Product Reformulation
21 Strategies for Food Reformulation
To produce healthier food, the food industry is challenged to change the formulation of their foods, that is, they are encouraged to reformulate their foods. From a nutritional point of view, the emphasis on food reformulation is mainly on sugar and salt reduction.
Changing recipes has large effects for the food industry. Originally, salt and sugars were added not only for taste but also to preserve fresh foods and to lengthen shelf life. By adding sugar and salt, osmosis is used to dehydrate foods, thereby preventing the growth of bacteria and fungi.
Foods that are reformulated can only be a success if consumers buy them. So, food technologists are developing strategies on how to produce foods that taste similar and are equally liked by the consumer. The products that have the greatest impact are the products that are consumed by a large part of the population in large quantities and therefore deliver a substantial contribution to intake.
lowering salt
Bread, meat products, cheese, and ready-to-eat meals have the largest contribution to salt intake in the Netherlands. In the Netherlands, great effort has been put into lowering salt levels in bread without informing the public. This has been a great challenge as salt also has a function in yeast activity, strengthening the gluten network, and thus the airiness of the dough. It has been argued that optimal salt concentrations can be shifted by lowering the intensity of salt very slowly. That is, preferences for salt concentrations shift when people are gradually exposed to lower levels of salt.
Other strategies include replacing NaCl for KCl, however, a downside to this is that KCl has a slight metallic aftertaste. Other options are to make use of the multimodal nature of our sensory systems and add aroma or other tastes to mask the lower salt levels.
lowering sugar
Sweetness is an inborn preference, and it is unclear if sweetness preference can be changed by gradually lowering the exposure to sweet tastes. Several alternatives to replace sugar exist, for example non-nutritive sweeteners.
For sugar, the foods that have the highest impact on consumption are sugar-sweetened beverages (SSBs), dairy, bakery products, and confectionery (cookies/cakes/sweets). Like salt, sugar has other functional roles in foods, for example, during heating it forms flavours and gives colour to foods (Maillard reactions), it provides viscosity and mouthfeel, affects the gluten network in bakery products, and it also provides bulk (volume).
Lowering saturated fat
The Dutch Government and the food industry have set maximum limits for saturated fat in food products. The maximum intake limit for saturated fat, as recommended by Dutch dietary guidelines, is less than 10% of total energy intake. These limits vary by product category. For example, the specific target for the food group processed meats is set at a maximum of 5 grams of saturated fat per 100 grams.
The Dutch National Institute for Public Health and Environment (RIVM) monitored these levels and found that, compared to 2018, the saturated fat levels in some cold meats, like meat loaf and liver sausage, have decreased. On average, 86% of food products had saturated fat levels at or below the maximum limit[1].
effect of reformulation
Food product reformulation can change taste, texture, aroma, and appearance, potentially affecting consumer acceptance. Sensory testing is important to ensure the reformulated product still meets consumer expectations. In the following Video 10, the consequences of product reformulation for a business are explained.
Video 10. Consequences of product reformulation in a food company.
Example 8 – Protein transition
The protein transition, which involves shifting from animal-based proteins to plant-based alternatives, impacts the sensory properties of people’s diets.
Meat replacers are designed to mimic the sensory properties of meat, including taste, texture, and appearance. Challenges in designing meat replacers mainly lie in these three areas. Meat analogues often use flavourings and seasonings to replicate the umami flavours of meat. Ingredients like soy, wheat gluten, and pea protein are commonly used, and they are often combined with flavours to enhance the meat-like taste.
Another focus is creating a fibrous and juicy texture similar to meat. Methods like extrusion cooking and the addition of binding agents are applied to achieve a meat-like texture. Additionally, some products include fats to replicate the mouthfeel of animal fat.
Visual appeal is an important factor for consumer acceptance. Meat replacers are often coloured with natural ingredients like beet juice to replicate the red colour of raw meat and the browning effect when cooked.
Legumes and vegetables can also be used as a replacement for meat in the protein transition, but do not aim to mimic meat. However, the sensory properties and nutritional value of legumes and vegetables are very different to those of meat products. For example, legumes like lentils, chickpeas, and beans have been described to have distinct earthy and nutty flavours. Furthermore, the taste of legumes and vegetables can be described as neutral, whereas the taste of meats and meat replacers are usually described as savoury. However, preparation methods and seasonings can enhance savoury taste of legumes and vegetables.
Example 9 – Fermentation
Fermentation is the process of growing a microorganism on a feedstock (raw industrial material) to convert the feedstock into the desired products. Fermentation not only enhances the sensory properties of food but also often improves its nutritional value by increasing the availability of vitamins and minerals.
Sensory properties of food that can be enhanced by fermentation are, for example, taste, texture and aroma. Taste enhancement can be achieved via the introduction of microorganisms that produce enzymes and metabolites, which break down food components into simpler compounds. For example, lactic acid bacteria in yogurt produces tangy flavours, while yeast in bread and beer contributes to savoury taste.
Fermentation can also reduce undesirable off-taste, as it can decrease the bitterness in some legumes and vegetables, making them more palatable. Texture can be improved by fermentation, for example, rising of yeast dough results in the production of carbon dioxide, which makes bread light and airy. Aromatic compounds can be produced by microorganisms, producing volatile compounds that contribute to the aroma of the food. For example, the fermentation of cocoa beans for chocolate production develops a complex aroma profile.
Examples of fermented foods can be found in multiple food groups:
- Dairy products: yogurt, cheese or kefir
- Beverages: beer, wine or kombucha
- Vegetables: sauerkraut, kimchi or pickles
- Legumes: tempeh, miso, soy yogurt
- Grains: sourdough bread, coffee or cocoa
- Steenbergen, E., Wilson-van den Hooven, E. C., ter Borg, S., Brants, H. A. M., Niekerk, E. M., Lindeboom, A., ... & Milder, I. E. J. (2021). Zout-, verzadigd vet-en suikergehalten in bewerkte voedingsmiddelen. RIVM Herformuleringsmonitor 2020. ↵
Extrusion cooking is a food processing technique where mixed ingredients are forced through an opening in a perforated plate, using a machine called an extruder. This process involves high pressure and temperature, which cooks the food as it is pushed through the perforated plate