• Skip to primary navigation
  • Skip to main content
Patric Chocolate Logo

Patric Food & Beverage Development

Food Scientist with a Chef's Palate

  • Home
  • About
  • Services
  • Learn
    • All Articles
    • SCIENCE
    • CRAFT
    • BUSINESS
    • Case Studies
  • Free eBook
  • Contact
Show Search
Hide Search
Articles / product development

product development

Functional Beverage Formulation: When Protein, Fiber, Electrolytes, and Actives All Have to Work Together

September 15, 2026 by Kristen Nicoletti

A functional beverage can look deceptively simple from the outside. There is water. There is flavor. There are a few ingredients with impressive résumés. Protein does one thing. Fiber does another. Electrolytes handle hydration. Magnesium, amino acids, botanicals, or other actives arrive carrying their own list of promised benefits. Put them all together and, in theory, you have a better beverage. Except chemistry does not care about your marketing plan.

The moment those ingredients enter the same bottle, they stop behaving like independent items on a formulation sheet and start behaving like members of the same physical and chemical system. They influence one another. They change the environment around one another. And occasionally they make it very clear that nobody asked whether they wanted to coexist in the first place. That is where functional beverage formulation becomes interesting.

A beverage is a system

Consumers increasingly want beverages to do more than provide refreshment. Hydration may now be combined with protein, fiber, digestive-health ingredients, vitamins, minerals, amino acids, botanicals, or ingredients associated with energy, relaxation, and mood. That makes perfect sense from a product-positioning standpoint. If someone is going to buy a beverage anyway, why not give them several useful functions at once?

The formulation problem begins when we assume those benefits can simply be stacked on top of one another. A beverage is not an empty container into which ingredients can be dropped without consequence. It is a chemical environment defined by pH, temperature, water activity, dissolved solids, ionic strength, processing conditions, and the interactions among everything inside it. Change one of those variables and you may change several others.

Add protein, and now pH matters differently. Add minerals, and the protein may behave differently. Add fiber, and viscosity may change. Change viscosity, and flavor perception can change. Add an active ingredient with a strong bitter note, and suddenly the flavor system has a new job. This is not four separate problems. It is one interconnected problem.

Protein is not just protein

Protein is a useful place to begin because it demonstrates how quickly formulation becomes contextual. It is easy to say that a beverage will contain ten, twenty, or thirty grams of protein. It is harder to answer what happens to that protein after everything else is added. Proteins respond to their surroundings. pH, heat, mineral concentration, hydration, and processing conditions can all influence whether a protein remains dispersed, thickens, aggregates, or eventually settles.

Minerals make this particularly interesting. Calcium, for example, can interact with protein systems in ways that alter viscosity and stability. Add magnesium, potassium, sodium, or other electrolyte salts and the ionic environment changes again.

So, the useful question is not, “Does this protein work in beverages?” The useful question is, “Does this protein work in this beverage, with these minerals, at this pH, under this process, for the entire intended shelf life?” That one extra sentence contains most of the real formulation problem.

Fiber changes the physics

Fiber introduces a different kind of complication. Depending on the source and concentration, fiber can affect water binding, viscosity, suspension, mouthfeel, and flavor perception. Some fibers integrate relatively quietly. Others make their presence known. They can produce thickness, dryness, chalkiness, particulate texture, lingering mouthcoating, or simply make a beverage feel heavier than the concept was supposed to be. If you are formulating a shake, that may be perfectly acceptable. If you are formulating something that is supposed to drink like flavored water, it is a very different story.

This is one of the recurring tensions in functional beverage development. The amount of an ingredient required to support the desired benefit may not be the amount that produces the desired sensory experience. Chemistry and marketing are often negotiating with each other at this point.

Electrolytes come with flavor

Electrolytes may be familiar to consumers, but from a formulation standpoint they are not merely invisible sources of nutrition. Mineral salts taste like things. Some potassium salts can produce bitterness, metallic notes, or chemical character. Magnesium salts can be extremely bitter. Calcium sources can bring their own sensory effects. Even two different salts supplying the same mineral may behave differently in terms of solubility, taste, stability, and cost.

That means an electrolyte system cannot be developed in isolation from the flavor system. You can formulate a beverage that hits every mineral target beautifully and still produce something nobody wants to finish. Technically correct is not the same thing as commercially successful.

Actives complicate things further

Now add botanical extracts, amino acids, vitamins, peptides, or other functional ingredients. Many of these were not selected because they are delicious. They may be bitter, grassy, earthy, astringent, metallic, medicinal, or some combination of the above.

The first instinct is often to mask those characteristics. Sometimes that works. Sometimes it simply moves the problem. More sweetness may suppress bitterness but make the beverage too sweet. More acid may brighten the flavor while creating stability issues elsewhere. A stronger flavor system may hide the active but completely change the identity of the product.

At some point the smarter solution may be to stop fighting the ingredient. A flavor system that works with the inherent sensory character of an active can sometimes perform better than one designed to bury it. This is a general principle worth remembering in formulation: when an ingredient refuses to disappear, it may be more useful to design around it than against it.

Dissolved today does not mean stable tomorrow

One of the great traps in beverage development is the successful first prototype. Everything dissolves. The beverage looks good. The texture is right. The flavor works. Nothing has settled. It is tempting to declare victory.

But the beverage has only existed for an afternoon. Real products need to survive processing, packaging, transportation, storage, temperature fluctuations, and time. A formula that looks perfectly stable when freshly prepared may later develop sediment, haze, phase separation, viscosity changes, color changes, flavor degradation, or instability in one of the functional ingredients.

Solubility tells you what happened today. Stability tells you what happens next. The two are not the same thing.

Manufacturing has its own physics

Then the beverage has to be manufactured. This is where benchtop optimism occasionally meets commercial reality. A formula designed for hot fill lives in a different processing environment than one intended for retort, UHT, aseptic processing, or refrigerated distribution. Heat can alter proteins and degrade sensitive compounds. Homogenization changes the physical system. Hydration time matters. Order of addition matters. Even the point at which two ingredients meet during batching can matter.

A beverage can be perfectly reasonable in a laboratory and completely impractical at manufacturing scale. That is why the process is not something that happens to the formula after it is finished. The process is part of the formula.

Eventually, all of this has to fit into one serving

Function stacking also has a more basic limitation. Ingredients take up space. If a beverage needs substantial protein, meaningful fiber, multiple electrolytes, amino acids, botanicals, vitamins, and several other functional ingredients, total solids begin to climb quickly. So do viscosity, flavor challenges, cost, and the number of possible interactions.

At some point it becomes worth asking a very simple question: How many functions does this product actually need? A beverage delivering three meaningful benefits exceptionally well may be a stronger product than one containing six ingredients at awkward levels simply because six looks more impressive on a package. More functionality is not automatically more value. Sometimes it is simply more formulation.

Supplement ingredients do not automatically become beverage ingredients

This is especially important for companies moving from supplements into conventional foods and beverages. An ingredient may work beautifully in a capsule, powder, gummy, or dietary supplement and still be a poor fit for a beverage. The sensory environment is different. The processing environment is different. The regulatory framework may also be different.

An ingredient used in a dietary supplement does not automatically have the same regulatory basis when intentionally added to a conventional food or beverage, and claims that are acceptable in one category may not transfer directly into another. This is exactly the kind of issue worth identifying early. There is little value in solving the stability and flavor problems of an ingredient if the basic assumptions surrounding its use or positioning later have to change.

Start with the product, not the ingredient wish list

The most productive functional beverage projects usually begin with constraints. What is the beverage supposed to do? Which benefits are essential? How much of each functional ingredient actually needs to be delivered? What should the product taste like? Should it be light, creamy, carbonated, clear, opaque, thin, or substantial? What manufacturing process will be used? What shelf life is required? What will happen to the product during distribution?

Once those questions are answered, ingredients can be evaluated in context. Perhaps the protein needs to change. Perhaps the original fiber source creates too much viscosity. Perhaps a different magnesium salt performs better sensorially. Perhaps a botanical ingredient needs a flavor system built around it. Perhaps the desired dosage simply makes no sense in the intended serving size.

These are not failures. These are useful discoveries.

They are also much cheaper discoveries to make during formulation than after packaging has been designed, claims have been built into the marketing strategy, ingredients have been purchased, and a co-manufacturer is waiting for a commercial formula.

The consumer experiences one beverage

Functional beverage development can involve dozens of individual decisions, but consumers do not experience those decisions individually. They do not taste the protein strategy separately from the mineral system. They do not experience the fiber independently from the flavor. They do not care that the active ingredient was difficult to stabilize or that the manufacturing process required three reformulations. They open one bottle and take one sip.

That is ultimately what function stacking has to accomplish. The ingredients must coexist chemically. The product must survive manufacturing. The claims and ingredient use need to make sense. The beverage needs to remain stable. And after all of that, it still needs to taste good enough that somebody wants to drink it again.

If you are developing a beverage with several functional targets, involving Patric Food & Beverage Development before the ingredient system is locked can help identify conflicts early, evaluate how the components will behave as a complete system, and determine whether the benefits you want to deliver can actually coexist in a stable, manufacturable, and enjoyable beverage.

Filed Under: All posts, Process Optimization, Product Development & Optimization, SCIENCE Tagged With: Beverages, food science, product development

Client Spotlight: Glim Wellness Brings Functional Cacao and Herbal Tea Rituals to Everyday Life

July 8, 2026 by Kristen Nicoletti

Every once in a while, a project comes through our lab that feels especially easy to root for. Glim Wellness is one of those projects.

Founded by Varsha Chawla, Glim Wellness was created around a simple but powerful idea: wellness support should not feel like another chore. It should feel like something you actually want to do. Something warm, comforting, and enjoyable. Something that fits into real life.

Glim’s product line includes three adaptogenic, functional beverage mixes that are cacao and herbal tea based: Cacao Balance, Cacao Dream, and Dream Tea. The products are designed to support sleep and energy while also helping promote hormone balance.

But what makes Glim especially interesting is not just what is in the products. It is the way they are meant to be used. “So many supplements are taken as pills, capsules, or gummies, ignoring the entire point of functional wellness support: a ritual that helps you get from one state to the next,” Varsha said. “There is nothing ritualistic about swallowing pills and I wanted to change that.”

That idea became the foundation of the brand. Glim was not meant to be another supplement routine. It was meant to be a set of functional drinks that people could actually enjoy making and drinking.

A brand built from real life

Varsha originally created these products for herself. As a busy mom and marathon runner, she knew firsthand how much sleep and energy support can matter. Like many people, she was trying to manage a full life while still wanting to feel rested, steady, and supported.

That personal starting point gives Glim a groundedness that we really appreciate. It does not feel like a brand built around trends. It feels like a brand built around an actual need.

While Glim naturally speaks to people moving through hormonal shifts and changing energy needs, the products are not limited to one type of customer. Cacao Dream and Dream Tea, for example, were designed for sleep support and can be used by anyone looking for a comforting nighttime ritual. Varsha shared that plenty of male customers enjoy them as a nightcap.

That is one of the things we like about Glim. The brand has a clear point of view, but it does not feel narrow. It started with Varsha’s own life, but it gives customers room to find their own rhythm with the products.

Turning a ritual into a real product

From a product development standpoint, Glim was interesting because the idea sat at the intersection of several things that are not always easy to make work together: indulgent cacao, functional herbal ingredients, clean-label expectations, and the practical realities of a powdered beverage mix.

The products needed to feel cozy, calming, and enjoyable, while still being rooted in thoughtful functional ingredients. Every ingredient was carefully sourced, fair-trade certified, and organic. Glim also intentionally avoided several ingredients that have become common in the wellness space, including artificial sweeteners, stevia, melatonin, and overly stimulating “energy” formulas that can leave people feeling jittery or depleted.

Those choices were important to the brand, but they also made the formulation work more nuanced. Clean-label development is rarely as simple as leaving things out. When you choose not to rely on certain sweeteners, flavors, or technical shortcuts, the rest of the formula has to work harder. Cacao can bring richness and depth, but also bitterness and sediment. Herbal ingredients can support the product story, but also bring strong aromas or polarizing flavor notes. Sweetness has to be balanced carefully. Powdered beverage mixes need to flow, disperse, and remain practical to manufacture.

Glim could not just be a supplement with flavor added. It needed to be a genuinely enjoyable food and beverage experience that also carried functional ingredients. That was where Patric Food and Beverage Development helped translate the brand vision into a more technically grounded formulation path.

Finding the right balance

Varsha came to the project with a clear sense of what she wanted the products to taste and feel like. Patric Development’s role was to help bring that vision into a finished product line.

A lot of the work involved thinking through the major formulation risks early: cacao flavor, herbal aroma, sweetness balance, oxidation risk, powder flow, solubility, dispersion, and the tradeoff between clean-label ingredients and technical performance.

The goal was to help Glim stay natural and premium without letting the products become unstable, gritty, overly bitter, or difficult to manufacture. For Varsha, one of the first moments when the brand started to feel real came when she received the initial prototype samples.

“I clearly remember when I received the first prototype samples from Patric Food and Beverage Development,” she said. “That was a moment when things really started to feel real. Tasting the product was amazing and that first formulation was so special to me.”

That stage of the process is always meaningful. There is a point where an idea stops being theoretical. It is no longer just a concept, an ingredient list, or a product brief. It becomes something you can taste, adjust, and imagine in someone’s kitchen.

It is also the point where the details start to matter even more. In a functional beverage mix, swapping one ingredient for another is rarely a simple one-for-one change. A different cacao powder may bring a different bitterness level, color, fat content, or mouthfeel. A sweetener change can affect flavor balance, solubility, and aftertaste. A functional ingredient may support the product’s positioning, but also introduce off-notes, grit, or processing challenges. Those are the kinds of details that can make or break a product once it moves beyond the first idea.

The reality of ingredient sourcing

One part of the development process that surprised Varsha was how long ingredient sourcing can take. That is something many founders do not fully expect at first. Ingredients with the same name are not always interchangeable. Different suppliers, origins, processing methods, certifications, flavor profiles, and availability constraints can all change the final product.

With Glim, sourcing was especially important because the ingredients were central to both the product experience and the brand identity. The cacao, botanicals, sweeteners, and functional ingredients all had to work together, not just from a functional standpoint, but from a flavor and consumer experience standpoint too.

Varsha noted that the sourcing process took time, but that it was worth it. Taking the time to research, build relationships, and evaluate ingredients helped create products that were not only functional, but also tasted good.

There were also challenges along the way. Glim ran into cacao shortages and had to change ingredient suppliers several times due to larger political and economic conditions affecting the market. Those kinds of issues are difficult to predict, especially for a young brand trying to build something carefully and responsibly.

That is one reason we appreciated Varsha’s approach so much. She had a clear brand vision, but she was also open to technical reality and iteration. She cared about making something genuinely good, not just checking off claims or following trends.

A product line people want to come back to

While all three Glim products have received strong feedback, Varsha is especially excited for people to experience Cacao Dream. Cacao Dream is a rich, chocolatey beverage that can be enjoyed hot or cold. It was designed as a calming evening ritual, with ingredients like magnesium bisglycinate and L-theanine included as part of the formula.

For customers who want something cozy at night without reaching for a traditional dessert, a caffeinated drink, or a melatonin-based product, Cacao Dream offers another option. And that really captures the heart of Glim. The products are functional, but they are also meant to feel comforting, thoughtful, and easy to enjoy.

Varsha shared that all three products have received amazing responses, and that hearing consumers rave about something she worked so hard to build has been one of the most rewarding parts so far.

Where to find Glim Wellness

Glim Wellness has officially launched and is currently working on retail partnerships. For now, the products are available through the Glim Wellness website.

You can visit Glim Wellness at:

https://www.glimwellness.com

You can also learn more and follow along here:

Instagram: https://www.instagram.com/glimwellness

YouTube: https://www.youtube.com/@GlimWellness

Varsha also encourages customers to sign up for the newsletter at the bottom of the Glim Wellness website for exclusive discounts, recipes, and updates.

As Varsha said, launching a product line takes a lot of patience, hard work, and dedication. The best way to support the brand is by placing an order, leaving a review, and spreading the word.

We are proud to have been part of Glim’s development process and excited to see these products out in the world.

Functional products work best when they are not just technically sound, but also enjoyable, thoughtful, and realistic for everyday life. Glim Wellness is a great example of that idea in action.

