanned fruits will be studied. Infrared drying technologies will be investigated to improve the quality of fruits and vegetables. Technologies to manufacture fruit based liquid delivery systems for sore throats will be researched as well. Studies testing the nutritional benefits of restructured fruit and vegetables and the effects that processing has on those benefits will be initiated. In FY 2006, we will continue research on extrusion processing of microwavable fruits and vegetables. Continued studies on processing effects on nutritional benefits of restructured fruits and vegetables will be performed. 7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end- user (industry, farmer, other scientists)? What are the constraints, if known, to the adoption and durability of the technology products? A) A patent application was licensed to an industrial partner who built a plant to manufacture 100% fruit health bars that are currently available in the marketplace. B) A second patent application was issued on formed restructured fruit and vegetable products and we are anticipating the licensing of it within the next year. C) We are currently working on three CRADAs with industrial cooperators on various different processing technologies to increase utilization and consumption of fruits and vegetables. D) We work closely with the NASA Food Technology Commercial Research Center to apply our processing technologies to space. E) Presentations and extensive interactions with various industrial partners and commodity organizations continue to be emphasized in our program. 8. List your most important publications in the popular press and presentations to organizations and articles written about your work. (NOTE: This does not replace your peer-reviewed publications listed below). Chem Matters Magazine CNN Headline News Self Magazine Men's Health Magazine KFMB-TV CBS-Philadelphia The Hartford Courant Focus TV Produktions GmbH Family Circle Grocery Headquarters Magazine Plastics in Packaging Macchina del tempo (Time machine) HealthDay Alternative Medicine Magazine KFI News New Innovations in Edible Films. Invited presentation at the PIRA Flexible Packaging Conference, Birmingham, England, 2002. Innovative Food Processing for Health. Invited presentation at the PWA Leadership Conference, Scottsdale, AR, 2002. Food Processing Technologies to Add Value to Tropical Fruits. Invited presentation at the University of Hawaii and PBARC, Hilo, HA, 2002. Processing Technologies to Add Value to Fruits and Vegetables. Invited presentation given to the REEE Advisory Board, Salinas, CA, 2003. Innovative Fruit Processing for Promoting Health and Sustainable Rural Communities. Invited presentation at the Federal Laboratory Consortium Meeting, Tucson, AR, 2003.

Impacts
(N/A)

Publications

Huxsoll, C.C., McHugh, T.H., Olson, D.A. Intermediate-moisture formed food products made from partially dehydrated fruit and/or vegetables and novel methods of packaging thereof. 2003. Docket No. 0039.00. Serial No. 09/774, 810 (Patent Pending).
McHugh, T.H., Olsen, C.W., Senesi, E. Fruit and Vegetable Wraps: Application to Partially Dehydrated Apple Pieces. Shahidi, F., Spanier, C- T.H. and Braggins, T. editors. Kluwer Academics/Plenum Publishing, New York, NY. Quality of Fresh and Processed Foods. 2003. p. 289-299.
Senesi, E., McHugh, T.H. Film e coperture eduli con matrici a base di frutta. Industrie alimentari. 2002. v. XLI dicembre. p. 1289-1294.
Sorthornvit, R., Olsen, C., McHugh, T.H., Krochta, J.M. Formation conditions, water-vapor permeability, and solubility of compression-molded whey protein films. Journal of Food Science. 2003. v. 68. p. 1985-1989.

