A recipe that works well in a test kitchen may not work in a production facility when ingredient specifications change. Minor changes in moisture levels, proteins, particle size, enzyme activities or functionality can significantly influence the mixing, texture, processing time, yield and overall quality of the product.
Thus, the task is no mean feat for food manufacturers since it calls for expertise and knowledge of how the ingredient fits into the overall formula.
Why Ingredient Specifications Change
There may be several causes for changes in ingredient specifications. Seasonality, availability of raw materials, logistics, and supplier changes may affect raw materials; agricultural conditions may affect the characteristics and behavior of the crops.
Consider flour as an example. Protein, moisture content, ash content, and enzyme activity are some key quality parameters; however, they do not always give the complete picture. Functional aspects such as water absorptivity, dough behavior, and mixing tolerance of flour may affect its manufacturing behavior.
Thus, it may be noted that two batches of flour with identical specifications may have different performances in a commercial process.
1. Start by Understanding the Specification Change
It is important for manufacturers to know exactly what has been altered in the formula and whether the alteration is within the specification range.
Concerning flour ingredients, some of the parameters include:
- Protein Content: Influences gluten development, dough strength, and product structure.
- Moisture: Can affect ingredient stability, solids content, processing, and hydration requirements.
- Ash: Can influence flour color, extraction characteristics, and the appearance of the finished product.
- Enzyme Activity: Can affect starch breakdown, fermentation, and crumb characteristics.
- Water Absorption: Determines the amount of water required to achieve the desired dough consistency.
- Rheological Properties: Provide information about dough strength, elasticity, extensibility, and handling characteristics.
A certificate of analysis (COA) must be compared against the manufacturer's approved specification and not just the commercial name of the ingredient. The American Society of Baking (ASOB) indicates that the specifications of flour may include analytical and functional tests, including farinograph, alveograph, falling number and particle-size measurements.
2. Determine What the Ingredient Does in the Recipe
Ingredient specifications can change for several reasons, including seasonal variations, raw material availability, agricultural conditions, logistics, and changes in suppliers or production processes. These factors can influence the characteristics and functional performance of raw materials.
Flour is a good example. Protein content, moisture, ash, and enzyme activity are important quality parameters, but they may not provide a complete picture of how flour will perform in production. Functional characteristics such as water absorption, dough behavior, and mixing tolerance can also affect processing performance.
As a result, two batches of flour with similar analytical specifications may still perform differently in a commercial production environment.
3. Adjust the Recipe Systematically
Trial and error is not an efficient approach in recipe modification.
Producers could begin with the component that is influenced the most by the changed specification. If moisture or water absorbency in the flour changes, then water should be modified first (if the moisture content in the flour changes, the water should be adjusted). Process variables or flour blend modification may have to be considered if protein/gluten functionality changes.
The following may be some modifications:
- Water or other liquid levels
- Mixing time and intensity
- Resting or fermentation time
- Ingredient ratios
- Baking temperature or time
- Dough processing conditions
- Use of functional ingredients
- Production or process speed
It is not necessary to make the new ingredient behave exactly like the old one. The objective is to bring back the specific quality properties of the finished product.
Validate Changes Through Controlled Trials
After the suggested adjustment to the formulation is made, it is advisable that manufacturers conduct structured experiments before introducing the adjustment into the market.
There should be comparison experiments conducted to measure certain criteria using the original formulation and the new adjusted one. These measurements differ from one product to another and include things like dough consistency, loaf volume, texture, colour, moisture content, weight, yield, shelf life and other sensory properties.
Pilot testing is highly recommended when dealing with large volumes of products, as the processing conditions under laboratory settings do not represent those in a commercial plant.
Manufacturers should include the formulation, lot, COA, conditions of processing and the experiment results to document the change. This will help quality and research and development team members deal with the next change of the specification more effectively.
4. Consider Labelling and Regulatory Implications
Changes might not only affect the product when a modification is done to the formula. If an ingredient is replaced or changed for whatever reason, then companies need to examine their ingredient declarations, allergen information, nutrition information and all other labelling requirements.
In the United States, major food allergens must be declared in accordance with applicable FDA labeling requirements. Changes to ingredients or formulations may also affect ingredient declarations, allergen information, nutrition labeling, and other regulatory requirements.
Therefore, prior to an ingredient being modified in production, communication between the procurement, R&D and QA departments is crucial.
5. Build Flexibility into Ingredient Specifications
One effective way of doing this is through specifications according to the performance of the product and not just one number.
Manufacturers would do well to develop specifications for flour that consider the protein, moisture, ash, enzyme activity and functionality of flour, as opposed to considering flour in terms of protein content only. Specifications should be according to the product and should not argue that one specification of flour works for all products.
This will give the manufacturers flexibility while buying, without affecting their products' consistency.
The key to Consistency is the Ingredient
This is not untrue because specifications of ingredients can indeed differ, but consistency can always be achieved through proper testing, modification of formulations, and forging of supplier ties.
For businesses that depend on flour, New England Flour provides flour solutions for specific applications that will help manufacturers remain consistent.