Filed Under: All posts, BUSINESS, Case Studies, CRAFT Tagged With: Client Success, product development

Is Fiber the New Protein?

June 1, 2026 by Kristen Nicoletti

For years, protein has been the functional ingredient brands have tried to add to almost everything. Bars, cookies, cereals, chips, drinks, ice creams, and snacks across the grocery store have all been reformulated, repositioned, or relaunched around protein.

Now fiber is beginning to look like the next major opportunity. Consumer attention is shifting. Gut health, digestive wellness, satiety, blood sugar response, nutrient density, and “better-for-you” indulgence are becoming more important across food and beverage categories. Brands are beginning to realize that fiber can be more than a quiet line on the Nutrition Facts panel.

For food and beverage companies, this creates a real opportunity. It also creates a real formulation challenge. Fiber is not one ingredient, and it does not behave one way. Different fiber types can affect texture, flavor, viscosity, processing, labeling, claims, cost, and consumer perception in very different ways.

That means successful high-fiber product development needs to start before the marketing claim is written.

Fiber is becoming a product-positioning tool

The interest in fiber is coming from several directions at once. Some products are using fiber to support gut-health or prebiotic positioning. Others are using it in keto-friendly, low-glycemic, or reduced-sugar products. Some are using fiber to create a more nutritious version of an indulgent product. Others are using it to support satiety or to give a snack, beverage, or bakery item a more functional reason to exist.

This is why fiber is becoming attractive to brands. It can support a nutrition message, but it can also help solve formulation problems. In the right system, fiber may contribute body, water binding, structure, suspension, chew, or texture. It may help replace some solids when sugar is reduced. It may support a better mouthfeel in a beverage or a more satisfying bite in a bar. It may help a product feel more substantial without changing the basic category promise.

But those benefits depend heavily on the fiber source, the dosage, the processing conditions, the serving size, and the rest of the formula. A high-fiber product is not automatically a better product. A poorly formulated high-fiber product can be gritty, gummy, dry, heavy, bland, unstable, or difficult to manufacture.

Fiber types are not interchangeable

One of the most important things to understand is that “fiber” is a category, not a single ingredient.

Fiber is a category, not a single ingredient. Some fibers, such as fructooligosaccharides/FOS and galactooligosaccharides/GOS, are often used for prebiotic or gut-health positioning. Others, such as resistant starch and resistant dextrin, may be useful when a product needs fiber with a different impact on texture, carbohydrate positioning, or processing behavior. Psyllium husk and beta-glucan can contribute viscosity and water binding, which may be helpful in some applications and problematic in others. Acacia gum and pectin can support body, stabilization, or texture while often fitting more comfortably into a clean label story. Cellulose, microcrystalline cellulose/MCC, methylcellulose, hydroxypropyl methylcellulose/HPMC, and carboxymethylcellulose/CMC can be powerful functional tools, but they may raise different formulation and ingredient-positioning questions. The point is not that one fiber is universally better than another. The point is that each one brings its own mix of nutrition, function, sensory impact, labeling considerations, and consumer perception.

Put more simply: some fibers are soluble. Some are insoluble. Some create viscosity. Some are relatively neutral in texture. Some are good at binding water. Some are useful for body and suspension. Some can contribute graininess. Some affect flavor release. Some fit easily into clean label positioning, while others may be technically effective but harder to explain on an ingredient statement.

This is where formulation strategy matters. A beverage may need a fiber that hydrates cleanly, stays stable, and does not create excessive thickness. A cookie may need a fiber that helps manage moisture without making the product dry or sandy. A keto-friendly bar may need a fiber that supports carbohydrate positioning, but the same ingredient may also affect chew, stickiness, flavor-binding, or digestive tolerance. There is rarely a universal “best” fiber. There is only the fiber that best fits the product, the process, the label, the sensory target, and the business goal.

The right fiber depends on the job

Before choosing a fiber, it helps to define what the ingredient needs to accomplish.

  • Is the main goal to support a Nutrition Facts declaration?
  • Is the brand trying to make a “good source of fiber” or “high fiber” claim?
  • Is the product being positioned around gut health, prebiotics, keto, low-glycemic response, or satiety?
  • Does the formula need help with viscosity, water binding, body, structure, or texture?
  • Does the product need a clean label ingredient story?
  • Does the target consumer need a low-FODMAP fiber approach?
  • Is flavor release a concern?
  • Will the fiber survive the process and remain acceptable through shelf life?

Those questions can lead to very different ingredient choices.

Acacia gum may be appealing in some beverages because of its relatively friendly ingredient-positioning and functionality. Pectin may be useful where gelling, texture, or fruit-based positioning are relevant. Resistant starch may make sense in some bakery or snack systems. Resistant dextrin may be useful where solubility and lower viscosity are important. Psyllium husk can provide strong water-binding and structure, but it can also create significant texture and viscosity effects. Beta-glucan brings both nutritional and functional relevance, but it must be managed carefully depending on the application.

Cellulose, MCC, methylcellulose, HPMC, and CMC can be powerful formulation tools, but they may raise different clean label questions depending on the brand and category. That does not make them wrong. It means the technical benefit has to be weighed against the ingredient-positioning strategy. The right answer depends on the product.

Sensory quality determines whether consumers come back

Fiber can help create a strong front-of-pack message, but sensory quality determines repeat purchase. This is where many high-fiber products struggle. Some fibers create graininess. Some create chalkiness. Some make products feel dry or dense. Some increase viscosity in a way that makes a beverage feel heavy, slimy, or difficult to drink. Some bind flavor compounds and reduce aroma impact. Some mute sweetness or make flavors feel less clean. Some bring their own cereal-like, woody, earthy, bitter, or fermented notes.

These effects may be manageable, but they need to be addressed deliberately. Flavor systems may need adjustment. Sweetness, acidity, salt, and fat perception may shift. Hydration steps may need to change. Processing order may matter. Particle size may matter. Water activity and shelf-life texture may need to be evaluated. A product that tastes good on day one may become harder, drier, thicker, or grainier over time.

That is why high-fiber development should not be treated as a simple fortification exercise. It is a full product development problem.

Clean label goals can complicate fiber selection

Fiber can also create tension between technical performance and brand positioning. Some fiber sources sound familiar to consumers. Psyllium husk, pectin, acacia gum, resistant starch, and beta-glucan may fit naturally into certain clean label or plant-forward products, depending on the brand and category.

Other fiber-related ingredients may sound more technical. Cellulose, microcrystalline cellulose, methylcellulose, HPMC, and CMC can provide useful functional properties, but they may not align with every brand’s clean label expectations.

This is not just a marketing issue. It affects formulation choices early. A brand that prioritizes clean label ingredient-positioning may accept more formulation difficulty to keep the ingredient statement familiar. A keto-friendly product may prioritize carbohydrate strategy and texture. A low-glycemic product may prioritize a fiber system that supports its intended positioning. A low-FODMAP product may avoid certain fibers that would otherwise be attractive for gut-health or prebiotic messaging. The ingredient choice should support the whole product concept, not just one claim.

Nutrition labeling and claims need to be built in early

Fiber also requires careful labeling review. For U.S. conventional foods, not every ingredient marketed as fiber can automatically be counted as dietary fiber on the Nutrition Facts label. FDA’s dietary fiber definition includes non-digestible soluble and insoluble carbohydrates with three or more monomeric units, and lignin, that are intrinsic and intact in plants. It also includes isolated or synthetic non-digestible carbohydrates that FDA has determined have beneficial physiological effects. FDA identifies beta-glucan soluble fiber, psyllium husk, cellulose, pectin, and HPMC among the isolated or synthetic non-digestible carbohydrates that meet the dietary fiber definition. FDA has also stated enforcement discretion for additional fibers, including inulin and inulin-type fructans, GOS, resistant maltodextrin/dextrin, and acacia gum, pending rulemaking.

That distinction matters during development. If a brand wants to declare dietary fiber or make a fiber-related claim, the formula needs to be built with ingredients that support the intended declaration. When foods contain both fibers that meet the dietary fiber definition and added non-digestible carbohydrates that do not, FDA explains that records are needed to support the amount declared as dietary fiber because analytical methods do not distinguish between the two.

Nutrient content claims also have specific rules. Under 21 CFR 101.54, “high,” “rich in,” or “excellent source of” generally require 20% or more of the Daily Value per reference amount customarily consumed. “Good source,” “contains,” or “provides” generally require 10 to 19% of the Daily Value. Fiber claims can also trigger additional disclosure requirements if the food is not low in total fat.

In practical terms, this means serving size, fiber source, dosage, claim language, and finished product performance all need to be considered together. The worst time to discover a labeling problem is after the formula has already been scaled, costed, packaged, and prepared for launch.

More fiber is not always better

As fiber becomes more marketable, some brands will be tempted to push the number as high as possible. That may not always be the best strategy. A product with a moderate fiber claim and a strong sensory experience may be more successful than a product with a more aggressive claim that tastes gritty, drinks too thick, causes digestive discomfort, or feels obviously compromised.

The right fiber level depends on the product format, the claim target, the serving size, the consumer expectation, and the rest of the formulation. A high-fiber brownie, soda, cracker, yogurt alternative, protein bar, or frozen dessert will each have different constraints.

There is also a category expectation to respect. Consumers may accept some functional cues in a nutrition bar that they would reject in a cookie. They may accept body in a smoothie that would feel wrong in a sparkling beverage. They may tolerate some earthy notes in a seeded cracker that would not work in a vanilla beverage or a fruit confection. Fiber has to fit the product experience.

The opportunity is real, but the execution matters

Fiber is likely to become more important across food and beverage development because it sits at the intersection of several consumer interests: digestive wellness, gut health, satiety, blood sugar awareness, nutrient density, and more functional everyday foods.

For brands, the opportunity is not simply to add fiber. The opportunity is to develop products where fiber makes sense. Products that taste good. Products that process reliably. Products that support the right nutrition labeling and claims. Products that use the right fiber types for the application. Products that balance clean label expectations with technical performance. Products that do not sacrifice flavor, texture, or repeat purchase for a front-of-pack message.

This is where formulation experience becomes important. A successful high-fiber product has to work as a food first.

So, is fiber the new protein?

Not nutritionally. But commercially, it may be moving into a similar role. Like protein, fiber can give brands a functional message that consumers recognize. It can help make familiar products feel more relevant to current wellness priorities. It can support product renovation, new product development, and sharper ingredient-positioning.

But fiber also brings its own set of formulation challenges. It can affect viscosity, graininess, flavor-binding, sweetness perception, texture, processing, digestive tolerance, labeling, claims, and clean label strategy. That is why fiber should not be treated as an afterthought or a marketing add-on. It should be part of the product development strategy from the beginning.

Developing a high-fiber food or beverage?

Whether you are building a new high-fiber snack, improving a gut-health beverage, exploring keto-friendly or low-glycemic fiber options, troubleshooting graininess or viscosity, or trying to understand which fiber types make sense for your label and positioning goals, Patric Food & Beverage Development can help.

We work across formulation, sensory quality, ingredient functionality, labeling considerations, and commercialization so your product does not just look good on the Nutrition Facts panel. It works in the real world, too.

Filed Under: All posts, BUSINESS, CRAFT, Product Development & Optimization, SCIENCE Tagged With: Fiber, food science, product development

Sugar Reduction Is Easy to Promise and Hard to Execute

May 7, 2026 by Kristen Nicoletti

Sugar reduction sounds straightforward from a distance. Consumers want less sugar. Retailers want products that align with evolving health expectations. Brands want to stay relevant without losing product quality or repeat purchase. On paper, the direction seems obvious. In practice, sugar reduction is one of the fastest ways to discover how much work sugar was doing in a formula long before anyone noticed.

Consumer interest is still real. IFIC’s 2025 Food & Health Survey reported that 75% of Americans were trying to limit or avoid sugar, and among those respondents, 63% said they were focused specifically on added sugars.

That matters because most sugar-reduction conversations begin as a nutrition or marketing objective, but they quickly become a formulation, process, and commercialization problem. Sugar is not just sweetness. In many products, it contributes solids, bulk, browning behavior, moisture management, freezing point effects, and overall product performance. Current industry coverage also reflects how formulators are using sugar-related ingredients for functions tied to texture and stability, not just sweetness.

Why sugar reduction projects stall

A lot of brands assume the main challenge is finding the right sweetener system. Sometimes that is part of it, but it is rarely the whole story.

The harder problem is that once sucrose comes down, the rest of the formula tends to reveal its dependencies. Texture can drift. Mouthfeel can thin out. Flavor may become less rounded or less forgiving. Shelf life may tighten. A product that seemed stable in the original system can become noticeably more fragile after even a modest reduction.

For many brands, sugar reduction is no longer just a labeling or positioning exercise. It quickly becomes a product-performance question involving texture, shelf life, flavor balance, and process stability. Trade coverage in 2026 has focused heavily on that issue, especially in applications where formulators are trying to preserve eating quality after reducing sugar.

Sugar does more than make products sweet

This is where many otherwise sensible projects start to lose time and money.

In baked goods, sugar can influence tenderness, spread, browning, and water activity. In frozen applications, it can affect scoopability and ice crystal behavior. In beverages, reducing sugar can affect more than sweetness alone. Depending on the application, it may also change perceived body and the balance of acids, bitterness, or other strong flavor notes.

That is also why sugar reduction is rarely a one-ingredient substitution exercise. Teams may need to rethink sweetener blends, bulking systems, fibers, hydrocolloids, flavor modulation, and process parameters at the same time. Sometimes the best answer is not a dramatic reduction. Sometimes it is a smaller improvement that protects quality and margin while still moving the formula in the right direction.

The tradeoffs are usually category-specific

There is no universal sugar-reduction playbook because the functional role of sugar depends heavily on the product.

In bakery and snacks, reduced sugar can show up quickly as dryness, firmness, or faster staling. In those categories, texture is often central to repeat purchase, which raises the stakes for any reformulation that compromises it. Recent industry reporting on bakery and snack development has emphasized just how commercially important texture has become.

In beverages, the challenge is often less about structure and more about taste architecture. A reduced-sugar drink may still hit its target sweetness, but feel hollow, sharp, or unfinished. In products with functional ingredients, proteins, botanicals, caffeine, or minerals, sugar reduction can also expose bitterness or metallic notes that were previously moderated. That can push teams into a more complex balancing act involving masking, acid adjustment, and flavor design rather than sweetness replacement alone.

In frozen and dairy-adjacent products, teams may be dealing with body, stability, and freeze-thaw performance at the same time. In confectionery, crystallization behavior and texture consistency can become major constraints. The point is not that sugar reduction is impossible. It is that every category has its own failure modes, and many of them do not become obvious until bench success meets real shelf life or production conditions.

What brands often underestimate

One common mistake is treating sugar reduction as a claim-first project.

If the commercial goal is simply to say less sugar on pack, teams can end up optimizing for the label while weakening the product itself. That is risky in a market where consumers still care deeply about taste and where ingredient and sweetener perceptions can shape purchase behavior. IFIC’s consumer research indicates that brands face pressure to reduce sugar without creating ingredient statements, taste profiles, or sweetener choices that consumers find confusing or unappealing.

Another mistake is assuming a sugar-reduction project will stay confined to sweetness. In practice, the work often spreads into texture, shelf life, cost, sourcing, and process performance. That is why the easiest-looking projects can become the most expensive if the team does not define its technical priorities early.

A better way to evaluate a sugar reduction project

Before starting a full development sprint, it helps to ask a more disciplined set of questions.

What is sugar doing in this formula beyond sweetness?

Which product attributes are non-negotiable for the consumer experience?

How much reduction is realistically possible before quality or process performance starts to erode?

What will the revised system do to cost, ingredient statement complexity, and supply-chain flexibility?

And perhaps most importantly, does the commercial upside justify the technical disruption?

Those are not abstract R&D questions. They are business questions. A successful sugar-reduction project has to survive sensory review, process reality, shelf life, sourcing, and margin pressure, not just a nutrition panel conversation.

The broader public-health context is still clear. FDA states that the Dietary Guidelines for Americans recommend limiting calories from added sugars to less than 10% of total calories per day, and the Nutrition Facts Daily Value for added sugars is 50 grams based on a 2,000-calorie diet.

Sugar reduction is worth pursuing, but not casually

There is still real opportunity here. Consumers continue to care. Brands continue to pursue better nutritional positioning. And many products genuinely can be improved.