Progress 10/01/01 to 09/30/02

Outputs
1. What major problem or issue is being resolved and how are you resolving it? This project addresses issues involving consumer health, agricultural product utilization, rural employment, competition in international markets and processing waste. The goal is to develop processing technologies to produce convenient, healthy, value-added restructured fruits and vegetables, thereby increasing the contribution of fruits and vegetables to the diet. Processing technologies investigated include casting, extrusion, starch molding, drying, dehydrofreezing, dehydrocanning and vacuum forming. Potential health benefits include higher levels of phytochemicals and lower levels of pesticides because of the pureed fruits and vegetables. These new value-added foods will facilitate extension of the processing season because the fruits and vegetables are first processed during the harvest season into a stable aseptically packaged puree, and then the puree is further processed during the remainder of the year into final restructured fruits and vegetables. Year-round processing reduces irregular and seasonal rural employment and increases overall utilization of processing equipment. By using fruit purees, more complete utilization and consequently less waste of harvested fruits and vegetables can be achieved. New markets for the fruit and vegetable harvest, beyond traditional canned and frozen foods, are needed to maintain and improve the economic vitality of the fruit and vegetable production industries in both national and international markets. 2. How serious is the problem? Why does it matter? The USDA Nutrition Pyramid recommends the consumption of 5-6 servings of fruits and vegetables per day, but surveys show that most Americans consume only half of that amount. Convenience is necessary to increase consumption. The markets for fruits and vegetables are limited because traditional, economic processing technologies are restricted to relatively few forms or styles. Seasonal hiring in the farm industry is costly as rural employers are required to pay benefits year round even for seasonal employees. Seasonal processing is costly because the processing equipment is used only during the harvest and is idle during the remainder of the year. Due in part to the Food Quality and Protection Act, there is an increased need for technologies which reduce levels of pesticides in foods. All of the above listed problems are serious agricultural issues which are being addressed by this project. In these ways this work has a significant impact on the public, the food industry, rural communities, commodity organizations and farmers. 3. How does it relate to the national Program(s) and National Program Component(s) to which it has been assigned? This research has been assigned to National Program 306, Quality and Utilization of Agricultural Products. By providing new outlets for underutilized fruit and vegetable materials, the value-added processes researched through this project can enhance long-term viability and competitiveness of U.S. farmers within the global economy. Through research on new food processing technologies for fruits and vegetables the economic base for agricultural foods can be diversified and farmer income streams can be stabilized. 4. What was your most significant accomplishment this past year? A. New processing technologies are needed to increase utilization and consumption of fruits by American consumers. In FY02, researchers in the Processed Foods Research Unit at WRRC developed and licensed a technology for forming 100% fruit health bars from pears to add value and create new markets for pears. The industrial partner who licensed this technology is scaling up the process at a plant in a rural area of Oregon, which presently has high unemployment, to begin to manufacture the fruit bars. This grass roots effort of pear growers has recently expanded beyond pears and into other fruits and vegetables from the Western states and is expected to help growers' profits while assisting Americans in meeting their daily requirements for fruits and vegetables. B. New processing technologies are needed to increase utilization and consumption of fruits and vegetables by consumers in the U.S. In FY02, researchers in the Processed Foods Research Unit at WRRC developed casting technologies to produce 100% fruit and vegetable wraps and entered into a CRADA with an industrial partner to scale up the production process for these films. This research has not only generated an extraordinary amount of national and international press interest in the past year, including a story on ABC's World News Tonight with Peter Jennings, but also won a Best of What's New Award from Popular Science magazine this year. It is anticipated that the 100% fruit and vegetable wraps will be commercially available in the near future and will result in increased utilization and consumption of fruits and vegetables, improving not only the American diet but also the environment by reducing amounts of disposable packaging materials. C. The accomplishment 4A has impact on rural employment in that the plant is being built in an area where there is 34% unemployment. These accomplishments also impact children's nutritional status by providing alternatives to increase consumption of fruits and vegetables. D. Progress Report. Through a CRADA with an industrial cooperator, a process for scaling up production of fruit and vegetable wraps is being researched. One hundred percent fruit and vegetable wraps will be manufactured using a commercial casting processing system. These wraps can increase shelf life, improve quality and enhance the nutritional value of food systems. Numerous food companies are interested in the fruit and vegetable wraps and we hope to see them available in the marketplace within the