Building a Better Breakfast Cereal - Part One

By Lynn A. Kuntz, Editor, Food Product Design

From childhood, we're bombarded with the message: "Breakfast is the most important meal of the day." But how many of us heed that advice? In these hectic times, we're lucky if we grab a cup of coffee as we rush out the door each morning. Cereal manufacturers keep trying to entice us to linger over the breakfast table by offering elections that not only taste good, but are good for you.

Last year, the United States held the largest share of the cereal market, worth an estimated $10 billion, according to Euromonitor. The attention paid to cereal-box personalities and advertising is enormous, but so is what's inside the box. This is particularly true when incorporating recent health issues into the design.

To build a better breakfast cereal, food technologists find themselves challenged with designing nutritious, highly palatable products at a price consumers can afford. No matter how nutritious the cereal, if it doesn't taste good, most consumers won't eat it. "In the development of healthy cereals, you have to meet certain minimum requirements for taste and texture," says Steve Ink, Ph.D., director of nutrition research, The Quaker Oats Co., Barrington, IL. "In the all-family and kids cereal categories, you have very little trade-off with taste and texture in order to have a successful product. If your cereal is geared toward more mature consumers, then there's a little bit more latitude for offering some taste and texture alternatives."

Grainy focus
Wheat, corn, rice, oats and barley are the major grains used in breakfast cereals. Although many breakfast cereals contain refined grains and sugars, they are fortified with vitamins and minerals. Some question the nutritional value of fortified sugary cereals. In its March Nutrition Action Health Letter, the Center for Science in the Public Interest states: "...Added vitamins don't make a refined or sweetened cereal healthier than an unfortified, whole-grain one."

Some might debate that statement, but nutrition experts agree that whole grains offer nutrients, trace minerals and fiber that help protect against cancer, heart disease and diabetes. "Food manufacturers can start by using the whole grain in designing breakfast cereals," says Judi Adams, R.D., president, Wheat Foods Council, Englewood, CO.

Cereal grains are natural sources of vitamin B6, folic acid, pantothenic acid and zinc. Grains also provide good sources of iron, magnesium and copper. The oils of the embryos of cereal grains are rich in vitamin E. Cereal lipids are relatively rich in linoleic acid, an essential fatty acid. If the protein is protected from damage during processing, it can positively impact the diet, although grains typically lack sufficient levels of the essential amino acid, lysine.

Nutrition experts recommend 20 to 35 grams of fiber a day from whole grains, fruits and vegetables. Studies have shown that soluble and insoluble fiber are dietary necessities. Soluble fiber can lower blood cholesterol, while insoluble fiber helps prevent constipation, diverticulosis, and possibly colon cancer and diabetes. Most whole-grain cereals contain at least 4 grams of fiber per serving. The fiber levels in common whole grains range from approximately 2% (corn) up to 11% (buckwheat).

Read all about it
Although cereal manufacturers continue developing new breakfast cereals, one new angle has been to focus on traditional ingredients with newfound health benefits, such as oats and psyllium. The gold ring is to have FDA-sanctioned health benefits associated with these ingredients approved for labeling. Recently, some products have achieved this status, while others haven't been as lucky:

Oats. The spotlight continues to shine on oats as a heart-healthy ingredient. In January 1997, FDA approved labeling linking oats and good health, a claim supported by more than 30 years of scientific research on the effect of oatmeal on lowering cholesterol.

To qualify for the claim, products must contain 0.75 gram or more of soluble oat fiber (beta-glucan) per serving. This is 25% of the daily 3 gram amount scientific studies have shown helps consumers lower their cholesterol levels. Consumers would need to eat 1 1/2 cups of cooked (or 3/4 cup uncooked) oatmeal to reach the 3 gram target.

General Mills' Cheerios breakfast cereal is effective for reducing the risk of heart disease and for lowering cholesterol, according to a study conducted by the University of Minnesota Heart Disease Prevention Clinic, and published in the January/February 1998 Nutrition in Clinical Care. Eating 1.5 oz. of oat-based Cheerios twice daily lowered cholesterol levels of study participants by an average of 3.8%. Some participants found their cholesterol lowered by as much as 18%.

Besides its ability to lower cholesterol, emerging research suggests that eating oatmeal produces other health benefits. Because oatmeal is sodium-free, it can play a role in reduced-sodium diets for blood-pressure reduction. Oatmeal also may play a role in appetite control. The soluble fiber in oatmeal helps keep people full longer. This may reduce mid-morning hunger and the snacking urge.