But sugar reduction works best when it is approached as a full product-development problem rather than a quick response to market pressure. The strongest projects are usually the ones that begin with technical honesty: understanding what sugar is doing now, deciding what absolutely must be preserved, and building a replacement strategy around how the product needs to behave in the real world.

If your team is evaluating a sugar-reduction initiative, we can help you identify the functional role sugar is playing in your formula, pressure-test the likely tradeoffs, and determine whether there is a practical path to a lower-sugar product that still performs the way it needs to.

Filed Under: All posts, BUSINESS, SCIENCE Tagged With: chemistry, product development

The Scaling Wall: Why Great Small-Batch Products Fail in Commercial Manufacturing

April 6, 2026 by Kristen Nicoletti

Every CPG founder has the same milestone in mind. The day your kitchen-tested product moves from a five-quart mixer to a commercial production line. You have dialed in the flavor. The branding feels cohesive. Retail buyers are interested. Purchase orders arrive.

Then the first pallet shows up from the co-packer.

And something is off.

The texture is gummy. The color looks dull. The shelf life data does not match your pilot batch. The product you perfected in small scale no longer behaves the same way at production scale.

This moment is so common in food and beverage manufacturing that it has a name in our world. We call it hitting the scaling wall.

Scaling is not simply making more. It is translating a formula into a completely different physical environment. Once you move into industrial tanks, continuous flow systems, automated fillers, and high-speed packaging, the physics governing your product change. The underlying chemistry does not care that your recipe “worked before.”

Below are five of the most common and costly failure points we see when products move from bench scale to commercial production.

The Shear Force Phenomenon

In a home kitchen, you stir. In a plant, you shear.

Industrial pumps, high-speed mixers, inline homogenizers, and long transfer lines expose product to intense mechanical forces. This is hydrodynamic shear, and it can fundamentally alter the structure of your formulation.

What goes wrong

Proteins can denature under excessive shear. Emulsions can destabilize. Hydrocolloid networks can weaken. Particle size distribution shifts. What was once a stable emulsion in a bowl can fracture when pushed through a high-pressure homogenizer and pumped hundreds of feet through stainless steel piping.

What you see

A sauce that was thick and creamy becomes loose and porous. A beverage loses its suspension stability. A dairy system shows phase separation. The microstructure has literally been torn apart.

Scale introduces energy density that does not exist in small batch testing. If your formulation is not engineered for that environment, it will fail under stress.

The Long Run Texture Collapse

Small batch production is short and controlled. Commercial production is continuous and prolonged.

Residence time becomes a critical variable. In large scale manufacturing, product may sit in heated hoppers, holding tanks, or continuous systems for hours instead of minutes.

What goes wrong

Extended heat exposure continues to drive reactions. Starches can over-gelatinize or degrade. Hydrocolloids such as pectin, agar, or carrageenan may lose functional integrity under sustained thermal load. Protein networks can tighten or collapse.

In extruded or baked products, moisture and heat exposure over long runs can weaken structural frameworks that are essential for expansion and crispness.

What you see

The first production run looks excellent. By the time you are thousands of units in, texture shifts. Crisp snacks become dense. Gels become brittle or synerese. Viscosity drifts out of specification.

This is not a random event. It is a time-dependent structural failure driven by prolonged processing conditions.

Water Activity Drift

Moisture content and water activity are not the same thing.

Moisture content tells you how much water is present. Water activity, or aw, tells you how much of that water is available to support microbial growth or migrate between components.

In small batch testing, short timelines can mask moisture migration issues. Commercial products experience weeks or months of distribution before reaching the consumer.

What goes wrong

Water moves. It always moves toward equilibrium. In a filled pastry, moisture migrates from the fruit layer into the crust. In a multi-component snack, the soft inclusions equilibrate with the dry base.

If aw rises above 0.85, you cross a critical regulatory and safety threshold for shelf stable products. What was once safe in short term testing may become microbiologically vulnerable.

What you see

Soggy bases. Rock hard fillings. Mold growth in products that were assumed shelf stable. Unexpected spoilage during shelf life studies.

Water activity management is not optional at scale. It must be engineered into the system from the beginning.


Fill Weight Variability: The Profit Killer

When you hand-pack jars, you have control. You can visually confirm fill levels. You can correct inconsistencies.

At commercial speeds, fillers operate rapidly and rely on predictable flow behavior. Even a two-gram deviation, multiplied across thousands of units, materially impacts margin.

What goes wrong

Products that do not flow consistently through volumetric or piston fillers create variability. Powders can bridge. Viscous products can string. Particulates can clog valves.

If the filler compensates by overfilling to stay compliant, you experience product give-away. If it underfills, you risk short-weight violations and retailer penalties.

What you see

Eroded margins from chronic overfill. Rejected lots. Retail compliance issues. Cost structures that no longer support your pricing model.

Flow properties must be validated under real manufacturing conditions. Otherwise, profitability becomes an unintended casualty of scale.


Packaging Interactions

Packaging is not just a container. It is a functional barrier system.

At small scale, many founders choose stock packaging to reduce cost and complexity. At commercial scale, the interaction between your product and its packaging becomes a technical variable that can compromise quality.

What goes wrong

High-fat systems can absorb or “scalp” flavor compounds from packaging materials. High-acid products can challenge seal integrity. Oxygen transmission rates that were ignored in early stages begin to matter over six months of storage.

Barrier properties, headspace oxygen, and liner compatibility all influence product stability.

What you see

Oxidation. Rancidity. Metallic off-notes. Seal failures. Premature staling long before the labeled shelf life.

A technically sound formulation can still fail if the packaging is not engineered to protect it.


The Real Lesson: Scaling Is Applied Food Physics

The most frustrating part of hitting the “scaling wall” is that it’s rarely about a bad idea. Usually, the product didn’t fail because of the recipe—it failed because the physics changed.

Commercial manufacturing is a totally different beast. Between intense mechanical pressure, longer heating times, and high-speed automation, variables emerge that you just can’t see in a test kitchen.

Success at scale requires translation, not just duplication.

The brands that actually win aren’t always the ones with the most “creative” recipes; they’re the ones that respect the science of mass production and design for it from day one.

At Patric Food and Beverage Development, this is what we do every day. We bridge the gap between your kitchen-table concept and commercial reality, ensuring the product you fell in love with is the same one that ends up in the customer’s cart.

Ready to scale without the heartbreak? Let’s talk about your formulation.

Filed Under: All posts, BUSINESS, CRAFT Tagged With: formulation, product development, scaling

The Top 4 Challenges U.S. Food Manufacturers Will Face in 2026

January 12, 2026 by Kristen Nicoletti

The U.S. food manufacturing landscape continues to evolve quickly, but 2026 is shaping up to be a year where several major pressures converge. Regulatory requirements are expanding, packaging rules are becoming more complex, labeling timelines are tightening, and supply chain volatility remains a constant.

For many manufacturers, the challenge will not be a single change. It will be the need to manage multiple changes at once, without disrupting production, customer commitments, or food safety systems.

Below are the top four challenges food manufacturers should be preparing for in 2026 and what they mean in practical terms.

1) Traceability requirements and customer expectations are accelerating

Traceability is no longer a future-facing topic. Even as regulatory timelines evolve, the expectation that manufacturers can quickly produce accurate, lot-level records has already become common across retail, foodservice, and audit environments.

In practice, stronger traceability requirements often require more than adding a few new records. They drive process and system changes across procurement, receiving, production, warehousing, and distribution.

Key impacts include:

  • More detailed recordkeeping for incoming ingredients and outgoing finished goods
  • Stronger control of lot codes, rework tracking, and inventory movements
  • Better coordination with suppliers and co-manufacturers to align data formats and documentation
  • Faster record retrieval for investigations, withdrawals, and recall events

For many teams, the hardest part is not collecting data. It is building a consistent system that is reliable under pressure and works across multiple sites and partners.

2) Packaging compliance will be more complicated and more state-driven

Packaging is increasingly shaped by regulatory pressure, particularly at the state level. Manufacturers selling across multiple states may face rules that differ by region, creating additional requirements for packaging specifications, vendor documentation, and compliance verification.

Packaging compliance issues can affect manufacturers even when the product formula does not change. The package itself can create risk, especially when there are restrictions or reporting requirements tied to food contact materials.

In 2026, manufacturers may need to:

  • Evaluate packaging materials for restricted substances, including PFAS-related concerns
  • Manage state-by-state compliance for distributed products
  • Confirm vendor documentation is current and defensible
  • Address packaging changes without interrupting distribution or increasing waste from obsolete inventory

This is one of the areas where the workload often lands across multiple departments, including regulatory, procurement, marketing, and operations.

3) Labeling change cycles are becoming tighter and more disruptive

Labeling updates are a normal part of food manufacturing, but uniform compliance dates and evolving expectations are increasing the operational burden. Label updates often require synchronized planning across regulatory review, artwork revision, print scheduling, inventory management, and retailer communication.

Even small label changes can create major disruption when multiple products or packaging formats are involved.

Manufacturers should expect labeling updates to require:

  • More time to manage cross-functional approvals
  • Better version control and documentation
  • Careful inventory planning to avoid write-offs or stranded packaging stock
  • Coordination between labeling requirements and supplier or formula changes

A labeling update can become costly when it overlaps with packaging compliance changes or ingredient substitutions caused by supply chain issues.

4) Cost volatility and sourcing disruption will continue to stress compliance systems

Supply chain conditions remain unstable across many categories, and food manufacturing is especially sensitive to shifts in ingredient availability, packaging supply, and import pricing. Cost pressures can create frequent supplier changes and substitutions, which can introduce compliance and quality risks if change control processes are not strong.

Common risk points include:

  • Substituting ingredients or suppliers without updating documentation, specifications, or labeling
  • Switching packaging materials without verifying state-level compliance
  • Introducing new suppliers without strong qualification steps
  • Losing track of records when products move across facilities, co-packers, or distributors

In 2026, manufacturers that can move quickly while maintaining control will have a competitive advantage. That requires disciplined change control, aligned teams, and documentation that can keep pace with operational realities.

What manufacturers can do now to reduce risk in 2026

Manufacturers that handle these challenges well usually focus on a few foundational practices:

  • Clear ownership of traceability records and record retrieval processes
  • A packaging governance process that ties together compliance, procurement, and brand needs
  • A structured labeling workflow that prevents rushed changes late in the cycle
  • Strong change control practices for suppliers, ingredients, packaging, and labeling
  • Training that helps teams understand the “why” behind requirements, not just the steps

These are not glamorous projects, but they prevent expensive disruptions later.

How we can help

Many food manufacturers already have strong teams in place. The challenge in 2026 will be bandwidth, coordination, and making sure systems can handle multiple changes at once.

We help manufacturers build practical solutions that fit real operations, including:

  • Reformulations to improve clean label ingredients list
  • Reformulations to streamline processes
  • Reformulations to minimize risk of supplier shortages
  • Ingredient sourcing to speed up supplier changes when needed
  • Labeling transition planning, including regulatory review

Whether a business needs a targeted compliance review or a longer-term roadmap, we help teams reduce risk, improve clarity, and stay ahead of the changes shaping 2026.

Filed Under: All posts, BUSINESS Tagged With: formulation, product development, scaling

Prop 65 Food Labeling in 2025: Navigating California’s New Rules for Food, Beverage & Supplement Brands

June 10, 2025 by Kristen Nicoletti

California’s Proposition 65 (Prop 65) is entering a new era in 2025, and food industry makers need to pay attention. Prop 65 has long loomed over product labeling for foods, beverages, and nutraceuticals, requiring clear warnings if products expose consumers to certain chemicals. Now, significant changes to Prop 65 warning regulations take effect in 2025 – especially for the short-form warnings often used on food packages. These changes mark the biggest shift in years, and they’re more than just bureaucratic updates. They affect how you, as a food or supplement brand, must label your products in California and manage chemical content. Non-compliance can mean costly litigation and damaged consumer trust.

This post will break down what’s changing, why it matters, and how you can not only comply but turn these changes into an opportunity. We’ll cover the new 2025 Prop 65 warning rules, the science of Prop 65 chemical thresholds, recent enforcement trends (from chocolate and coffee to supplements), and a compliance checklist and timeline. By the end, you’ll have a clearer picture of Prop 65’s impact and a path forward – and if you need tailored guidance, we’re here to help with a strategy session.

An example of a Prop 65 short-form warning label (pre-2025). These generic warnings – often seen on food and supplement packaging – omit specific chemical names. In 2025, such labels must be updated to name at least one chemical to comply with new regulations.

Prop 65’s Influence on Food & Supplement Labeling

Prop 65 (formally the Safe Drinking Water and Toxic Enforcement Act of 1986) has a massive influence on how products are labeled in California. Under this law, businesses must provide a “clear and reasonable” warning if their product exposes consumers to any of 900+ listed chemicals known to cause cancer or reproductive harm. For food, beverage, and nutraceutical makers, this means even trace contaminants (like heavy metals or processing byproducts) can trigger a required warning label.

Over the decades, Prop 65 warnings have become ubiquitous – from snack foods to dietary supplements – alerting Californians to potential chemical exposures. Why does this matter to food industry decision-makers? Because Prop 65 is effectively a de facto national standard: if you sell in California, you likely adjust your entire product line’s labeling or formulation to avoid a “Cancer/Reproductive Harm” warning that could alarm customers. The Prop 65 sign (often a yellow triangle warning symbol with an exclamation point) on your product can impact consumer perception and trust.

By 2025, Prop 65’s requirements are tightening. California wants the warnings to be more informative and specific, pushing companies toward greater transparency about which chemical is the concern. For the food sector – already under consumer scrutiny for ingredient safety – this ups the ante. Failing to comply isn’t just a regulatory issue; it can also become a public relations headache. Prop 65 allows private enforcers to sue businesses for violations, and the food industry has been a frequent target of such actions.

In short, Prop 65 has shaped a culture of “warning-aware” labeling in California. The 2025 changes aim to sharpen that culture by eliminating generic caution and encouraging actual risk reduction. For food and supplement makers, it’s both a challenge and (as we’ll see) an opportunity to build trust by demonstrating high safety standards.

What’s Changing in 2025: New Prop 65 Food Warning Rules

Effective January 1, 2025, California is implementing new Prop 65 warning regulations that particularly impact short-form warnings on product labels. These changes were adopted in late 2024 after regulators concluded that the old short-form labels were too generic. Below we break down the key updates:

  • Chemical Name Required: The biggest change is that short-form warnings must now identify at least one specific chemical in the product that is causing the risk. Previously, a small package could use a short warning like “WARNING: Cancer and Reproductive Harm – www.P65Warnings.ca.gov” with no chemical named. In 2025, if you use a short-form label, it must include the name of at least one listed chemical for each type of risk (one carcinogen and/or one reproductive toxicant) your product contains. For example, a new compliant warning might read: “WARNING: This product can expose you to lead, which is known to the State of California to cause cancer. For more information, visit P65Warnings.ca.gov”. If a product has chemicals for both cancer and reproductive harm, the label needs to mention one of each (it could be two different chemicals, or the same chemical if it causes both effects).
  • No More Generic Short-Form for Food: In the past, it was somewhat unclear if foods could use the abbreviated warning. Now short-form warnings are explicitly allowed for food and beverage products, but they must use the new language. The short-form can now be applied to any product label (no size restrictions on the label area), so long as you meet the content requirements. This means even small packages can still use a short warning – but you can’t hide behind vague wording. You’ll need to plan label space for naming chemicals.
  • “CA WARNING” Option: To help consumers recognize the warning as a California-specific requirement, businesses can now use alternative signal words. Instead of just “WARNING:” at the start, the regulations permit “CA WARNING:” or “CALIFORNIA WARNING:”. This is optional, but many companies may adopt it to assure non-California customers that the warning is due to California law (not a universal safety issue). For example: “CA WARNING: Risk of cancer from exposure to [Chemical Name]…” is acceptable and meets the requirement.
  • Formatting Tweaks: The new rules maintain a minimum font size of 6-point for warnings (so it’s legible), but they remove the old requirement that the warning text be no smaller than the largest text on the package. This gives a bit more flexibility in design. The familiar yellow triangle symbol with an exclamation point is still required on labels (or black and white if yellow is not used). Essentially, ensure the warning is noticeable and the text stands out (e.g. black on yellow or white, or similar high-contrast colors).
  • Short-Form Allowed Online with Grace Period: If you sell products online, note that short-form warnings can be used in internet listings too. California is giving a 60-day grace period for online retailers to update warnings after they’re notified of non-compliance during the transition. During the three-year transition (2025–2027), if you discover your website still has an old warning, you have 60 days to fix it.