next year. Effects of processing conditions on final food quality and shelf life are being researched. Through collaborations with another industrial partner, patented ARS technology was licensed and a plant is being manufactured to commercially produce a 100% fruit health bar. This food bar offers a healthy alternative for consumers versus confectionery products. The plant is being constructed through a grass roots effort of pear growers and is anticipated to add significant value to their pear crop in the years to come. Processing effects on final food properties, nutrition and shelf- life are being researched. Through a third CRADA with an industrial partner, processing technologies for manufacturing a restructured vegetable food are being explored. Technologies such as dehydrofreezing, forming and drying are being researched to add value, increase convenience and enhance consumption of vegetables by consumers. Effects of processing on final food properties and nutrition are being researched. Began a collaboration with the Pacific Basin Agricultural Research Center to increase utilization of tropical fruits through the development and commercialization of healthy, value-added fruits. Edible film and vacuum forming technologies are being explored through this collaborative effort to develop a variety of final products. The PBARC is providing financial support for this research. 5. Describe your major accomplishments over the life of the project, including their predicted or actual impact? This is a continuation of project 5325-42000-032-00. Major accomplishments over the life of the project include: 1) Invention of a novel combined process utilizing drying in combination with twin screw extrusion was developed to produce up to 100% fruit and vegetable snacks. The patent on this process was recently licensed to an industrial partner who expects to introduce a 100% fruit bar into the marketplace this fall. 2) Innovative processing research on starch molding technologies were developed to manufacture novel, shelf-stable, nutritious fruit snacks and fruit/nut health bars. 3) Novel gel systems containing alginates and fruit purees without any additional pectin, calcium or sugar source were discovered and innovative vacuum forming technologies were employed to manufacture final foods which could be used as condiments, snacks or ingredients in salads and baked goods. A patent application is under review regarding this discovery. 4) Casting technologies for the formation of 100% fruit and vegetable wraps have been researched and continue to be investigated to increase shelf-life, quality and nutritional value of foods. Successful implementation of these technologies will lead to expanded markets for growers, enhanced profits for farmers and improved consumer nutrition. 6. What do you expect to accomplish, year by year, over the next 3 years? In FY03, we expect to support research relating to forming technology employing fresh fruits. An example of end use is provided by technology used to manufacture the 100% fruit health bars. The plant could be fully operational in the next year and the bars will be available in the marketplace, in the school lunch program and the military rations program soon after. In addition, we plan to work more on the casting technologies used to manufacture 100% fruit and vegetable edible films and work towards enhancing the process efficiency and the final food flavor. This technology is also expected to be commercialized in the upcoming year. In FY2004 we anticipate commencing researching extrusion processing of microwavable fruits and vegetables. Additional studies on hurdle technologies to enhance processing of dehydrofrozen and dehydrocanned fruits will be studied. Technologies to manufacture fruit based liquid delivery systems for sore throats will be researched as well. Studies testing the nutritional benefits of restructured fruit and vegetables and the effects that processing has on those benefits will be initiated. In FY2005 we will continue research on extrusion processing of microwavable fruits and vegetables. Continued studies on processing effects on nutritional benefits of restructured fruits and vegetables will be performed. Commercialization of 100% fruit liquid delivery systems is anticipated. 7. What technologies have been transferred and to whom? When is the technology likely to become available to the end user (industry, farmer other scientist)? What are the constraints, if known, to the adoption durability of the technology? A patent application was licensed to an industrial partner who is in the process of building a plant to manufacture 100% fruit health bars within the next year. B) A second patent application was filed on formed restructured fruit and vegetable products and we are awaiting a response from the examiner. C) We are currently working on three CRADAs with industrial cooperators on various different processing technologies to increase utilization and consumption of fruits and vegetables. D) We work closely with the NASA Food Technology Commercial Research Center to apply our processing technologies to space. E) Presentations and extensive interactions with various industrial partners and commodity organizations continue to be emphasized in our program. 8. List your most important publications and presentations, and articles written about your work (NOTE: this does not replace your review publications which are listed below) Fox New Online World News Tonight with Peter Jennings Chem Matters Magazine Seattle Times Self Magazine Popular Science Magazine Men's Health Magazine Readers Digest Magazine Biocycle Magazine University of California Davis Magazine Health Magazine Jay Leno Show Progressive Grocer Magazine FOCUS Magazine Illustrated Current News Business Coast News Maxim magazine Star-K Kosher Certification magazine