Psyllium. In mid-February of this year, following on the heels of oat-related health claims, FDA approved a similar heart health-related claim about soluble fiber from psyllium seed husk. FDA gave the green light to Kellogg Company and other cereal manufacturers to inform consumers that eating a diet with psyllium-containing foods might help reduce the risk of heart disease.

FDA's approval came in response to a petition submitted by Kellogg in June 1996. Independent research conducted during the past 30 years shows that eating four servings of foods daily containing at least 1.7 grams of soluble fiber from psyllium husk, as part of a diet low in saturated fat and cholesterol, reduces total cholesterol by about 5%, on average. It also lowers low-density lipoprotein (LDL) cholesterol by about 9% in individuals with elevated cholesterol levels. The cholesterol-lowering effect translates to a 15% to 20% decrease in heart-disease risk in the population.

Kellogg introduced their psyllium-containing cereal, Kellogg's All-Bran Bran Buds, in 1991. Besides psyllium, the cereal also contains wheat-bran fiber. "You would need to eat 2 1/2 servings of our Bran Buds, or a little less than a cup, to get the benefit from psyllium according to the health claim," says Anthony Hebron, spokesman, Kellogg Company, Battle Creek, MI.

Psyllium husk is extracted by crushing the hulls of psyllium seeds, which come from the Plantago plant, a type of plantain grown mainly in India. This ingredient is able to absorb many times its weight in water, swelling to a mucilaginous mass.

Americans may be most familiar with psyllium-husk fiber in laxative products. Psyllium husk also is used as a minor stabilizer in ice cream and soups.

Wheat bran. In April 1997, Kellogg filed a petition asking FDA to approve a claim linking wheat bran to reduced colon-cancer risk. FDA denied the petition. "We had over 100 studies conducted over 25 years in this submission, but the FDA needs further clinical studies," Hebron says. The benefits of wheat bran can be obtained by consuming either three tablespoons of Kellogg's All Bran cereal or a 1/2 cup of Kellogg's Raisin Bran cereal, company officials say.

With the continuing advances of science, more traditional cereals will likely be viewed as "good for you." Others might have to revise their formulations - either adding or subtracting ingredients, or adjusting levels - to keep up with emerging health studies.

Grain-ola
Manufacturers can add value to products by using specialty grains, which can add new textures, flavors and colors, and provide a more healthful image. Consumers who eat several servings of grains daily can enjoy variety as well as convenience.

Bulgur wheat is a nutritious grain with a nut-like flavor that is a dietary staple in Middle Eastern countries. In the United States, it is gaining popularity in vegetarian entr‰es, salads and side dishes. With its high fiber and carbohydrate content, low-fat Bulgur wheat fits well with the Mediterranean diet.

Although bulgur wheat can be cooked into a nutritious hot breakfast cereal, it's not that popular a breakfast item in this country. As a hot cereal, bulgur produces a product with more particle-size definition, similar to oatmeal. "We need more education about specialty grains like bulgur wheat," says Michael Orlando, president, Sunnyland Mills, Fresno, CA. "Not many people know about bulgur in the U.S. Last year, we successfully made a puffed-bulgur product that has a nutty character, and is very nutritious."

Bulgur wheat is whole wheat steamed to partially cook and gelatinize the starch, before being dried, cracked and sifted. The term "bulgur" refers to this process. "During the cooking process, as the grains begin to hydrate, many of the nutrients migrate from the outer bran layer into the inside of the kernel," Orlando explains. "The starch granules open during cooking, then partially close during the drying process. After this parboiling, we go through a grinding process, where we crack the grain into particles. We sift it and separate it into various particle sizes for different applications. It's important to have very uniform particle sizes so the grains cook at an even rate."

Sunnyland Mills produces four types of premium traditional bulgur wheat, ranging from fine to extra coarse particle sizes. They also offer organically certified bulgur wheat in fine and coarse grinds.

"Several aspects of our processing makes our bulgur wheat unique," Orlando says. "Our product is triple-cleaned. We use white wheat, which has little tannic acid. Bulgur wheat made from red wheat has a slightly bitter flavor from the tannic acid, and takes longer to cook. White wheat makes the best bulgur. It's not only softer, so that it hydrates at a more even rate, but it doesn't have the off-flavors associated with tannins in red wheat."

Besides plenty of carbohydrates, a 40-gram serving of bulgur wheat contains 5 grams of dietary fiber (insoluble), and 5 grams of protein.

