DCDÒ Butternut soup pilot project proves case for how modern technology is increasing nutrition, shortening processing chains, incurring no waste and generating better economics – whilst feeding the hungry
COVID-19 and subsequent economic lockdowns, have accelerated the road to hunger for many – the world over. In South Africa, the need to access affordable sustenance, has significantly increased. Accessing nutritious foods that are easily afforded, is a different matter… until now.
Providing a workable solution applicable to all food security scenarios world-wide, bio-technology company, Green Cell Technologies® (GCT®) manufactured the soup using their unique patented process, Dynamic Cellular Disruption® (DCD®) and Disruptor™ technology. GCT has now substantially proven that it is able to feed more than the proverbial 5000 with healthy and tasty food that does not cost the earth.
Introduction and Background to DCDÒ
Molecules found in cellular structures of meat, fruit, vegetables, berries, nuts, and seeds provide sustaining nutrition to achieve good health and wellbeing. Those molecules represent a comprehensive – across the spectrum – variety of all the macro and micronutrients necessary for human beings (and animals) to flourish.
However, current food and beverage processing methods kill off molecules that provide nutrition by using incorrect heat, generating oxidative stress or enzyme action etc, thereby removing their efficacy, and thus only achieving bulk or a sense of satiety but, not much nutrition. Additionally, these existing methods cannot easily and effectively process skins and seeds (which contain significant nutritional properties), or radically reduce the fibre particle size to a level that will not upset the organoleptic sensibilities of the consumer. Therefore, a conventional processor ends each day with not only a large pile of waste, which impacts the environment but, also a product that has a vastly reduced nutritional profile. Ironically, the waste represents the majority of the raw material molecules that are required for optimal nutrition. The waste also represents most of the fibre, which if ingested, would aid other nutritional and health benefits but instead, leaves consumers fibre deficient.
Food and beverages can now be processed through a patented method called DCDÒ utilising a piece of technology – the Disruptor™. Disruptor technology deploys a non-thermal, non-chemical process that opens 99.999998% of all cell structures. During the DCD process, other than pipe loss, which is the same volume irrespective of the production size, there is no waste product and the plant material is used in its entirety. DCD renders bio-available, all the molecules for the body to utilise. DCD does not manufacture molecules but instead, extracts what is available within the cell structure – more efficiently. This is from the source material and therefore, outcomes are wholly reliant on the source material itself.
DCD also reduces microbiological contaminants, yeasts and moulds found in source materials. Therefore, the product that has passed through the Disruptor will show improved microbiological cleanliness.
In short, the DCD process and Disruptor technology increase the available nutrition per serving, reduce particle size and waste, which has a positive impact on the consumer as well as the environment. The increased extraction of molecules signifies an increase in yield, and with the utilisation of what would normally be considered waste, has a positive economic impact on the processing value chain.
Conventional versus DCD processing: Butternut Soup
Conventional manufacturing of butternut soup entails after washing of the materials, the skinning, seed removal and cutting up of the butternut, which is then put into a large pot to boil for several hours in order to soften the butternut to make it edible. This is labour, time and energy intensive and generates waste that still needs to be managed. In short, in one soup kitchen we are conducting production trials for, it takes three hours to produce 300kg of soup and they do that three times a day.
However, butternut soup manufactured through DCD and Disruptor technology (in the pilot plant – it should be noted that full commercial Disruptors offer higher throughput options), may process at a rate of 600kg/hour, therefore 1800kg for the same time as described above. In a soup kitchen scenario, there would be no waste, all that is required is to pour the prepared soup into the pot, augment as required (water to dilute, seasoning additional ingredients etc.), heat and serve with all the benefits as described in the “Introduction and Background” above.
Butternut soup testing methodology
To show that DCD and Disruptor technology adds value to food and beverage manufacture, as opposed to conventional processing methods, samples were taken of the pre-DCD and post DCD soup material and sent for the following tests at accredited commercial or academic laboratories:
- University of Stellenbosch for pre- and post-DCD amino acid profile measurement.
- SGS laboratories for pre- and post-DCD microbiological and heavy metal measurement.
- Hearshaw and Kinnes for pre- and post-DCD pesticide residue measurement.
Phyto-Chemistry test results: Amino Acids (protein)
The test report as from the University of Stellenbosch, an internationally recognised academic facility, measured proteins as a marker to show improvement using DCD and Disruptor technology, because it is one the most important building blocks in the human diet. The report shows an average protein increase of 132.7%.
This translates into using less raw material to achieve the same level of nutrition, which promotes food security as well as improved nutrition for the consumer. One needs to also consider that ordinarily, 40% of a butternut is discarded (that is 400kg for every ton processed), which is now all in the soup and therefore a much higher fibre content is included, which promotes amongst other benefits, bowel health – normally absent from fruit and vegetable extractions.