Impacts
(N/A)

Publications

McHugh, T.H. Edible Packaging. Resource Magazine. 2001. v. 11. p. 7-8.
McHugh, T.H., Olsen, C.W. Tensile properties of fruit and vegetable edible films. Institute of Food Technologists. 2002. Abstract No. 100B-32.
Huxsoll, C.C., Olson, D.A., McHugh, T.H. Rehydrated dehydrofrozen fruit as potential retail and food service products. Institute of Food Technologists. 2002. Abstract No. 30G-7.
Sothornvit, R., Olsen, C.W., McHugh, T.H., Krochta, J.M. Compression- molded whey protein films: effect of moisture and glycerol content on water vapor permeability, protein solubility and mechanical properties. Institute of Food Technologists. 2002. Abstract No. 100B-26.

Progress 10/01/00 to 09/30/01

Outputs
1. What major problem or issue is being resolved and how are you resolving it? This project is an extension of CRIS 5325-41000-032 addressing issues involving consumer health, product utilization, rural employment, and processing waste. The goal is to develop technologies to produce convenient, healthy, and attractive restructured fruit and vegetable products; thereby increasing the contribution of fruits and vegetables to the diet. Technologies investigated included edible films, extrusion, starch molding and vacuum forming. Potential health benefits included higher levels of natural phytochemicals and lower levels of pesticides because of the use of pureed fruits and vegetables. These new value-added products will facilitate extension of the processing season because the fruits and vegetables are first processed during the harvest season into a stable aseptically packaged puree, and then the puree is further processed during the remainder of the year into final restructured products. Year-round processing reduces irregular or seasonal rural employment and increases utilization of expensive equipment. By using fruit purees, more complete utilization and consequently less waste of harvested fruits and vegetables can be achieved. New markets for the fruit and vegetable harvest beyond the traditional canned and frozen products are needed to maintain and improve the economic vitality of the fruit and vegetable production industries in both national and international markets. 2. How serious is the problem? Why does it matter? The USDA Nutrition Pyramid recommends the consumption of 5-6 portions of fruits and vegetables per day, but surveys show that most people eat only half that amount. Convenience is necessary to increase consumption. The markets for many fruit and vegetable products are limited because traditional, economic technologies are restricted to relatively few forms or styles. Seasonal hiring in the farm industry is costly as rural employers are required to pay benefits year round even for seasonal employees. Seasonal processing is costly because the processing equipment is used only during the harvest and is idle during the remainder of the year. Due in part to the Food Quality Protection Act, there is an increased need for products containing reduced levels of pesticides. All the above listed problems are serious agricultural issues which were addressed by this project. In these ways this work had a significant impact on the public, the food industry, rural communities, commodity organizations, and farmers. 3. How does it relate to the National Program(s) and National Component(s)? This research is assigned to National Program 306, Quality and Utilization of Agricultural Products. By providing new outlets for underutilized fruit and vegetable materials, the value-added products and technologies developed through this research can enhance long-term viability and competitiveness of U.S. farmers within the global economy. Through the expansion of our knowledge of the structure, properties and function of fruit and vegetable materials, new food, feed and industrial products can be developed. Products developed using our technologies will also diversify the economic base of agriculture and stabilize income streams for farmers. 4. What were the most significant accomplishments this past year? A. Single Most Significant Accomplishment: New product categories are needed to achieve better utilization of fruits and vegetables. At WRRC researchers have created edible fruit and vegetable films as packaging wraps for food products to improve their nutritional profile, extend their shelf life and increase their quality. New technologies for forming edible films from fruits and vegetables were defined and the mass transfer and tensile properties of these films were characterized. Fruit and vegetable edible films offer opportunities to reduce the need for synthetic packaging, improve recyclability, enhance the competitive position of farmers within a global community, and improve nutrition. B. Other Significant Accomplishments: Better utilization of fruits and vegetables will ensure grower and processor stability and increase dietary consumption of fruits and vegetables. ARS researchers in collaboration with a CRADA partner sought to define new product categories meeting this goal. The researchers created a