Compliance Timeline: The state has provided a transition period to implement these changes. The new warning regulations take effect Jan 1, 2025, but you have until Jan 1, 2028 to fully switch existing products to the new short-form labels. Products manufactured and labeled before January 1, 2028 can continue to use the old short-form wording and will still be considered in “safe harbor” compliance. However, any product made on or after Jan 1, 2028 must use the new warning language (if you choose to use a short-form at all). In practical terms, 2025 is the time to start phasing in new labels for new product runs, and 2026–2027 is your window to update all packaging so that by 2028 you’re fully compliant. It’s wise not to wait until the last minute, as label changes can be resource-intensive.

In summary, Prop 65 short-form warnings are getting longer (by necessity of naming chemicals) and somewhat more complex, but California believes this provides consumers with more useful information. As a food or nutraceutical business, you should review your current labels now. Any product that currently just slaps on a generic Prop 65 warning will need a redesign to include chemical specifics if you want to keep using the short-form format. Some companies might even consider switching to the longer-form warning to avoid confusion, especially if multiple chemicals need naming – but that comes with its own space and wording challenges for small packages. The key is to plan ahead and integrate these new requirements into your packaging refresh cycles well before the 2028 deadline.

The Science Behind Prop 65: Thresholds, “Safe Harbor” Levels & Testing

To comply strategically (and perhaps avoid warnings altogether), it helps to understand the science of Prop 65 – how chemical risk is determined and what triggers a warning. Prop 65 doesn’t ban chemicals; it forces disclosure unless you can show the exposure level is below a certain threshold of risk. These thresholds are often called “safe harbor” levels. Here’s what that means in plain terms:

  • Safe Harbor Levels: For many Prop 65 chemicals, California’s OEHHA (Office of Environmental Health Hazard Assessment) has set numerical exposure limits deemed “safe.” If your product exposes a person to a chemical at or below that level, no warning is required. If the exposure is above that level, you must either provide a warning or be ready to prove that the exposure is still not significant. There are two types of safe harbor levels:
    • No Significant Risk Levels (NSRLs): These apply to carcinogens. An NSRL is basically the daily exposure level that would cause at most a 1 in 100,000 cancer risk over a 70-year lifetime. In simpler terms, if people consume that amount or less each day, the risk of cancer is considered negligible.
    • Maximum Allowable Dose Levels (MADLs): These apply to reproductive toxicants (chemicals that cause birth defects or reproductive harm). A MADL is typically 1/1000 of the no-effect level from studies, meaning it has a built-in 1,000-fold safety factor. If you stay at or below the MADL, you’re presumed safe from needing a warning.

California has established over 300 such safe harbor levels for various chemicals. These numbers are often tiny – especially for potent carcinogens or developmental toxins – which is why even natural foods can run afoul of them. For instance, lead, a heavy metal sometimes found in dietary supplements or chocolate, has a Prop 65 MADL of just 0.5 micrograms per day. To visualize how small that is: 0.5 µg is 0.0005 milligrams – practically a speck. Another example is acrylamide, a chemical formed when coffee beans are roasted or when bread is baked. Acrylamide’s NSRL (for cancer) is only 0.2 micrograms per day. Cadmium, a heavy metal in soil that can end up in cacao or leafy herbs, has a safe harbor level around 4.1 µg per day (for oral exposure). These infinitesimal thresholds mean even trace contaminants matter.

  • Testing and Finding These Chemicals: Unlike some regulations, Prop 65 doesn’t mandate specific testing protocols or certification. It puts the onus on businesses to know their products. Practically, many food and supplement companies choose to conduct lab testing on their products and ingredients to identify any Prop 65-listed chemicals (like heavy metals, acrylamide, pesticide residues, etc.). Testing might include, for example, using atomic absorption or ICP-MS analyses for metals (to detect lead, cadmium, arsenic, mercury down to parts-per-billion levels), or chromatography methods for chemicals like acrylamide. The Prop 65 regulations themselves do not require testing – you could also rely on knowledge of your supply chain or published data – but without testing, it’s risky. If you guess wrong and a private enforcer finds your product over the limit, you’re in trouble.

It’s important to note: A product exceeding a safe harbor level doesn’t mean it’s automatically illegal or must be pulled – it means a warning is required unless you can reduce the exposure. Some companies opt to label by default (“when in doubt, warn”), but California actually discourages unnecessary warnings because over-warning defeats the purpose of informing consumers. The ideal goal (from both a public health and branding perspective) is to keep chemical levels low enough that no warning is needed. This is where testing and quality control come in: it lets you identify if reformulation or sourcing changes are needed to get below those thresholds.

  • Exposure Calculation: One tricky aspect is that Prop 65 thresholds are in terms of exposure to the consumer, not simply the concentration in the product. So you have to calculate how much of the chemical a typical user of your product would ingest, inhale, or absorb in a day. For food, it’s usually ingestion per serving or per recommended dose (for supplements). For example, if a protein powder serving is 30 grams and it contains 1 µg of lead, a consumer might get 1 µg per day from it – which is double the 0.5 µg safe harbor for lead, thus a warning would be requiredoehha.ca.gov. But if you could source cleaner ingredients and cut that down to 0.3 µg per serving, you’d be below the threshold and no warning needed. Such calculations often require toxicologists or regulatory experts, especially if no official safe harbor exists and you need to do a risk analysis from scratch.

In summary, Prop 65 compliance for food and supplement makers involves a blend of regulatory science and proactive QA. Understanding these ultra-low thresholds empowers you to make decisions: do we label, or do we reduce the chemical? Many companies quietly do extensive testing and reformulation to avoid having to slap a Prop 65 warning on their product – because once that label is on, it may deter customers (nobody likes seeing “Cancer” associated with their snack bar or vitamin bottle). In the next section, we’ll see how enforcement and lawsuits play out when companies miss the mark, and what trends are emerging.

Enforcement Trends and Litigation Risks in the Food Industry

Prop 65 isn’t policed by routine government inspections; it’s largely enforced through civil lawsuits. California allows private enforcers (individuals or groups, often dubbed “bounty hunters”) to sue companies on behalf of the public if they fail to provide required warnings. If the lawsuit succeeds or settles, the enforcer can collect penalties and attorney fees – which has spurred a cottage industry of Prop 65 litigation. For food, beverage, and supplement makers, this means constant vigilance is needed. Recent trends show where enforcers are focusing:

  • Heavy Metals in Foods & Supplements: Year after year, heavy metals like lead, cadmium, mercury, and arsenic top the list of Prop 65 food violation notices. In 2023, Prop 65 notices hit a record high; citizen plaintiff groups filed over 1,000 notices in just the third quarter of 2023 alone. Many targeted foods and dietary supplements. For example, a single quarter saw 84 notices over heavy metals in dietary supplements (protein powders, nutrition shakes, etc.). Another cluster of notices targeted various foods (like dried fruits, seeds, spices) for lead content. The trend is clear: if your product is a concentrated plant-based or mineral-based item, it’s likely on the radar. Botanicals can uptake metals from soil, and processes like drying or concentrating ingredients can elevate the parts-per-million of these contaminants. Supplement companies have been hit hard – think of protein powders or superfood blends that unknowingly contain micrograms of lead or cadmium. The litigation risk here is not hypothetical; it’s active. For instance, a brand of supplement (let’s say a greens powder) found with 1 µg of lead per serving could face a Prop 65 notice since it lacked a warning for exceeding 0.5 µg/day safe harbor. Settlements often require companies to reformulate to below 0.5 µg or start labeling every bottle with a warning.
  • Case Study – Dark Chocolate & Heavy Metals: Chocolate might not seem like a usual suspect, but consider this a high-profile Prop 65 saga. In 2018, a nonprofit group As You Sow sued major chocolate makers, claiming their dark chocolate contained lead and cadmium above safe harbor levels without warnings. Mars, Hershey’s, Lindt, Trader Joe’s and others ended up in a settlement, agreeing to reduce these metals or face warning requirements. They set industry guideline levels for lead/cadmium in chocolate based on cocoa content. Despite this, a December 2022 consumer report found that 23 of 28 sampled dark chocolate bars still exceeded California’s lead or cadmium limits, sparking new lawsuits in 2023. This case illustrates two things: (1) Even natural ingredients (cacao beans absorb cadmium from soil) can pose Prop 65 problems, and (2) compliance is an ongoing journey – the chocolate industry had to invest in sourcing and process changes to address these metals. The trust takeaway: Companies that proactively tackle such issues (and communicate it) can turn it into a positive story of caring for consumer safety. Those that ignore it get dragged into court and headlines.
  • Case Study – Coffee & Acrylamide: Perhaps the most famous Prop 65 food fight was over coffee. Coffee naturally contains acrylamide (a byproduct of roasting). In 2018, after a lengthy lawsuit, a California judge initially ruled that coffee must carry a cancer warning because of acrylamide. The coffee industry (and even scientists and regulators) rebelled – arguing that coffee’s overall health benefits and inconclusive cancer links made the warning misleading. In a rare twist, California regulators stepped in. OEHHA issued a regulation in 2019 declaring that exposures to chemicals in coffee (from roasting/brewing) do not pose a significant cancer risk, effectively exempting coffee from Prop 65 warnings. So today, you generally do not see Prop 65 warnings on coffee – a relief to both industry and consumers. However, the acrylamide issue lives on for other foods (like fried potatoes, baked goods). In fact, ongoing litigation (Cal. Chamber of Commerce v. Becerra) has put a temporary hold on new acrylamide lawsuits for food products, on the grounds that the warnings might be “controversial or misleading” speech. As of 2024, private enforcers are barred from filing new acrylamide-in-food cases until that First Amendment fight is resolved. This is a fascinating development – it suggests the enforcement climate can shift. But unless your product is coffee (explicitly exempt) or covered by some new rule, you should still treat acrylamide and similar cooking byproducts as a compliance concern.
  • Emerging Chemicals – PFAS and More: Enforcement trends evolve with new chemical listings. PFAS (per- and polyfluoroalkyl substances) like PFOA and PFOS were added to the Prop 65 list in 2021–2022. We’re now seeing the first Prop 65 notices for PFAS in products – including some foods and packaging. For example, a plaintiff group might test a fiber food packaging or non-stick spray oil for PFAS. The numbers are smaller so far compared to metals, but it’s a space to watch as consumers grow more aware of “forever chemicals.” We also see phthalates (plasticizers) frequently targeted, including in food packaging or processing equipment that might leach into food.
  • Penalties and Risks: If you’re found in violation of Prop 65 (i.e., you didn’t warn and your product exceeds safe harbor exposure), penalties can be steep – up to $2,500 per violation per day. In practice, settlements depend on sales volume and severity, but can easily reach tens or hundreds of thousands of dollars, plus you’ll usually have to pay the plaintiff’s legal fees and either start labeling or reformulate. Beyond the direct costs, consider brand damage: a Prop 65 notice or lawsuit is public. Advocacy groups often publish press releases shaming companies for “exposing people to toxic chemicals.” Retailers might pull your product until it’s compliant. It’s not a scenario any food company wants to be in.

Bottom line: Enforcement of Prop 65 in the food and nutraceutical realm is active and unforgiving. Hot spots include heavy metals in supplements and natural foods, acrylamide in baked/roasted goods (though currently paused legally), and whatever new chemicals gain attention (like PFAS). Companies that stay ahead of these trends – by monitoring their products and adjusting formulations – not only avoid lawsuits but can actually earn consumer trust. Next, we’ll discuss what proactive steps you should be taking now to comply and even leverage compliance as a selling point.

What Food Brands Must Do Now to Comply (Compliance Checklist)

Faced with these changes and enforcement risks, what should food, beverage, and supplement brands do now? Here’s a step-by-step compliance checklist to make sure you’re ready for Prop 65’s 2025 era:

  1. Inventory Your Ingredients & Products: Make a list of all your products and identify any Prop 65 listed chemicals that could be present. Pay special attention to common culprits:
    • Heavy metals (lead, cadmium, arsenic, mercury) in ingredients like cacao, protein powders (especially plant-based proteins), seaweed, fruit concentrates, spices, and botanicals.
    • Acrylamide in anything roasted or fried (coffee, nuts, potato-based snacks, grain cereals, baked goods like cookies).
    • Other known chemicals like BPA (in can linings), pesticide residues on raw agricultural ingredients, mycotoxins (like ochratoxin A in certain foods), etc. Cross-check the Prop 65 chemical list for any surprises in your supply chain.
    • For supplements, think of herbal extracts (could have naturally occurring lead), calcium or mineral additives (may contain lead), or any solvent residues from extraction.
  2. Test Your Products (Know Your Numbers): It’s crucial to measure how much of these chemicals are in your products. Engage accredited labs to test suspect ingredients and final products for Prop 65 heavy metals and other relevant chemicals. For processed foods, test samples from typical production batches for acrylamide (if applicable). This data will tell you if you’re above or below the safe harbor levels. If all results are comfortably below thresholds, you have documentation to justify not warning. If some are over, quantify by how much.
  3. Assess Exposure vs. Safe Harbor: For any chemical detected, calculate the estimated daily exposure to a consumer:
    • For foods and beverages: use serving size. E.g., if lead is 0.3 µg per serving of a sauce and a serving is one tablespoon, a typical consumer might have that amount per day.
    • For supplements: use the recommended daily dose (e.g., 2 capsules). If those 2 capsules contain 1.5 µg of cadmium, that’s your daily exposure.
    • Compare these exposures to the Prop 65 safe harbor levels (NSRLs/MADLs). Prioritize any exceedances. For example, if your protein powder results show 0.8 µg of lead per serving (above 0.5 µgoehha.ca.gov), that product will need a warning or reformulation. Sometimes, multiple sources of the same chemical add up (e.g., a superfood mix with many ingredients each contributing some lead).
  4. Reformulate or Source Differently (if possible): If a product is over the limit, consider if you can reduce the levels:
    • Source cleaner raw materials: Some suppliers offer “Prop 65 compliant” ingredients (for instance, vitamin and herbal suppliers often have products tested below certain thresholds). This might mean paying more or tightening specs for impurities.
    • Change your recipe or process: For acrylamide, you could bake at a slightly lower temperature or use an enzyme (asparaginase) that reduces acrylamide formation in baked goods. For metals, perhaps remove or reduce an ingredient that’s the primary contributor (like swapping out a certain cacao source known to be high in cadmium).
    • Limit the serving size: Not ideal, but in some cases reducing a recommended serving can reduce daily exposure (this might apply to supplements – e.g., instruct 1 pill a day instead of 2, if nutritionally feasible).
    • Implement better QA: e.g., washing or peeling ingredients if surface contamination is an issue (lead on the surface of cacao beans can be reduced by cleaning).
    • The goal is to get each product’s chemical exposure at or below safe harbor, so you don’t need to warn at all. This not only avoids label warnings but also improves overall product safety.
  5. Update Warning Labels Where Needed: For any products that still unavoidably exceed safe harbor levels (or if reformulation isn’t feasible), you’ll need to provide Prop 65 warnings. Decide which warning method fits:
    • Short-Form Label (New 2025 format): Use this if space is limited. Remember to insert the chemical name(s) and follow the new phrasing. Update artwork to include the warning triangle and the exact wording with a chemical name and the P65 website. For example: “⚠️ WARNING: Consuming this product can expose you to arsenic, which is known to the State of California to cause cancer. For more info, visit P65Warnings.ca.gov/food.” (If both cancer and reproductive harm are concerns, see the allowed combined wording.)
    • Long-Form Label: Alternatively, you can use the full warning language, which for food typically starts with “WARNING: Consuming this product can expose you to chemicals including [name of chemical]…”. The long form might be necessary if you have multiple chemicals to list or want the flexibility to cover all in one statement. Ensure the URL “P65Warnings.ca.gov/food” is used for food products in the warning (this is the specific site for food info).
    • On-site and Online Warnings: If you sell in stores, your package label does the job. But if you also sell direct-to-consumer online or via catalog, Prop 65 requires mirroring that warning on the product page or catalog description as well. Make sure your e-commerce team displays the updated warnings clearly before purchase (for California consumers at least).
    • Plan label changes early: Design new labels or stickers and use up old inventory before the 2028 hard deadline. You might use over-stickering on existing packaging as a temporary fix if needed, but that can be labor-intensive and look sloppy, so better to integrate new warnings into printed packaging sooner.
  6. Document Everything: Keep records of your test results, supplier certifications, and your determinations of whether a warning is required. If you decide no warning is needed because you’re under safe harbor, have the data on file to back it up. This can be a shield if a claim arises – you can demonstrate you exercised due diligence and had a reasonable basis for no warning. If you do apply warnings, keep a log of when labels were changed, etc. Good documentation = good defense.
  7. Train Your Team: Make sure your R&D, quality control, and marketing teams know about these Prop 65 changes. They should understand why adding a chemical name on the label is required now (so no one “edits out” the scary chemical name during label design!). Sales and customer service should be prepped to answer questions, since customers might ask “Why does my favorite protein shake now list lead on the label?” – The honest answer can be that California requires this disclosure for transparency, and it doesn’t necessarily mean the product is harmful when used as directed.
  8. Consult Experts if Needed: Prop 65 can be legally and scientifically complex. Don’t hesitate to consult a Prop 65 compliance expert or toxicologist for tricky situations – for example, if you have a chemical with no established safe harbor level and you need to do a risk assessment, or if you’re unsure how to label a complex exposure scenario. The cost of advice is likely far less than the cost of a lawsuit.