Also consider 40% of so-called ‘waste’ is added back into the soup, which is mostly fibre, and despite that diluent effect, the proteins are still measuring 132.7% higher.
These results prove that there is a substantial increase in the extraction and release of phyto-chemistry from the source material using DCD and Disruptor technology.
Microbiological test results
The test reports from SGS, a SANAS and internationally accredited laboratory, measured total plate count for microbiological activity, yeasts, and moulds. It found that there was a 700-fold decrease in total plate count from 420000cfu/g to 600cfu/g between the pre-DCD and post-DCD samples. It also reduced yeasts and moulds to “not detected” from 5200cfu/g and 80cfu/g, respectively.
This is a significant improvement – as a direct result of utilising the Disruptor – bearing in mind that food standards require results to show less than 10000cfu/g and 100cfu/g for total plate count and yeasts/moulds, respectively (this does differ region to region).
This result proves that DCD and Disruptor technology have a positive effect on the reduction of microbial activity in the source material.
Heavy metal test results
SGS’s, test reports measured heavy metals typically tested for food and beverage production safety, those being, Mercury, Cadmium, Lead, and Arsenic. All the results are < 0.01 mg/kg where normal production (depending on source) will allow < 3mg/kg, <1mg/kg, <0.1mg/kg and <3mg/kg, respectively. There is no difference from pre-DCD to post-DCD proving that DCD and Disruptor technology do not increase the prevalence of heavy metals.
Pesticide residue test results
Hearshaw and Kinnes (H+K), a SANAS accredited laboratory, test, measured for residual pesticides in the butternut soup samples. They found Benzalkonium Chloride at a residue rate of 0.70 mg/kg and 0.40mg/kg from pre-DCD to post-DCD respectively. The decrease of about 42% is indicative of the inclusion of all the butternut skins and seeds, which has diluted the residue measured proportionately.
H+K also tested for approximately 250 other residual pesticide compounds of which, none were detected above their reporting limits.
The Benzalkonium Chloride is a compound found in the South African Bureau of Standards (SABS) approved sanitisers, disinfectants, and detergents that RWH is mandated to use as per ISO 22000:2018 certification requirements, to effectively achieve Clean in Place (CiP) in processing spaces. The Material Safety Data Sheets are attached as at Appendix 7, 8, and 9, proving their SABS compliance.
The Lethal Dose Median (LD50) for Benzalkonium Chloride is 240mg/kg, which would mean that a consumer would need to ingest 600kg of the butternut soup concentrate in one sitting for there to be a 0.5 probability of any toxic effect. This is shown to be more improbable if one considers that the concentrate processed using DCD and Disruptor technology, is diluted on average, four times, which means that a consumer would typically have to ingest 2400kg of soup in one sitting for there to be a 0.5 probability of any toxic effect.
This proves that DCD and Disruptor technology does not release or increase any additional pesticide residue and the soup is safe for human consumption. In fact, it further shows that DCD and Disruptor technology reduces residues due to dilution of added so-called ‘waste’ material.
Conventional processing of food and beverage consumer products does not efficiently extract nutritional compounds, it produces substantial waste, which is typically the goodness, and reduces fibre in the final product as compared to DCD and Disruptor technology.
DCD and Disruptor technology will reduce microbial loading and save preparation time in feeding/soup facilities. This means that the feeding facility will be able to serve more people and more often, which is enhanced productivity and promotes food security, than the same amount of source materials processed using conventional means.
The testing of the butternut soup has shown that there is a substantial release in protein and one can deduce that this will extend to other phyto-chemistry as well. The butternut soup is microbially and heavy metal clean and fit for human consumption. It can also be concluded that DCD and Disruptor technology does not release additional heavy metals and pesticide residues.
Given that producers, such as Citrosuco (the world’s largest orange product manufacturer), are deploying DCD and Disruptor technology and who have shown that this process and technology can be used with no side effects in the manufacture of products for consumers, it can therefore be concluded that this technology is suitable for providing products to soup kitchens to feed the needy – and beyond.
Looking beyond, Green Cell Technologies explain that the technology can process most all raw materials that can promote true nutrition, whilst negating food insecurity.
The full dossier is available at www.greencelltechnologies.com
Innovations in Food (& Beverage) Processing & Packaging is a quarterly magazine distributed globally both in Print and Digital formats. www.innovationsfood.com. Twitter: @Innovfoodtech. Instagram: @innovationsinfoodtechnology. Linkedin: www.linkedin.com/in/terry-prior52