Barley represents another grain gaining in popularity due to its health benefits. Although oats have received extensive press on their soluble fiber (beta-glucan) content and effect in lowering serum cholesterol, barley also has beta-glucans effective in this respect. Waxy hull-less barley has 6% to 9% soluble fiber, while hulled barley has 2.5% to 4%. Barley also contains insoluble fiber.

Barley can be used in hot and cold cereals, and is often used in combination with other grains. Various forms of barley can be used in cereals - hulled, pearled, cut or cracked, grits or meal - and can be extruded into various shapes. In hot cereals, quick flakes cook up within five minutes because of their small particle size. In granola or muesli-style cereals, whole kernels, rolled flakes, or cut and rolled flakes can be used.

"Other grains are gaining in popularity, such as triticale, spelt, kamut and even flax," says Rebecca Krueger, Ph.D., technical services director at Innovative Grain Technologies (IGT), Lincoln, NE.

Flaxseed can be added as nuggets to cereals to provide a crunchy texture. Flaxseed, also called linseed, is rich in omega-3 (linolenic) and omega-6 (linoleic) fatty acids. In fact, 57% of flax's fat is omega-3, more than any other plant-derived oil. Flaxseed also contains all eight essential amino acids and twice the total dietary fiber of oat bran. Researchers have found that a diet rich in flaxseed lowers serum cholesterol and triglyceride levels significantly.

IGT manufacturers a whole flax for RTE cereals.
"It is used in health-type cereals," Krueger says. "Although it is high in oil (38%) it's very nutritious. Right now, it seems to appeal to the health-food sector. Cooking improves the taste of flax - after roasting, it takes on a nutty taste." Whole flax also contains about 21% protein and 25% dietary fiber.

Sprouted grains. "The ancient technology of sprouting grains is coming to the forefront," says Robert Serrano, vice president of technical operations, Grain Millers, Inc., Eugene, OR. Wheat ingredients based on controlled malting and kilning (roasting) technology can help food product developers design unique, healthful cereals. Sprouted and kilned wheat flakes, wheat nuggets, meals and flours also can help manufacturers save money by reducing the amount of sweetener used when formulating granola, muesli and other RTE cereals. The rich, malted flavor notes and toasted color notes can enhance RTE cereal formulations by using meals and flours at amounts between 2% to 6%, based on total weight.

"Through the sprouting of grain, nutrients become more bioavailable and they are easier to digest," Serrano says. Sprouted and kilned wheat products can be used in formulating cereals for those with special nutritional needs, including infants, the elderly and athletes. "Good-tasting germinated cereal grains will play a significant role in the development of functional foods for the next century."

Rice extract. Food product designers are always seeking label-friendly ingredients. In the cereal industry, processing can require the use of oils, mono- and diglycerides, gums or lecithin to facilitate extrusion. An ingredient extracted from rice bran can help manufacturers reduce downtime during extrusion by reducing stickiness and die-plugging. Corn and crisped rice, for example, can be difficult to extrude.

"Our ingredient can be labeled as 'rice extract,' when it is used as an ingredient," says Steve Peirce, president, Ribus, Inc., St. Louis. "If it is used as processing aid, no label is required. The rice extract has everything rice bran has in it, except the fiber.

"Rice bran has B vitamins, antioxidants, trace minerals and other nutrients," he explains. "Although fiber is removed from the functional ingredient initially, we can customize the amount of fiber and nutrients to suit a specific application.

"If you are doing a honeycomb-shaped cereal or something that has a definite shape, we can reduce the bulk density, which makes it puff larger. However, we can also give it a more definite shape as we reduce the bulk density. A box of cereal looks fuller, and is actually fuller, although you've got the same amount of weight in it. The rice extract can be used at 0.5% as a processing aid. As an ingredient, its use ranges from 1% to 1.5% on a dry-weight basis."

Nutritious maximus
Processing can destroy valuable nutrients in cereals. "In order to maximize nutrients, our process uses the whole grain," Krueger says. However, the highly unsaturated fat, which is located in the endosperm of grains, has a tendency toward rancidity. "In our processing of grains, we inactivate the lipase enzymes that could cause rancidity. Denaturing the enzymes helps extend shelf life." Some manufacturers separate the various parts of the grain to avoid rancidity, and then recombine them after removing some, or all, fat.

Roasting cereal grains helps impart a better flavor. Roasted flavors are popular in cereals and snacks and other foods. "We use a dry-roasting process to maximize the nutrients," Krueger says. "Our process involves heating only for short periods of time. Also, our process effectively lowers the microbial load of our raw materials." IGT uses a patented infrared process to reduce microbes and lower enzyme activity in grains.