Following this checklist will put you in a strong position to comply with the Prop 65 2025 regulations. It’s a process that involves both your technical team (for testing and reformulation) and your compliance team (for labeling). The silver lining is that by doing this homework, you not only avoid penalties but potentially improve your product’s safety profile. In fact, it can feed into a marketing angle, which brings us to the next point: how to turn Prop 65 compliance into a strategic advantage.

Strategic Opportunities: Reformulation Wins & Marketing “Prop 65 Compliant” Products

Compliance is not just about risk avoidance – it can also be an opportunity for innovation and brand differentiation. Forward-thinking food and nutraceutical companies are using Prop 65 as a catalyst to improve their products and even as a selling point. Here’s how you can make the most of it:

  • Leverage Reformulation as a Quality Upgrade: If Prop 65 pushes you to reformulate to lower a contaminant, you can spin that positively. For example, say you reduced lead in your herbal supplement to below California’s threshold by sourcing from a cleaner farm or using a new purification step. That means your product is now objectively safer and purer. This can be marketed (carefully) as improved quality. Consumers care about heavy metals and toxins, especially in products like baby foods, chocolates, protein powders, etc. While you should avoid alarmist language, you can tout things like “Now with 40% less heavy metals than the previous formula” or “We’ve enhanced our sourcing for even cleaner ingredients.” Essentially, Prop 65 compliance efforts can align with the broader consumer demand for clean label and safe products.
  • “Prop 65 Compliant” as a Badge (Use Caution): Some companies may be tempted to directly claim “Prop 65 compliant” or “Meets California’s Prop 65 standards” on marketing materials. This can indeed signal that your product passed one of the toughest chemical safety gauntlets. However, be cautious: you don’t want to confuse consumers or imply regulatory endorsement. A savvy way is to incorporate it into your B2B communications or detailed product info sheets. For instance, a supplement manufacturer might assure its distributor that “All ingredients are below Prop 65 lead limits” – building trust that they won’t have surprise labeling issues. Publicly, you might frame it as: “Tested for over 200 contaminants including heavy metals to meet California’s stringent requirements.” This indirectly signals Prop 65 compliance in consumer-friendly terms.
  • Marketing in Non-CA Regions: If your product doesn’t require a Prop 65 warning, that’s a competitive edge in California itself (no scary label needed on store shelves). But even outside California, the fact that you meet Prop 65 standards can be used to assure quality. Many brands add statements like “Tested for heavy metals” on their packaging or websites. Given recent news stories about heavy metals in baby food and chocolate, consumers are seeking reassurance. You might include a seal or note: “Meets California food safety standards for lead and cadmium” – which is essentially Prop 65 safe harbor level compliance, phrased as a benefit.
  • Innovation in Food Science: The threat of Prop 65 can drive R&D to find creative solutions. We mentioned the acrylamide example: some snack makers introduced new baking techniques or even ingredients (like replacing certain amino acids) to lower acrylamide formation. Likewise, chocolatiers are experimenting with blending high-cadmium cocoas with low-cadmium cocoas to dilute the content, or adjusting fermentation methods to prevent external contamination by lead dust. These innovations not only solve compliance issues but can improve overall product consistency and open up new IP or process optimizations. By embracing these challenges, your company can stay ahead of regulations and be seen as a leader in safety and quality.
  • Case Study – Turning Compliance into Brand Trust: Consider the baby food industry (not our main focus, but instructive). After reports of heavy metals, several brands started publishing heavy metal testing results and touting how they stay under even Prop 65 levels for arsenic, lead, etc., even though baby food isn’t legally required to have Prop 65 labels at the federal level. Those brands seized the moment to build trust with anxious parents by voluntarily adhering to California’s strictest standards. A similar approach can work for you: if you make, say, protein bars, you could advertise that you adhere to California’s Prop 65 heavy metal limits, distinguishing your bars from cheaper competitors that might have higher contaminant levels (and warnings on them in CA).
  • “Clean Label” and Prop 65: The clean label movement (consumer desire for simple, natural, and safe ingredients) dovetails with Prop 65 compliance. Use your compliance efforts to also evaluate if any Prop 65 chemicals are coming from additives or packaging that you can eliminate. For example, removing an artificial color that contains trace lead as an impurity not only avoids Prop 65 issues but also gives you a cleaner ingredient list. It’s a chance to kill two birds with one stone: regulatory compliance and marketability.

Finally, don’t fear the Prop 65 label if it’s truly unavoidable. Sometimes a food (like a calcium supplement from natural oyster shell) just naturally has a bit of lead that can’t be removed without destroying the product’s essence. In such cases, apply the warning and be transparent. You can include information on your website to educate consumers: e.g., “Why does this product have a Prop 65 warning? This calcium supplement is derived from natural sources that contain trace elements. The warning is to comply with California law, and the product passes all federal safety standards. We test to ensure levels are as low as possible.” Many California consumers are somewhat desensitized to Prop 65 warnings (they see them often), but providing context can mitigate concern and show that you’re not sweeping it under the rug.

In summary, treating Prop 65 not just as a hurdle but as a quality benchmark can yield dividends. You make safer products (which is good in itself), and you can earn trust by showing customers you’re meeting one of the toughest standards around. With smart communication, what could be a negative (a scary warning or a recall) turns into a positive narrative (your brand cares deeply about safety and transparency).

Conclusion: Turning Compliance into Trust – Your Prop 65 Game Plan for 2025

The 2025 Prop 65 labeling changes are a major shift for anyone in the food, beverage, or nutraceutical space. They signal California’s push for more informative warnings and, by extension, safer products. For businesses, it’s a call to action to tighten up quality control and be transparent with consumers. While the prospect of naming chemicals like lead or acrylamide on your product labels can be daunting, it’s ultimately about empowering consumers and ensuring long-term trust in your brand.

By understanding the new regulations, examining your products for Prop 65 chemicals, and taking proactive steps to comply (as we’ve outlined above), you won’t be caught off guard. Instead, you’ll be ahead of the curve – turning what could be a compliance headache into a strength. Companies that adapt quickly will avoid lawsuits and possibly even avoid having to use the warning labels at all (the ideal scenario). Those that ignore the changes risk legal action, financial penalties, and reputational harm.

Ask yourself: Where do you want your brand to stand in 2025? Displaying a Prop 65 warning out of necessity (or worse, getting served with a 60-day notice by a litigious group)? Or showcasing your commitment to safety by minimizing contaminants and communicating openly with your customers?

Your Prop 65 Game Plan:

  • Educate and assess – Brief your team on the new rules and evaluate every product for potential issues now.
  • Mitigate risk – Reformulate or label as appropriate before the enforcers or regulators come knocking.
  • Communicate proactively – Use compliance as a trust-builder, not something to hide.

We’re here to help you navigate these challenges. Our expertise in food compliance and Prop 65 strategy has helped numerous brands turn compliance into a competitive advantage. Whether you have a specific question about testing for a chemical, need guidance on rewriting your warnings, or want an audit of your entire product line for Prop 65 risks, our team is ready to assist.

Ready to secure your place on the right side of Prop 65 in 2025? Don’t wait for a lawsuit or a last-minute scramble. Book a Prop 65 compliance strategy call with us today and let’s create a customized roadmap for your business. We’ll work with you to ensure your labels are compliant, your formulations optimized, and your brand protected.By embracing Prop 65’s 2025 changes now, you’re not just avoiding penalties – you’re investing in your brand’s reputation for safety and transparency. In an industry where consumer trust is everything, that’s a return well worth the effort. 🚀

Sources:

  1. California Office of Environmental Health Hazard Assessment (OEHHA), Proposition 65 Clear and Reasonable Warnings – Short-form Warning Amendmentssgs.comsgs.com.
  2. Thompson Hine LLP, California Proposition 65 Warning Changes Go into Effect January 1, 2025 (Dec. 2024)foley.com.
  3. OEHHA, FAQs for Businesses – Safe Harbor Levels and Warningsp65warnings.ca.govp65warnings.ca.gov.
  4. Z2Data, California Is Imposing New Labeling Requirements for Prop 65z2data.comz2data.com.
  5. Foley & Lardner LLP, Prop 65: Changes to Short-Form Warnings Will Cause Long-Term Impacts (Apr. 2025)foley.comfoley.com.
  6. Downey Brand LLP, Surprising Surge in Sauces Tops Prop 65 Food Notices in Q3 2023downeybrand.comdowneybrand.com.
  7. Covington & Burling, Dark Chocolate Lawsuits – Lead and Cadmium in Excess of Prop 65 Limits (Jan. 2023)insideclassactions.cominsideclassactions.com.
  8. OEHHA, Coffee and Proposition 65 – FAQ (2019)p65warnings.ca.govp65warnings.ca.gov.
  9. SGS, California Approves Amendment to Prop 65 Short-Form Warning Methods (Dec. 2024)sgs.comsgs.com.

Filed Under: All posts, BUSINESS, CRAFT Tagged With: Food Law, product development, Prop65

9 Most Fascinating Challenges in Custom Gummy Development (And How We Solve Them)

February 6, 2025 by Kristen Nicoletti

Creating the perfect gummy isn’t just about sweetness and chewiness—it’s a delicate balance of science and artistry. Whether you’re crafting vegan gummies, functional candies, or a bold new flavor profile, each step in the process brings unique challenges. At Patric Food and Beverage Development, we specialize in overcoming these hurdles to help you create gummies that deliver on taste, texture, and functionality. Here’s a closer look at nine challenges you might face—and how we tackle them with precision.


1. Gelatin vs. Pectin: Choosing the Right Base

The Problem: A client wanted a heat-stable gummy but also wanted to maintain the same bouncy texture they loved in gelatin-based products.

The Science: Gelatin and pectin gel differently and have distinct textural characteristics. Pectin requires precise acid and sugar levels to set properly. To solve this, we prepared multiple gummy batches using different gelling agents—pectin, gelatin, agar, carrageenan, and various blends. Employing our latest-generation Stable Micro Systems texture analyzer for formal texture profile analysis, plus sensory assessments by our team, allowed us to pinpoint the optimal formula that balanced heat stability and the bounciness our client desired.


2. Sugar Crystallization: A Sticky Situation

The Problem: A potential client noticed their gummies developed a grainy texture after a few weeks on the shelf.

The Science: This graininess often arises from exceeding sugar solubility limits, enabling sucrose crystals to form in the finished product over time. Close attention must be paid to the solubility of every ingredient in the gummy, and certain stabilizers or sugar alternatives can help. For example, starch syrups both replace a portion of the sucrose and increase the viscosity and stability of the candy.


3. Uneven Dosage in Functional Gummies

The Problem: A client producing CBD-infused gummies found that dosage levels varied widely, causing compliance issues and customer complaints.

The Science: We emphasized that high-shear mixing is essential for homogeneity, and we advised testing product samples at different points in the confectionery kettle over time to identify and correct mixing shortfalls. Additionally, the format of the CBD matters. Diluting the active in MCT oil or using emulsifiers (or even a pre-made CBD emulsion) can greatly improve the uniform distribution of the CBD in the gummy base.


4. Bitterness from Active Ingredients

The Problem: A cannabis gummy maker struggled with a pronounced bitterness from their active ingredients.

The Science: We deployed a multi-pronged strategy—bitterness blockers, natural sweeteners, and precise acid adjustments—paired with flavor profiles known to mask bitterness (such as grapefruit or other citrus). After multiple trials, we landed on a flavor system that masked unwanted notes while maintaining a clean-label formula.


5. Moisture Issues: Too Sticky or Too Hard

The Problem: A confectionery company noticed their gummies became sticky during summer months.

The Science: Many gummy ingredients are hygroscopic and readily absorb moisture. Compounding matters, standard plastic films are permeable to water vapor, so gummies will slowly absorb ambient humidity if not stored in cool, low-humidity conditions. One of the most effective solutions is multi-layer (e.g., mylar) packaging that includes plastic and a metallic film barrier. Many manufacturers overlook packaging details—this simple fix often solves their stickiness woes.


6. Heat Stability: Surviving the Hot Shipment

The Problem: A nutraceutical gummy company launched a product with almost 50% active ingredient, but the specialized pectin required for gelation wasn’t as heat-stable as a standard type. Gummies melted and deformed during hot-weather shipping.

The Science: Careful selection of the specific pectin grade is crucial. The type of pectin (high-methoxyl, low-methoxyl, amidated, etc.) matters because each reacts differently to sugar (Brix), pH, and divalent cations (such as calcium, magnesium, and zinc). A heat-stability trial before finalizing pectin type is highly recommended for any product shipping in warm climates.


7. Texture Perfection: Finding the Right Bite

The Problem: A startup making functional gummies received consumer complaints about overly tough chew.

The Science: Gummy texture depends on the balance of gelling agents, sugars, and acids. However, certain sugar replacers and high levels of active ingredients can push the formulation beyond typical textural tweaks. In these cases, less common food ingredients can act as “conditioners.” For instance, MCT oil (or other fats) can soften a firm gummy. There are also non-fat ingredients that have powerful softening effects, and strategic blends can deliver an even greater reduction in toughness.


8. pH Sensitivity: The Gelling Balancing Act

The Problem: A gummy made with natural fruit flavors failed to set, creating a sticky mess.

The Science: Beyond having the correct sugar concentration (Brix) and a sufficient level of pectin, pectin also requires a precise pH range for optimal gel formation. We introduced additional acid and buffering agents to maintain this ideal pH while increasing pectin concentration. This ensured a consistent set, even with fruits like banana that are lower in acidity.


9. Color and Flavor Stability: Fading Over Time

The Problem: A client using vegetable-derived colors noticed that their gummies faded in color and lost flavor after several months.

The Science: Natural colors degrade more easily than artificial FD&C colors. We examined antioxidant use, modified the packaging to reduce light and oxygen exposure, and optimized the choice of colorants. These steps significantly extended the shelf life of both color and flavor.


Bringing Gummy Dreams to Life

From small startups to established brands, we help clients turn gummy challenges into gummy successes. Whether it’s masking bitterness, improving shelf stability, or ensuring the perfect texture, our scientific expertise and state-of-the-art lab equipment can tackle the most complex problems.

Have a gummy problem that needs solving?
Get in touch to learn how we can bring your vision to life!

Filed Under: All posts, SCIENCE Tagged With: chemistry, Gummy, product development, science

Partnering for Success: Meeting the Diverse Needs of Food and Beverage Clients

May 7, 2024 by Kristen Nicoletti

The food and beverage industry is constantly evolving, driven by shifting consumer preferences and technological advancements. For businesses striving to stay competitive, flexibility and innovation are not just advantageous—they’re essential. At Patric Food and Beverage Development, we understand these challenges. Our approach combines scientific expertise, advanced lab capabilities, and a deep commitment to client collaboration to meet and exceed the multifaceted needs of our clients.

Quality Assurance and Technical Standards

Quality cannot be compromised, and our clients depend on us to meet rigorous technical specifications. Our lab is equipped with industry-leading technology, from pH meters to water activity meters, to colorimeters and spectrophotometers, which all play a critical role in ensuring the integrity of food and beverage products under development. These tools help guarantee that every product meets stringent quality standards before it reaches the market.

