There are no simple changes
“Reformulation requires much more than removing or replacing a specific
ingredient. It demands a thorough understanding of the underlying science”- Dr
Steven Walker.
Dr Steven J. Walker is Director General of Campden
BRI. For more information visit www.campden.co.uk.
As leaders in the field of food science and technology, all of us at Campden
BRI know that seemingly simple changes to recipes can have significant
consequences for product safety, quality and manufacturing.
Product
reformulation
has to anticipate and allow for these changes. It demands of manufacturers and
their advisers a full understanding of the science of the product and the
technology
of its production. Anything less than this can pose serious risks.
Salt, for example, has a preservative effect: at appropriate levels it can
prevent
or reduce the growth of problem microorganisms. Sophisticated computer
models can predict the effect on shelflife of changing salt levels. By reducing
the salt in ham from 3.7% to 1.9%, for example, the time taken for an
observable
increase in the level of Clostridium botulinum falls from 22 to 9 days.
So, if
salt is taken out some other strategy for product preservation and safety
assurance
is needed. In other instances, changes may reduce the 'use by' date, thereby
increasing costs and potentially increasing wastage.
Whilst very useful, this 'predictive' approach is not by itself sufficient. It
would usually be followed with experimental assessment, in which reformulated
prototypes are 'challenged' with the micro-organism of concern under
appropriate
conditions to assess actual
microbial growth. The planning, execution and interpretation of such trials
demand
significant scientific and technical expertise.
Whilst fat does not have a preservation effect, its replacement with a
substitute
can affect the water available to microorganisms (water activity) which can
be important in preservation. Other ingredients influence product pH, which
also helps control microbial growth in many products.
Product safety is assured through the process of HACCP (Hazard Analysis
Critical Control Point), which helps ensure that hazards are controlled. Any
change to
a product's formulation or process requires a thorough review of the HACCP plan
–
to ensure that safety is not inadvertently compromised. This again demands
scientific, technical and operational expertise.
Reformulations can also have consequences for the mechanics of
processing. While bread is not particularly high in salt, it is part of our
staple diet
and so contributes to dietary salt intake.
However, reducing salt not only influences bread flavour, texture and
appearance,
but can significantly increase dough stickiness. This poses potentially major
complications for the equipment used in
dough production.
Maintaining product quality is another important aspect of reformulation. Some
10 years ago research demonstrated significant consumer resistance to lower
fat bakery products: they were felt to be of poorer quality, were more
expensive
and
the achievable fat reduction was small. It has taken extensive formulation
trials,
in which fat was replaced with starch for example, to establish ways of
producing
appealing cakes with significantly less fat and calories.
When products have been reformulated, care has to be taken with product
labelling,
to ensure compliance (for instance with nutrition claims regulations) and to
avoid
consumer confusion (for example, by not updating cooking instructions).
In short, reformulation almost always requires much more than removing a
specific ingredient or replacing it with a substitute. It demands a thorough
understanding of the underlying science and technology, and can require
significant
research and development to avoid compromising product safety and quality.
More information
Last reviewed: 06 Jul 2009