A cornucopia of health
In addition to the old standbys, new healthful ingredients also should be considered for cereal formulation. For example, inulin and oligofructose have been tested in cereals. They are reported to improve extruded products and increase cereal bowl life. In the gut, these ingredients promote the growth of beneficial bacteria.

Traditional items - such as nuts, fruit bits and pieces, and nuggets made from various grains - can add visual and health appeal to breakfast cereals. These can add fiber, vitamins and minerals, pushing up the nutritional content without increasing the level of fortification blends.

Dried fruits can supply additional nutritional enhancement in the form of phytochemicals. Although the science is still in its infancy, many researchers have found links between health benefits and substances occurring in fruits at minute levels. Some of these include: grape resveratrol and heart disease; blueberry anthocyanins and eyesight; and citrus bioflavonoids and vitamin C absorption enhancement.

Nuts contribute fiber (approximately 5% to 11% of the nut) and protein (10% to 25% of the nut). They also can add vitamins B6 and E, iron and potassium. While they do contain significant fat levels, this doesn't mean they're inappropriate in a healthful product. First of all, the fat content of the total cereal can remain relatively low if the level of nuts doesn't rise too high. Since nuts are more expensive than grain ingredients, it's likely economic limitations would prevent companies from adding a high level of nuts, thereby preventing excessive fat levels in cereals. Secondly, the type of fat in most nuts - monounsaturated and polyunsaturated - may reduce blood cholesterol levels, and protect against heart disease. Walnuts have this effect, according to a study by Loma Linda University, Loma Linda, CA, published in the New England Journal of Medicine in 1993.

Fiber
As mentioned, fiber is an important dietary component. Recent studies show it may play a role in fighting several diseases.

Cancer. Many studies show a link between lower fat and high fiber consumption and reduced incidence of colon cancer. One 1992 study conducted at Harvard Medical School found that men who consumed 12 grams of fiber a day were twice as likely to develop pre-cancerous effects in the colon as men having a daily fiber intake of about 30 grams. Experts believe that insoluble fiber adds bulk to stool. This decreases the level of carcinogens and decreases the time spent in the digestive tract. Other studies have linked high fiber diets to the reduction of breast cancer, but this connection is still under debate.

Diabetes. Soluble fiber slows carbohydrate digestion and absorption. This may help control blood sugar levels. A Harvard School of Public Health study, published in February 1997 issue of The Journal of the American Medical Association, found that a high-sugar, low-fiber diet more than doubles women's risk of Type II (non-insulin-dependent) diabetes.

Digestive disorders. Insoluble fiber aids digestion by adding bulk, and increasing gut transit time. This can help prevent constipation and may help reduce the risk of diverticulitis.

Heart Disease. Soluble fiber binds to cholesterol in the gastrointestinal tract, which reduces blood cholesterol levels. Soluble fiber also may slow the body's production of cholesterol and make LDL particles larger and less dense. These larger particles may be less damaging than the smaller, denser ones.

Obesity. Fiber provides bulk and reduces calories. Insoluble fiber is indigestible and generally considered to have no calories. Many types of soluble fiber contribute less than 4 calories per gram and inhibit fat absorption.

Whole grains, fruits and nuts need not be the only source of fiber in a breakfast cereal. Addition of ingredients with significant fiber content might allow label claims of "good source of fiber" (at least 2.5 grams per serving) or "excellent source of fiber" (at least 5.0 grams of fiber).

Ingredients that supply high levels of fiber include: pectins and many gums, cellulose, psyllium seed husk, oat hull fiber, citrus fiber, pea fiber, corn bran, and soy polysaccharide. The fiber content ranges from 60% to +90%, depending on the product used. In addition, certain lower-molecular-weight carbohydrates are not completely digested by humans. These include sugar alcohols, such as sorbitol and mannitol, polydextroses and fructooligosaccharides. However, if these materials do not analyze as dietary fiber by Association of Official Analytical Chemists methods, FDA requires they be labeled as "other carbohydrates" rather than dietary fiber.

When choosing a fiber for incorporation into a breakfast cereal, several factors (in addition to fiber content) affect the outcome. These include: particle shape and size, flavor, appearance, water-binding ability as well as physical effects on the mixing and forming process, whether extrusion, flaking or moulding.

Click here to read Building a Better Breakfast Cereal - Part Two.

Photo: National Starch and Chemical Company
Photo: Grain Millers, Inc.

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