Navigating Regulatory Compliance and Nutritional Labeling

The maze of regulatory compliance and nutritional labeling is complex, but our expertise in these areas ensures that our clients’ products comply with applicable laws and regulations. This not only helps in avoiding costly penalties but also builds consumer trust in brand integrity.

Cost Management and Budgeting

Budget constraints are a reality for many of our clients, and we prioritize delivering cost-effective solutions without compromising on quality. Transparency in pricing and flexible costing models are part of our commitment to client satisfaction. While we understand that engaging a consultant with over two decades of manufacturing and development experience and a PhD in Food Science may come at a premium, the depth of expertise Dr. Alan McClure brings ensures efficiency and innovation that can significantly reduce costs in the long run. We balance high-quality ingredients and manufacturing processes with efficient cost management strategies to deliver value that not only meets but enhances your market position. This approach not only addresses immediate budgetary concerns but also invests in your product’s long-term success.

Health-Focused Product Development

Today’s consumers are more health-conscious than ever, demanding products that cater specifically to their nutritional needs. Whether it’s formulating beverages with reduced caffeine content or developing snacks for youth athletes, our state-of-the-art R&D lab is equipped to deliver. Through our comprehensive ingredient sourcing processes, we meticulously select components that meet the unique dietary requirements of our clients’ target markets. This careful selection ensures that our health-focused products are not only innovative but also scientifically validated to meet precise nutritional targets, aligning perfectly with consumer expectations.

Innovative Ingredient Sourcing and Product Formulation

Navigating the complexities of ingredient sourcing and product formulation requires a blend of creativity and scientific rigor. At Patric Food and Beverage Development, we excel in identifying and procuring the highest quality ingredients that meet specific client and budgetary needs. Dr. Alan McClure’s scientific approach to product development, grounded in his extensive expertise in flavor chemistry and sensory analysis, enhances our capability to innovate while ensuring product safety and effectiveness. This rigorous sourcing process, combined with our innovative formulation strategies, allows us to create unique, market-ready products that stand out for their quality and consumer appeal.

Efficient Project Management and Timeliness

Efficient project management is crucial to delivering projects on time and within scope. Our meticulous planning and execution strategies ensure clear communication about timelines and deliverables. This systematic approach minimizes delays and ensures that every project milestone is met with precision.

Scalability and Manufacturing Support

As our clients grow, their manufacturing needs evolve. We can provide crucial support in scaling up production, from sourcing co-packers to optimizing manufacturing processes. Our guidance ensures that as demand increases, our clients can meet it efficiently and without compromise on quality.

Iterative Development and Client Feedback

Our development process is highly collaborative. We believe in keeping our clients engaged through regular updates and incorporating their feedback at every stage. This iterative approach allows for continual improvement and ensures that the final product truly aligns with client expectations.

At Patric Food and Beverage Development, we are dedicated to pushing the boundaries of what is possible in the food and beverage industry. Our blend of scientific expertise, innovative solutions, and client-focused strategies make us the ideal partner for companies aiming to innovate and excel in a competitive market.

Are you ready to transform your food and beverage challenges into opportunities? Contact Patric Food and Beverage Development today to see how we can support your next project or schedule a consultation with Dr. Alan McClure.

Filed Under: All posts, BUSINESS Tagged With: experimental design, flavor chemistry, Formulations, product development

The Invisible Shield: Nitrogen Flushing in Beverage Safety and Quality

January 30, 2024 by Alan McClure

Mold Prevention: Role of Low pH and Preservatives:

In non-carbonated beverages, the fight against mold occurs at a microscopic level, with low pH as a primary defense. Beverages like energy drinks, often having a pH of less than 2.5, create an environment unsuitable for many molds. Preservatives, such as sodium benzoate, further strengthen this defense. However, there’s another crucial, yet often overlooked, method in this battle: nitrogen flushing.

Nitrogen Flushing: Key to Beverage Preservation

Nitrogen flushing, commonly used in the food and beverage industry, involves replacing oxygen in a container with nitrogen. This is crucial as mold requires oxygen to thrive. By using nitrogen, we thwart potential mold growth.

Combatting Oxidation:

Oxygen is essential not only for mold but also facilitates oxidation, which degrades beverage quality. Nitrogen flushing effectively slows down this process, preserving the beverage’s freshness and taste.

Prolonging Shelf Life:

Nitrogen flushing extends a beverage’s shelf life by inhibiting spoilage organisms and delaying oxidation. This benefits both consumers and manufacturers by ensuring longer-lasting freshness and reducing waste.

Creating a Positive-Pressure Barrier:

Nitrogen flushing also generates a positive pressure barrier in the container, which helps prevent external contaminants from entering, akin to an invisible protective shield.

Ensuring Quality in Every Sip:

When enjoying a beverage, it’s not only the ingredients that matter but also preservation techniques like nitrogen flushing. These methods ensure the safety, flavor, and longevity of beverages. Nitrogen flushing signifies a commitment to quality and safety in every sip!

Filed Under: All posts, CRAFT, SCIENCE Tagged With: Beverages, energy drinks, nitrogen flushing, product development, Quality, Safety

10 Reasons You Need a Food Science Lab for R&D

December 5, 2023 by Alan McClure

As a shrewd and effective entrepreneur in the food industry, you probably face important choices every day. Concerns about budget, quality, safety, production, market demands…

And of course most importantly—enchanting your customers with deliciousness. 

You may be wondering whether you really need a fullbore food science lab for your product development and R&D needs. Whether it’s worth the cost (or we prefer “investment” but we’ll get to that). 

So what makes food science consultants stand out? 

Well in addition to the incalculable experience, training, and molecular creativity earned through years of practice with the best equipment and the top culinary masters of our age…there are also some easily tangible tools & techniques for culinary R&D that only food scientists like us can offer. 

Seriously, come visit the lab! We have lots of cool stuff to show you (and let you taste)…

In the meantime, here are just 10 of the many things you definitely won’t get with your run-of-the-mill food development consultant.

1. Spinzall – The magic merry-go-round of food science

Spinzall food science R&D lab

This compact centrifuge is a maestro of the trade, breaking down mixtures into component parts; spinning a liquid at high speed to segregate its materials by density.

For example, a liquid such as lemon juice can separate into fruit solids, clarified juice, and citrus oils (also known as pellet, supernate, and oil layers, respectively).

By separating ingredients into their core components, the Spinzall centrifuge opens doors to understanding and manipulating food on a molecular level. It’s a stepping stone for crafting novel textures and flavors that tickle the taste buds in new, exhilarating ways:

  • Clarify juices for full flavor but a crystal-clear appearance
  • Extract essential oils from herbs
  • Remove suspended solids that can separate and/or spoil over time

The Spinzall is crucial for innovating textures, flavors, and new culinary creations—but it can also play a role in quality control and ensuring consistency across batches. 

By separating undesired particles and elements that affect flavor or shelf-life, it makes sure there’s nothing in your final product except pure goodness.

So the next time you marvel at the crystal clarity of a beverage or the unique texture of a modernist cuisine dish—remember, there may be a Spinzall and a team of curious food scientists behind the scenes, spinning their magic to elevate your culinary experience beyond the expected.

2. Analytical Balance – The art of precision

This ain’t your science teacher’s balance scale. It’s not even your college pot-dealer’s fancy digital scale.

The analytical balance we use in our food-science R&D lab measures mass down to the 10,000th of a gram. Put it this way: your typical high-quality digital scale can measure differences down to 0.01 grams. Our analytical balance measures down to 0.0001 grams

It’s so precise, it has to sit on a marble table, lest the room’s vibrations and air currents disrupt the measurement.

  • Dose small quantities of powerful ingredients with extreme accuracy.
  • Hit that accuracy with extreme precision, which means that measurement after measurement gives you the same result.
  • Protect the measurement from error introduced by building vibration and/or airflow

This level of precision may not seem important when it comes to playing around with individual recipes—but when you scale up for production, you multiply every factor by some order of magnitude. Which can make any small deviations in measurement quite impactful.

3. Psychrometer – Take the pulse of humidity

Turning from the material to the atmospheric side of food—the humble yet important psychrometer measures moisture in the air, which plays a pivotal role in the food we enjoy.

A Psychrometer comprises two thermometers; one dry and one wet. By comparing the temperature differential, it calculates the ambient humidity, which factors into food science on many levels.

Moisture influences how ingredients meld, the texture of food, and even its shelf life—so understanding how products behave at various humidity levels is crucial for developing tasty treats people can enjoy anywhere.

In a food science R&D lab, a psychrometer helps maintain carefully controlled environments to study and adjust for these important factors, ensuring that each bite delivers the experience your customers are hoping for.

  • Perfect the crunch of a chip
  • Ensure the right softness in bread
  • Extend the shelf life of packaged products

Managing humidity is key also for quality control. Think about what might happen if the humidity in your production facility was different from where you developed your recipe—that means the moisture content of your finished product doesn’t match your R&D, and you have no real control over what shows up in front of your customer.

We shudder to imagine…

4. Food Dehydrator – Leather it up

Ever marveled at the lasting texture of dried fruits or the savory intensity of jerky? A food dehydrator uses air circulation and sometimes low heat to evaporate moisture from foods, leaving behind morsels with condensed flavors, unique textures, and much longer shelf life.

  • Create healthy snacks that won’t go bad
  • Preserve seasonal produce for year-round enjoyment
  • Make high-quality dried herbs

By reducing moisture, a food dehydrator creates an unfriendly environment for bacteria and molds, which helps make perishable items last much longer.

The next time you enjoy a delicious dried apple slice or a toothsome piece of jerky—remember there’s a food dehydrator and maybe a food scientist or two monitoring the drying process carefully, measuring things like moisture content, water activity, and microbial activity, to bring forth the best product possible.

5. Chemical Dryer – A magic wand of waterlessness

Chemical dryer for food industry R&D

A chemical dryer like ours uses gentle vacuum conditions to remove moisture from a substance with minimal heat, which reduces any unwanted chemical changes.

Its primary use is to convert various chemical hydrates (having water) to anhydrous compounds (without water), which can then be used for their functional properties. For example, epsom salt is a hydrate in its standard form. But in its anhydrous form it can be used to pull moisture out of other solvents to help purify them, when even small amounts of moisture can be a problem. 

  • Dehydrate delicate substances that can’t tolerate heat or convection air currents
  • Remove all moisture when even minute amounts can be a problem
  • Complete the process of any ethanol-based solvent.

It’s much more gentle than a drying oven or even a dehydrator. Though our chemical dryer has the option to use low heat as well, for certain circumstances.

6. Water Purification – Tapping into elemental magic

When formulating beverages, we like to start from scratch with pure H20—to make sure every potential flavor factor is under our control from the start.

In our R&D lab, municipal water flows through several steps to remove any existing minerals, chemicals, or other impurities:

  • Water softener
  • Activated charcoal filter
  • Reverse osmosis system
  • Deionizer

Then we can add carbonation if that’s the kind of beverage we’re formulating, followed by any minerals or other flavor additives we want in the finished product, in very specific and controlled amounts.

But the important thing is that throughout the beverage development process, we control every aspect of the ingredient that represents the vast majority of the recipe: Water!

Read more about our food lab’s water purification setup at our sister site.

7. Sonicator – The sound bath & the fury

Sonicator food science R&D tool

A Sonicator uses ultrasonic waves to stir up a storm on a microscopic level, breaking down cells, mixing ingredients more thoroughly than a blender, or dispersing flavor particles evenly through liquids. 

The Sonicator transforms electrical energy into useful mechanical energy by pushing soundwaves through an aqueous medium at various frequencies depending on what you need. The effect is powerful enough that it can form cavitation bubbles in pure water!

  • Create stable emulsions
  • Extract compounds from plants or other tissue
  • Dissolve chemical compounds incredibly efficiently

This machine uniquely lets us blend and mix at high frequency without the spinning effect caused by other methods. And unlike blenders, doesn’t incorporate any oxygen into the mix—in fact, it forces dissolved gasses out! This means that when oxidation is a potential issue, sonication is the go-to option.

8. The Vortex Mixer – Whirling wonder of agitation

Vortex Mixer in the food science lab

The Vortex Mixer is a simple padded arm that holds a container of liquid. The pad oscillates at specific frequencies to swirl the liquid at precise high speeds (in the thousands of RPM).

Think of a wine aficionado swirling a glass by the stem to “breathe” or incorporate air into the wine for deeper enjoyment of its phenols and flavors.

Our Vortex Mixer does that, but at a speed that would make any sommelier weep. All in the name of uniform mixing, without the blade of a blender. 

  • Dissolve compounds more quickly
  • Break up centrifuge pellets
  • Mix highly viscous substances in a controlled space such as a centrifuge tube or test tube.

Compared to the Sonicator and other methods, it mixes incredibly quickly—just seconds sometimes. The Vortex Mixer also has an option to add vibration along with the swirling oscillation, which further helps randomize the mixing motion.

9. Induction Burner – Harnessing invisible power

Induction burner in our food science lab

Ahh the induction burner—a modern marvel that brings the power of magnetic fields to the stage of culinary science.

Induction burners electromagnetically excite the electrons in steel pots and pans to warm their contents without flames or direct heat.

The whole container heats evenly, reducing hot spots and burn points, and cooking what’s inside more quickly and consistently than other burners.

  • Cook sauces without breaking.
  • Boil much faster than than other methods.
  • Reduce delicate fruit purees without burning or sticking.

Induction burners offer precise control over temperature, as well as much better energy efficiency than traditional cooktops. They also help make the lab safer—because once you remove the metal implement, the induction surface is no longer active, and cools quickly to the touch.

10. Thermomix: The culinary composer

Using a Thermomix for food science R&D

The Thermomix is a marvel that can blend, chop, mince, stir, cook, steam, weigh, and more—all while maintaining total control over temperature and time. It conducts a symphony of precision and versatility, choreographing the ingredients to fulfill their exact and utmost potential in a recipe.

  • Knead dough & mix batter
  • Perfect confectionery recipes
  • Create beverages with unique properties

Simply program it with the process you want, weigh in the right ingredients, and the machine handles the rest with precision and accuracy…so the attending scientist/chef/creator can focus on other more important work than watching the pot.

The Food Science Wizard – Pulling the strings of theory

Okay yes, there’s an eleventh reason that unifies them all together. Welcome to the most intangible dimension of why food science R&D delivers results that other consumable consultants simply can’t measure up to. The least quantifiable, most important factor of the entire food science R&D process.

The scientist him/herself.

You can’t really measure the impact of creativity or lived experience. You can’t quantify inspiration, nor the random connections that spring up in the active mind of a deeply trained and educated expert.

We didn’t get into this field because we love equipment. We got into it because we love food, and want to know every little detail of how it works and how to make it better—down to a molecular level.

We develop our science and collect these and other incredibly valuable food-lab tools…but the real power driving what we do for people who want to sell consistent deliciousness to their customers, is our creativity. Both in problem-solving and product development.

Let us know what you’re working on, and we’ll be glad to teach you more about what we do!

Filed Under: All posts, BUSINESS, CRAFT, Process Optimization, Product Development & Optimization, SCIENCE Tagged With: beverage, equipment, food science, formulation, process, product development, scaling

Nutraceutical R&D: Beverage Formulation Station

October 30, 2023 by Alan McClure

If you visit the Patric Development food science lab, there’s a lot to take in. We have innumerable gadgets and special machines for developing the best recipes possible; for any kind of edible you can imagine.

But first: How about a nice cold glass of sparkling water on tap?

And this is sparkling water like you’ve never tasted it…highly carbonated, crystal clear, and very refreshing on the palate.

Well that’s just one of the unique features that makes our food science lab stand out from most food and beverage consultants. 

We’re here to serve.

But did we install a multi-thousand dollar system just to make the best, cleanest, perfect pH club soda for visitors?

No, of course not. It also serves a much deeper purpose…

Why do we have a state-of-the-art water purification system?

The main reason we set up this complex water station is to help with our initial prototyping stages of beverage formulation.

This is where we test flavor combinations, mouthfeel, bitterness, etc, when developing a nutraceutical, energy drink, or other beverage concept. 

And we want to start with water that’s totally pure. Cleared of any naturally occurring (e.g., minerals) or added compounds (e.g., chloramine) besides H2O that might affect how it tastes and how it interacts with other ingredients.

So here’s what happens to our water before it flows out of the tap:

Water softener

First we pass the very hard municipal water through a water softener. This gets rid of calcium, iron, and other minerals that might impact pH, flavor, etc.

