Accelerating ingredient replacement with predictive tools [Interview]

Manufacturers not only have to deal with complex supply chain issues; they must also pay attention to the regulatory environment as well as evolving consumer demands. All this places considerable pressure on time and resources and makes reformulation and the development of new products a challenging process.

Indeed, there is currently a lot of pressure on manufacturers to deliver clean-label products that appeal to consumers looking for safe, natural solutions. For many brands, this means having to reformulate.

“Changing the materials in a formulation is always quite a tough thing to do,” says Renata Negrini, technical service manager of food at Omya. “This often requires costly testing at pilot or production scales.”

Predictive tools to expedite ingredient trials

To address this, minerals and speciality ingredients supplier Omya is using predictive laboratory tools to expedite ingredient trials and help brands to reduce overall costs. At Fi Europe, Negrini will show how the company is applying Freeman Technology's FT4 powder rheometer to evaluate anti-caking agents to enhance flow and prevent caking in food products.

“We have a lot of experience in powder processing,” explains Negrini. “If you are a customer, you can bring your existing product, along with your existing anti-caking agent to us, and highlight any production line problems you might be experiencing.”

Omya can then run lab tests using this predictive technology to identify optimal anti-caking ingredients and offer a comparison to existing solutions being used.

“We have a range of naturally sourced non-nano minerals that can be tailored to improve flowability and prevent caking on food powdered matrices such as spices and seasonings, dairy and non-dairy, sports drinks, and bakery mixes,” says Negrini.

“Instead of just being a supplier however, we also offer this technical expertise and support. This enables brands to see how their finished product would actually look like and behave with new ingredients. We lower the risk for manufacturers engaged in reformulation, and we lower the cost.”

Applying predictive technologies at the very beginning of the supply chain can also help manufacturers ensure that they are on the right track from the beginning, by optimally aligning their production processes to ensure coherence and efficiency.

Sustainable solutions for today’s consumers

Typical end-users include food and beverage companies that use powered products, which can range from spices to whey proteins. Omya’s portfolio of non-nano solutions includes functionalised calcium carbonates, with customised particle sizes and porosity.

“Another key point we’ll be sharing at Fi Europe is how powdered products can help businesses be more sustainable,” says Negrini. “Longer shelf-life means less food waste. As a result, this is a sector that is attracting growing consumer interest.”

In the EU, over 59 million tonnes of food waste is generated every year, with an associated market value estimated of EUR 132 billion.

Omya can also help manufacturers achieve greater sustainability through natural calcium fortification and white pigment solutions. The company's product range includes high-purity natural calcium carbonates that are produced with a lower carbon footprint, meeting the growing consumer demand for environmentally friendly innovations.

“At Fi Europe, we’ll be discussing how we, as a raw material supplier, can offer sustainable solutions that reduce costs for manufacturers, and meet consumer concerns,” says Negrini.

You can find out more by attending Omya’s presentation at Fi Europe, entitled ‘Development of predictive tools for ingredient replacement: an example of caking and flow properties of food powders.’