novel, healthy, liquid delivery system made from fruits and vegetables using previously patented ARS restructuring technology. This research will benefit the public through improved nutrition and growers through increased utilization of raw materials and sales of value-added products. C. Significant Accomplishments/Activities that Support Special Target Populations: None. D. Progress report: A significant milestone reached in this research is the demonstration of the essential generality of the technology for restructuring foods. We had previously shown the ability to restructure fruit purees and now have extended the technology to include purees from a variety of vegetable crops. As a result of the high interest in this research we are exploring practical applications of the wrap forming technology and previously developed extrusion technology to create restructured food wraps and objects from fruits and vegetables and are actively involved with a number of interested CRADA and-pre CRADA partners. This involvement involves in-house research using our pilot plant facilities as well as pilot facilities of the industrial partners. This is a new project continuing the efforts of precedent project 5325-42000-032-00D, New Technologies to Increase Utilization of Fruits and Vegetablles as Restructured Products. 5. Describe the major accomplishments over the life of the project including their predicted or actual impact. This is a new continuation project. Major accomplishments of the precedent projects include: (1) A novel combined process utilizing drying in combination with twin-screw extrusion to produce up to 100% fruit and vegetable snack products. A patent on this process has been issued. (2) Novel, shelf-stable, nutritious fruit snacks and fruit/nut health bars using innovative formulation and processing methods including starch molding technologies (3) Novel gel systems containing alginates and fruit purees without any additional pectin, calcium or sugar source (4) Innovative vacuum forming technologies to manufacture final products for use as condiments, snacks or ingredients in salads and baked goods. (5) Successfully completed five CRADAs during its term. Successful implementation of these accomplishments will lead to increased grower markets and improved consumer nutrition. 6. What do you expect to accomplish, year by year, over the next 3 years? FY 2002: Extrusion will be applied for the efficient manufacture of edible films from fruits and vegetables. FY 2003: Commercialization of extruded products is expected. FY 2004: Increased emphasis on technology development of non-food products from fruit and vegetable processing waste materials. 7. What science and/or technologies have been transferred and to whom? When is the science and/or technology likely to become available to the end user (industry, farmer, other scientists)? What are the constraints if known, to the adoption & durability of the technology product? (A) A patent application has been filed on the formed restructured fruit and vegetable products. (B) We are currently negotiating a license for the patent on 100% fruit and vegetable snacks developed through dehydration in combination with extrusion. (C) We are currently working on a CRADA developing a novel, fruit-based liquid delivery system. We are also in the process of negotiating two other CRADAs. (D) Presentations were made to numerous potential industrial partners and commodity groups in the past year. 8. List your most important publications in the popular press (no abstracts) and presentations to non-scientific organizations and articles written about your work (NOTE: this does not replace your peer-reviewed publications which are listed below) (1) Pick and Roll. May 2001. Wired Magazine. (2) Edible Wraps. May 2001. Technology Review. (3) Protection You Can Eat. June 2001. Popular Science. (4) New York Post, Reuters Health, Successful Farming, Capital Press, Self Magazine, Cooking Light Magazine, Explore! Magazine, Mens Health Magazine are a few of the other U.S. based printed press sources which featured stories on this research. (5) ABC Television in Honolulu, BBC Television (TomorrowOs World), Bay TV, KRON and other National Broadcast Channels aired stories featuring our research. (6) NPROs Living on Earth Series, Charles Osgood Radio Show and BBC Radio Science Unit aired radio broadcasts regarding this research. (7) Finally numerous stories have been published in other parts of the world aome of which are Science & Vie (Paris), Packaging News (UK), Il Venerdi di Repubblica (Italy), De Ingenieur (Netherlands) and Asian Food Tech (China).

Impacts
(N/A)

Publications

McHugh, T.H., Mancini, F. Synergistic interactions between alginates and fruit purees for the formation of novel restructured fruit products. Food Hydrocolloids. 2001. Abstract. p. 35.
Olsen, C.W.,McHugh, T.H. Microbial growth during the formation of whey 2001. June. Abstract No. 73D-27.
Olson, D.A., Huxsoll, C.C. and McHugh, T.H. Storage studies on a shelf stable, value added fruit product. Institute of Food Technologists. 2001. Abstract No. 30B-9.