You may not think of minerals as impacting flavor—but consider the experience of drinking distilled water compared to a bottle of mineral water. Not only does it taste very different, but it feels different and quenches thirst differently too.

Trust the experts: we did a blind tasting of several market mineral waters, reverse-osmosis waters, and distilled water—and came to an important conclusion:

If you’re going to make a product that’s mostly water, then the mineral profile is a variable you definitely want full control over in the formulation and development process.

The activated charcoal water softener also removes any chlorine/chloramine, which can damage reverse osmosis membranes (where the water flows next).

Reverse osmosis (RO)

This process basically pushes water through a specialized membrane that filters out even more than the activated charcoal does (but it’s also more delicate). Running the two methods in sequence results in water approaching ~95% the purity of distilled water—but without all the hassle of distilling, collecting, and storing.

Deionizing cartridge

If we need even higher purity thresholds, we pass the RO water through a deionizing (DI) cartridge to remove the very last stragglers from the previous processes (e.g., silicas, nitrates, phosphates) attaining 99.9%+ pure water.

Now we have the equivalent of unlimited distilled water on-demand, cutting out plastic containers and deliveries and wasted energy and materials.

Then once we’ve put in all that hard work to create pure water, we can start adding things back in to build the foundations we want for our R&D projects.

Forced carbonation

In this step we add pressurized CO2, which dissolves in the water. This is called “forced” carbonation, as opposed to byproduct carbonation (like in fermentation).

It’s set to extra high carbonation; both because we like the taste and mouthfeel of it that way—but also because it will result in a prototype that’s actually characteristic of your final product, compared to starting with regular carbonated water which would turn out something kind of flat and lifeless.

This part of our beverage station is optional, and there are plenty of instances where we wouldn’t add carbonation.

For example, a vegetable supplement breakfast drink probably wouldn’t taste great carbonated…so in that case we’d bypass this step and move on to start playing with emulsions to make sure your ingredients don’t separate and settle.

So, like everything else we offer, it all depends on what you’re trying to achieve. 

Chilling plate

Before it hits the tap, our room-temperature water runs through a chilling plate to get it quickly and quite literally ice cold and ready to serve.

This way we can develop prototypes that match the conditions of consumption. Because even if your nutraceutical or energy drink is shelf-stable, chances are American consumers will still want to enjoy it cold. It’s just so much more refreshing that way. So that’s where we start. 

This step means that we’re getting into the shoes of your consumer—from the earliest stages of beverage formulation. Which ultimately results in a tastier, more enjoyable product for your customers. 

What our formulation beverage station means for you

Why should you care about any of this? 

Well if we didn’t take all these steps, and just used regular filtered water for prototyping, there would be slight differences in the final recipe, depending on the water you used for production. This would undermine consistency, which is vital for successful production and scaling.

But more important than that, it’s because all this precision helps us formulate a recipe that guarantees your emulsions don’t break or other ugly outcomes—by testing and controlling things like pH, brix, turbidity (cloudiness), and viscosity/mouthfeel, as well as assuring that ingredient profiles allow for shelf-life expectations and labeling targets.

Not a lot of beverage R&D labs can offer that kind of comprehensive prototyping and precision beverage formulation. But if you want to develop a scalable nutraceutical, energy drink, or other beverage that’s ready for market and comparable to any of the top brands, it’s a critical investment that will save time and money later down the line.

Contact us to see how we can help your beverage ideas succeed. 

Filed Under: All posts, CRAFT, Food & Beverage Process, Product Development & Optimization Tagged With: beverage, formulation, product development, scaling

Gelling Agents for Nutraceutical Gummies

September 18, 2023 by Alan McClure

We’ve come a long way from the Flintstones chewables we grew up on. Fortunately for all of us, we’re entering a golden age of gourmet vitamins, dietary supplements, and other nutraceuticals.

That’s why you’re here, right? To make people’s lives a little easier, and a tad tastier?

Well here’s some free food-science knowledge from true kitchen nerds about one of the key elements you’ll have to decide upon for your nutraceutical gummy formulation.

Do yourself a favor and save yourself some time in your nutraceutical product development by spending a moment here with experts who’ve already done the research for you…

 As a pioneer in the nutraceutical industry, it’s understandable that you won’t settle for creating anything less than a delicious, effective, consistent product. 

Before we dive into the science of gelling agents for nutraceutical gummies—to discover why your gummy keeps coming out overly chewy, bland, or unpredictable—let’s do a quick introduction just to make sure we’re all in the right room.

What are nutraceutical products?

Nutraceutical products are edible dietary supplements that provide a physiological benefit aside from regular nutrition.

As a nutraceutical innovator, you likely already know that the possible benefits of nutraceuticals are almost infinite. Businesses like yours are creating and perfecting nutraceutical products even as you read this, to provide myriad benefits like managing disease, sleep, mental health, and allergies!

Some of the most popular nutraceutical gummies on the market include:

  • CBD edibles
  • Vitamins 
  • Melatonin supplements
  • Compound pharmacy meds
  • Dietary supplements

While the popularity of nutraceuticals is on the rise in general, nutraceutical gummies, specifically, are by far outpacing other products in the nutraceutical industry. In fact, the gummy supplement industry has grown by more than 80% in the last two years! 

Even in the cannabis world, 71.1% of edible sales in the US are gummies. 

The people have spoken –they want a gummy and they expect it to be good. Whoever it is you’re hoping to help with your nutraceutical gummy, investing in perfecting the formula to ensure your product stacks up against the steep competition can make all the difference to your success. 

So how do you make a good nutraceutical product – specifically, a great gummy?

Since you’re here, you probably already know the therapeutic benefits you want from your nutraceutical gummies, and maybe you’ve even decided what flavor you want them to be—nice work.

But what about your gelling agent? As benign as the choice may seem, your gelling agent is the single gummy ingredient voted most likely to separate the great gummy from the “meh” gummy.

Why are there so many types of gelling agents for nutraceutical gummies?

If in your product development journey so far you’ve peeked behind the curtain of what goes into crafting the perfect gummy, you’ve seen that the list of possible gelling agents for nutraceutical gummies is long; pectin, gelatin, agar and many more—what’s the difference? 

The reason there are so many types of gelling agents in the nutraceutical industry is that each one has its own unique benefits and drawbacks—depending on what you’re trying to accomplish.

The right gelling agent for nutraceutical gummies depends on the functional purpose of the gummy (what benefit does your nutraceutical provide its consumer), the desired texture and flavor (how important is the “yum” factor), your own familiarity with the critical handling techniques of the agent, and whether the nutraceutical is a vegan or clean-label product.

What’s the best gelling agent for your nutraceutical gummies?

To answer that, put on your food scientist hat for a moment and ask yourself these other questions first: 

  • What are you making and what other ingredients are you using that may interact with the gelling agent? 
  • What are your priorities (flavor release, mouthfeel, simplicity, being vegan, temperature stability)? 
  • What temperature are you heating your mixture to? 
  • How comfortable are you handling finicky ingredients?
  • Do you have flexibility to mold at different temperature conditions?
  • Do you have a stoving room to remove excess gummy moisture?

You know your nutraceutical gummy needs better than anyone, so take a look at this chart of 7 common gelling agents, and get ready to conquer the nutraceutical industry. 

Below you’ll find the most popular gelling agents for nutraceutical gummies, including pectin, gelatin, agar, carrageenan, gellan gum, and acacia gum. Take a look at the benefits and drawbacks of each agent to help you balance your unique priorities and develop the perfect product.

7 Different gelling agents for nutraceutical gummies:

Pectin

Source: Plant tissues, (especially apples and citrus)

Varieties: High-methoxyl and low methoxyl (and many subcategories)

Benefits: 

  • Heat stability
  • Excellent flavor release
  • Many varieties including fast- and slow-set

Drawbacks: 

  • Tricky product handling
  • Sensitive to calcium and other cations

Vegan: Yes

Gelatin

Source: Beef, pig, fish

Varieties: Alkaline- or acid- extracted; Different strengths

Benefits: Very bouncy and classic like gummy bears

Drawbacks: 

  • Terrible flavor release
  • Not heat-stable
  • Sensitive to acid

Vegan: No

Agar

Source: Seaweed

Varieties: Seasonality leads to different strengths

Benefits: 

  • Easy to work with
  • Good heat stability

Drawbacks: 

  • Sensitive to acid
  • Poor flavor release
  • Brittle gel

Vegan: Yes

Carrageenan

Source: Seaweed

Varieties: Harvested from several types of seaweed (Kappa, Iota, Lambda)

Benefits: 

  • Varies by type (some gel and some don’t; some have good heat stability, some don’t)
  • A decent mimic for gelatin

Drawbacks: 

  • Mediocre flavor-release
  • Harder to work with than gelatin
  • Sensitive to acid
  • Sensitive to cations
  • Bad press lately re: health effects

Vegan: Yes

Gellan gum

Source: Bacteria

Varieties: High-Acyl and Low-Acyl (very different characteristics)

Benefits: Varies by type (some gel and some don’t; some have good heat stability and some don’t)

Drawbacks: 

  • Not great mouthfeel
  • Gel is brittle

Vegan: Generally considered vegetarian, but produced by bacteria (technically an animal)

Acacia gum

Source: Tree sap

Varieties: Incorrect species can be harvested

Benefits: Distinct chewy texture that is not truly a gel

Drawbacks: Off flavors are common due to impurities or incorrect species being harvested

Vegan: Yes

Starch

Source: Grain products

Varieties: Infinite varieties depending on ratios of amylose:amylopectin and whether the starch is modified and how

Benefits: Varies by type (some gel and some don’t; can have very distinct chewy characteristic unmatched by any other agent)

Drawbacks: 

  • Characteristics are all over the map due to infinite varieties
  • Modified versions aren’t seen as “clean label
  • Often requires special high-pressure jet cookers

Vegan: Yes

What happens if you use the wrong gelling ingredient?

The good news is that even if you’re not a food scientist and you mistakenly choose the wrong gelling agent for your product during R&D, you’ll most likely just end up with a melted, sticky mess. Or maybe a bitter, brittle mishap. No one is gonna get hurt because of your chemistry project gone awry.

However, we know that the long process of trial and error in product development can get old fast if you’re ready to start sharing your awesome product with people who need your help as soon as possible. That’s why some business owners like you decide to skip the kitchen experimentation and focus more time on the real mission: helping people feel better with your gummy. 

Our food scientists are always ready to help when it comes to choosing the right gelling agent for a nutraceutical gummy, or even a blend of multiple gelling agents! That’s right, some of them can be used together to particularly good effect for certain challenging issues.

If you’re excited to share the benefits of nutraceuticals and elevate your customer’s experience, selecting the right gelling agent for your gummy is an absolute must! 

Want to avoid some of the typical trial and error associated with this process? Go ahead and ask the questions only a food scientist would be able to answer: Contact us here!

Filed Under: CRAFT, Food & Beverage Process, Product Development & Optimization, SCIENCE Tagged With: food science, formulation, product development

Bitterness in Beverage Formulation

July 2, 2023 by Alan McClure

The beverage industry has witnessed a remarkable transformation in recent years, with an influx of small businesses dedicated to creating high-quality, smaller-batch products. This diversification has led to an explosion of unique flavors and ingredients, pushing the boundaries of traditional beverage offerings. 

Once upon a time, a “soft drink” was basically water, sugar (often corn syrup), flavoring, color, and maybe caffeine.

Believe it or not, Coke and Sprite are essentially the same recipe—except for a touch of herbal flavor and that iconic caramel coloring (plus the caffeine of course). 

Fortunately, creative beverage producers have broken free of the mold, reaching for new heights of uniqueness and ingredient use. But along with this delightful new turn in gourmet and high-quality beverages, comes a huge increase in the importance of understanding bitterness. 

One of the 5 basic taste categories, bitterness can add complexity and depth to beverages, though it can also turn off consumers for various reasons. Sometimes bitterness is part of the charm. Lots of delicious common beverages are bitter: coffee, tea, beer, tonic water, wine, grapefruit juice, numerous classic cocktails…

But when bitterness isn’t desired, or when it’s poorly balanced, it can be quite unpleasant for the consumer—especially for those unfortunate (but not uncommon) folks called “super tasters” who have high bitter sensitivity due to genetic contribution. Not so “super” for drink manufacturers…but fortunately there are plenty of ways to handle bitterness, even for the extrasensitive.

So let’s talk about naturally occurring bitterness in beverages, and the different ingredients that contribute to this controversial taste sensation.

How do you measure bitterness in foods & beverages?

Beer drinkers are readily familiar with IBUs. It’s an easy way of helping customers narrow their choices based on how bitter they prefer their beer.  

However the IBU is not a measurement of perceived bitterness; but rather the amount of iso-alpha acid (derived from hops) that’s dissolved in the solution, where 1 IBU = 1 ppm (or 1 mg/L).

So it only works with beer. And it’s really only a rough indicator, because you can sweeten a high-IBU beer to a point that it no longer tastes bitter, but still has a high concentration of iso-alpha acids. 

Another, more generalized way of measuring bitterness is Bitterness value, which is based on the smallest concentration of 1 gram of a substance dissolved in water, that can still be tasted as bitter. 

This scale centers around the perceived bitterness of quinine (an alkaloid extracted from chinchona bark) which still delivers a bitter taste all the way to 1 g dissolved in 2 liters2000 mL of water. 

On that scale, quinine has a bitterness value of 200,000. Pure caffeine has a similar value, though somewhat less.

And by the way, the most bitter natural substance is gentian root, which boasts a bitterness value of 58 million. Which means 1g of gentian extract can bitter up to 58,000 liters of water! That’s enough to fill a 9 x 4 meter backyard pool!

While this scale provides a numerical value for bitterness, it is crucial to remember that taste perception is highly subjective, influenced by personal preference and biological factors such as individual tastebud distribution and age.

What ingredients add bitterness to foods & beverages?

For beverage products like nutraceuticals, energy drinks, and carbonated soft drinks—whether clean-label or otherwise—there are a lot of ways to get the flavors and effects you want to give to your customers.

But many of these natural ingredients are inherently bitter, and require some kind of bitterness management.

Stimulants

Natural stimulant ingredients like caffeine, theobromine (found in cacao and small amounts in tea & coffee), mateine (found in yerba mate), and guaranine (found in guarana) can impart bitterness to beverages. 

While these compounds are known for their uplifting effects, their bitterness can vary depending on factors such as the roast level of coffee beans or the percentage of cacao in chocolate.

Fun fact: when training for expert sensory analysis of bitterness, the reference material used is a solution of pure caffeine. 

Alcohol

Ethanol (drinking alcohol) is a naturally bitter compound. The method of producing, refining, and aging the ultimate product contributes to the character and level of bitterness—because of compounds such as tannins, phenols, and hop-derived extracts. Which are responsible for the underlying bitterness balanced to perfection (one hopes) in wines, spirits, and beers.

Herbal & botanical bitterness

Many of the most common herbs & botanicals used for creating clean-label flavors add an element of bitterness. And some may surprise you, because their bitterness is usually balanced by other elements (cinnamon, for example, adds bitterness but we usually associate it with desserts).

Classic bitter beverage ingredients:

  • Chamomile
  • Dandelion
  • Citrus peels
  • Rhubarb
  • Grapefruit
  • Cranberry
  • Quinine
  • Wormwood
  • Gentian root

These natural compounds can add complexity and desirable astringency to a beverage formulation, but they can also be overdone to disastrous effect. (Ever leave cinnamon sticks too long in your hot cider? Yech!)

Cannabinoids

With the increasing popularity of cannabis-infused beverages, it’s important to understand how cannabinoids like THC and CBD, can introduce bitterness to a recipe. You can’t just add cannabis extract to your recipe and send it out. There’s work to do first…

Ways to balance & mask bitterness in beverage products

Creating a well-balanced and enjoyable beverage that’s more than just sugar, water, and artificial flavors, generally requires some degree of bitterness management. 

There are three main ways to approach this:

Flavor (aroma) synergy:

Combining bitter ingredients with complementary aromas (often mis-termed as “flavors”), can help balance the overall gustatory profile. Aromas can add pleasant associations and context to bitterness. 

For example, herbal bitterness can be mellowed by incorporating fruity or floral notes (a la strawberry/rhubarb). Grapefruit aroma is also particularly adept at making bitter beverage elements seem fitting and balanced. This synergy can create a more harmonious and pleasant flavor experience overall.

Taste synergy:

The term “taste” technically refers to the 5 types of flavor receptors we have: bitter, sweet, sour, salty, and umami. This method of balancing bitterness factors in foundational ingredients that bring taste but not aroma; like sugar, citric acid, water, and salt.

By carefully selecting and blending ingredients, beverage creators can manipulate the balance of bitterness. Different ratios and combinations of bitter and counterpart tastes (such as sugar) can lead to a well-balanced flavor profile, ensuring that bitterness does not overpower the drink. Skillful blending can result in a nuanced taste that appeals to a wide range of palates.

Bitterness suppression

Some ingredients have the ability to mask, diminish, or suppress the bitter taste of others. This includes simple, time-honored tricks—as well as high-level food-science techniques.

As you surely know, beverage producers all too often take the easy route—using large amounts of high-intensity sweeteners like stevia or monkfruit extract; which can help blot out bitterness while still maintaining a desirable level of sweetness. However, many consumers are quite sensitive to such non-nutritive sweeteners, which often carry off-flavors of their own (expecially at higher concentrations) sometimes even adding MORE bitterness to the aftertaste. So use with caution, and test via consumer analysis.

Getting more advanced; microencapsulation is a food chemistry technology that encloses bitter compounds within a hollow sugar molecule that prevents them from interacting with taste receptors on their way to the stomach, where the encapsulation readily breaks down. 

This technique is especially useful for cannabis edibles, where you want those active ingredients to digest into the bloodstream, but not impart their highly bitter characteristics.

Don’t leave bitterness up to chance

Bitterness, though subjective, plays a crucial role in creating complex and intriguing flavor profiles in beverages and other foods. Understanding the ingredients that contribute to bitterness and using effective techniques to balance or mask it, is key to developing exceptional beverage products that keep your customers coming back for more.

However, crafting a quality beverage recipe formulation that effectively addresses bitterness requires expertise and an understanding of the science behind taste perception. 

In this era of small businesses creating high-quality, smaller-batch products, the expertise of a food scientist can elevate your beverage offerings and help you stand out in a ridiculously crowded market. 

An experienced food science consultant (not necessarily me—but I do have 20 years of award-winning formulation experience working with highly bitter ingredients) can help you develop innovative and market-ready beverages that fix bitterness naturally, while meeting consumer demands. 

Want to develop a beverage that captivates the taste buds while addressing bitterness effectively? Reach out and let’s talk about how we can create a truly exceptional beverage formulation.

Filed Under: All posts, CRAFT, Food & Beverage Process, SCIENCE Tagged With: beverage, bitterness, cannabis, formulation, product development

Nutraceutical Food Scientist vs ChatGPT Gummies – Part 1

April 4, 2023 by Alan McClure

You may have already considered turning to ChatGPT to find new functional food recipes. 

If you’ve played around with it and you have any experience with making functional food products such as gummies, you may have noticed some chinks in the armor.

The first and last thing to remember about this program is that it is not sentient. It uses machine learning to sort through everything it can access on the internet–2021 and earlier– and pull an answer that its training says best fits your question.

First I asked ChatGPT 3.5 how to make the best vegan gummy. 

It’s a simple, basic question that anyone searching for a gummy recipe might ask, whether it will stand alone, serve a functional role, or even be a medicinal cannabis edible. 

I wanted a recipe that doesn’t use any animal-derived ingredient (i.e., no gelatin). I was expecting that ChatGPTwould probably suggest something fruit-flavored because that’s so common in the gummy world. 

As far as plant-derived gelling agents go, I know from experience that the three most common are pectin, agar, and starch. For homemade gummies, starch is rarely the choice, as the specialized-for-confectionery modified starches are hard to acquire, and standard starches, like corn starch, doesn’t serve the role as well. 

I also thought that if ChatGPT really understood “best” it would offer something with pectin, given the well-known excellent organoleptic characteristics that result from its use.

But this is what it came up with:


Here’s a recipe for making vegan gummies:

Ingredients:

  • 1/2 cup of fruit juice (preferably low pH like lemon juice or orange juice)
  • 1/4 cup of water
  • 1 tablespoon of agar agar powder (a vegan alternative to gelatin)
  • 1/2 teaspoon of citric acid
  • 1/4 teaspoon of salt
  • Optional: functional ingredient

Equipment:

  • Silicone gummy molds
  • Saucepan
  • Whisk
  • Dropper or syringe

Instructions:

  1. In a saucepan, mix together the fruit juice, water, agar agar powder, citric acid, and salt.
  2. Whisk the mixture together over low heat until the agar agar powder dissolves completely.
  3. Add the optional functional ingredient.
  4. Remove the saucepan from the heat and let it cool for a few minutes.
  5. Using a dropper or syringe, fill the silicone gummy molds with the mixture.
  6. Place the molds in the refrigerator for 30-60 minutes to let the gummies set.
  7. Once the gummies have set, remove them from the molds and store them in an airtight container in the refrigerator.

That’s it! This recipe should yield about 20-30 gummies, depending on the size of your molds. Make sure to label your gummies and keep them out of reach of children or pets

ChatGPT 3.5

Don’t use this ChatGPT gummy recipe!

TLDR: It will turn out sour and may not even gel.

Let me break down what went wrong, and then I’ll ask it a more specific question.

Precision measuring

Generally speaking, it’s better to measure by mass/weight than by volume. Ingredients tend to vary in density from producer to producer. For example ¼ tsp. salt will have a different mass of salt depending on the grain/flake shape and size. Which can change the flavor drastically, especially when you scale up for market (which you can’t realistically do volumetrically with dry ingredients).

It’s not surprising that ChatGPT pulled a gummy recipe with volume-based measurement. It’s just drawing from what’s available on the internet—which leans toward American preferences, and American households still don’t often have scales in their kitchens. But if you’re making gummies commercially, definitely measure your recipe by weight.

Flavor

It makes sense to see fruit as the basis of this recipe. Fruit juices and purees are common gummy ingredients.

But I am surprised to see it suggest a low pH (high acid) juice like lemon, especially since citric acid (which makes lemon sour) is also included. 

People generally prefer their fruit-flavored gummies to be sweet—and there is essentially no sugar in this recipe, especially if you go with lemon juice. But even orange, pineapple, or some other juice would skew toward the sour side…and without adding additional sugar to balance it, I suspect these gummies would taste quite harsh.

Okay but let’s say you’re averse to sugar, or you just like things super sour—there’s still the fact that many functional ingredients are inherently bitter. 

As any chef or food scientist knows, bitterness is enhanced by acid and mitigated by sweetness. So a recipe this sour would potentially be unpalatably bitter, without adding ingredients to manage bitterness.

And if we’re talking about flavor, we can’t just talk about sour, bitter, and sweet.

We also have to consider one of the biggest flavor factors in any recipe: aroma! It can’t just be an afterthought. 

You have to consider all the ingredients that add aroma to the recipe, and in the case of the ChatGPT one above, there isn’t much. Various extracts from fruit or spices are commonly used to add flavor to cooked confectionery such as gummies. Without them, you can end up with a very boring product. Cooking down lemon or orange juice, for example, results in a kind of “canned” washed-out flavor, and it’s not a good look. But imagine the essence of the zest of a lemon or orange rind, or excellent bourbon vanilla extract. Such ingredients can be used to great effect.

Using agar for gummies

Why did ChatGPT choose agar as a baseline for the gummies? It’s impossible to know for sure, but my guess is that more people use agar because it’s easier to work with and doesn’t require a specific pH range and sugar concentration in order to gel. 

Pectin is, for lack of a better word, more difficult.

And if you Google “vegan agar gummy” versus “vegan pectin gummy” you’ll notice there are almost 25% more instances of agar. 

Of course more doesn’t mean better. But ChatGPT has no way of knowing that. It has no mouth, taste buds, or experience-based understanding of flavor or mouthfeel.

Also, agar is known for having lots of variability in its gelling capacity, which is apparently based upon regional differences in chemical composition. This means sometimes even batch to batch variation of agar from the same manufacturer might cause noticeable texture differences. 

Another major consideration is that agar needs to be heated to dissolve in water—but when acid is also involved, the agar begins to break down; which dramatically reduces its gelling capacity. 

In other words step one—which calls for mixing the lemon juice, citric acid, and agar before heating—is not advised.

To do it right you would first cook agar in a sugar solution to a particular temperature or brix, and then cool it down to below 200° F before blending with acidic ingredients. 

Because of agar’s flexibility, ChatGPT’s gummy recipe might work—but it would then be using significantly more agar than necessary, and therefore your cost of goods increases for no reason other than following ChatGPT’s wasteful practices. 

Home gummy makers may not care, but business owners generally want to avoid wasting one of their more expensive gummy ingredients—when a slight change in process could solve the problem instead.

Remember, every inefficiency or extra cost magnifies significantly when you scale for manufacturing. And by then it’s too late…

Fortunately food science is here to rescue you from that sunk-cost fate. 

Shelf life

Remember that absence of sugar and the short cooking time? That adds up to a real short shelf-life, which is related to water activity.

Sugar and salt dampen that activity (so to speak). Without them, even low pH foods can grow mold. Disgusting, yes—but some molds also produce toxins. Which can bring legal trouble on top of the guaranteed ick factor that’ll sink your brand. Can you imagine the Google reviews…?

Unless you want to trust vendors to keep your product refrigerated at all times, you definitely wouldn’t want to use this recipe for commercial purposes.

Always always always run any newly developed products through shelf-life testing. (Ask me how)

How to get a decent gummy recipe from ChatGPT

ChatGPT’s strengths are also its weaknesses. All it does is pull from what already exists online. It’s not actually creating anything truly new. It can’t determine what will work versus what will fall flat and why. It has no sense—it’s just a masterful indexer and data analyzer.

Laying aside its lack of sensory input and actual experience to focus on what does make it a useful tool—one perpetual problem with the program still is that it’s hard to know what you don’t know. Both for the AI itself and for the humans trying to train it to give useful responses.

For example, how could ChatGPT reasonably know that pectin is preferable over agar for its superior flavor release, or that pectin has a more familiar mouthfeel for westerners? We would likely have to force it to consider these issues in our original question, and to do that, we’d have to realize that they are potential problems in the first place, and unless you are a confectionery expert or food scientist, that would be very unlikely information for you to have.

That said, if ChatGPT were trained to take into account issues like flavor release, mouthfeel, flavor profiles, and so forth, it may be able to self-correct. Each new version of ChatGPT leaps closer and closer to truly useful and not just entertaining.

But in the meantime, just remember that better questions can produce better results. (Hey—just like in science!)

So this time I asked ChatGPT:

How to make the best vegan gummy using pectin & granulated sugar, a recipe that will result in gummies that actually set, with a good mouthfeel and flavor. Listing ingredients in metric weights.

And here’s what it came up with:


Ingredients:

  • 250 ml fruit juice of your choice
  • 10 g pectin
  • 200 g granulated sugar
  • 2 g citric acid
  • 2 g vanilla extract
  • Optional: functional ingredient

Instructions:

  1. In a small saucepan, combine the fruit juice and pectin. Whisk until the pectin is fully dissolved.
  2. Add the sugar to the juice mixture and stir until it’s fully dissolved.
  3. Heat the mixture over low heat and add the citric acid and vanilla extract. Stir well.
  4. Continue heating the mixture over low heat, stirring occasionally, until it reaches 107°C. Use a candy thermometer to measure the temperature.
  5. Remove the mixture from the heat and let it cool for a few minutes.
  6. Add the optional functional ingredient and stir well.
  7. Pour the mixture into a silicone gummy mold, filling each mold about 3/4 full.
  8. Refrigerate the molds for at least an hour or until the gummies are firm.
  9. Remove the gummies from the mold and store them in an airtight container in the refrigerator for up to two weeks.

Be sure to label your gummies clearly and keep them out of reach of children and pets.

ChatGPT 3.5

This recipe looks somewhat better—but even at a glance I can tally up several issues that would prevent this from ever exceeding mediocre.

It did get rid of the extra water, which bodes well for shelf life. It also added a thermometer to the process, which is imperative when using pectin (though its heat/time ratio is a problem). And the flavor balance seems much more palatable, with vanilla added for more pronounced flavor.

But again, this recipe is still rife with problems. It would never work as a product for any reputable functional food business. And depending upon the pH of the fruit you choose, it might not even gel, though with the significant amount of pectin called for, it might also gel very firmly.

Read how I solve these problems (and more) in the next chapter of Food Scientist vs ChatGPT – in which I work with a client to develop this gummy recipe into a delicious, high-quality, long-lasting, and viable product for the nutraceutical gummy market.

Follow our LinkedIn for updates & the next installment!

Filed Under: All posts, CRAFT, SCIENCE Tagged With: agar, bitterness, ChatGPT, formulation, gummies, pectin, product development, science

How to Make Better Functional Chocolate with Food Science

November 9, 2022 by Alan McClure

Have you noticed that nearly all the functional chocolates available these days range from waxy and cloying, to mediocre and just barely tolerable?

Trust me, I’m a scientist—I’ve carried out careful sensory evaluation on a significant sample size of the functional chocolates. The results have been…disappointing. But I’m still hopeful. Why?

Because it means there’s a huge opportunity for a functional foods company (like yours) to corner the market niche of high-quality functional chocolate.

Until that happens though, we’re all consigned to gulping down “chocolates” that taste like muddy, bittersweet medicine. Gross.

At least each dose is small enough to take down in a bite or two…

But what if I told you that functional chocolate can be as fantastically flavored and gourmet as anything you’d find in a San Francisco Whole Foods or from a multi-generation French chocolate maker?

It just takes a little focused food science and finesse.

How to use functional ingredients in chocolates

I’m glad you asked. Whether you are trying to incorporate CBD, melatonin, or a newly available functional ingredient into your chocolate—high quality functional ingredients should be your starting point for making functional chocolate, not an afterthought.

Most functional chocolate producers add their functional ingredients almost as an afterthought. It’s just there to pack a punch and deliver a dose. So they can boast some fantastic milligram total on the packaging, and shove mediocre products down our greedy throats.

But don’t our greedy tongues deserve to be in on the experience too? Shouldn’t the chocolates we eat TASTE as good as they are a benefit to our health?

If you agree, here’s the start of an answer:

Think of your functional ingredient as a flavor ingredient. Not just a magic or medicinal one.

If it has clear aroma, bitter, or astringent notes, for example, these should be considered as components of the product from the ground up, not at the final moment.

What’s the best functional ingredient for chocolate?

First and foremost, invest in high-quality ingredients that have minimal off-flavors, if possible. In poorly purified ingredients there can be an array of unpleasant flavors. This is particularly common in the growing edibles industry.

But this is usually avoidable, because there are often a number of functional ingredient producers/vendors representing a range of qualities from cheap and dirty tasting, to clean and virtually without aroma, even if bitterness still needs to be dealt with. 

Because don’t your customers deserve better?

So why would you use anything other than high-quality ingredients in functional chocolates?

How to make high-quality functional chocolate?

Be thoughtful about every ingredient!

Making top quality chocolate always revolves around at least three main taste elements: sweet, bitter, and sour. Not to mention aroma and other sensory characteristics like astringency.

Cocoa is naturally bitter, and so are many functional ingredients. To compensate for the bitterness of functional ingredients, many brands will simply drop the cocoa percentage and drive up the sugar. But all of that sweetness also drives out the complexity.

There are many ways to mask, balance, and/or incorporate bitterness in functional foods, such as CBD-containing edibles, but remember—every adjustment you make in a chocolate recipe has a ripple effect.

Choosing ingredients that enhance existing flavors while naturally balancing those that tend to be more unpleasant, can go a long way toward creating top-quality functional chocolate to enchant the market. There are many ingredients we can use with this seemingly magical ability. If you’re wondering, one such great example is sea salt. It packs a huge punch when it comes to enhancing flavor of virtually any product.

Also, remember…

You don’t need to go bean-to-bar for gourmet functional chocolate

As a functional chocolate producer, you’re better off as a chocolatier rather than a chocolate maker. Going all the way back to the bean adds little to your goals and process except extra steps and stress.

Chocolate maker is someone who makes chocolate from scratch, using different percentages of cacao (cocoa beans that need to be sourced, roasted, and further processed) and other ingredients.

Chocolatier sources finished chocolate from a chocolate maker, and adds ingredients and flavors to create their own bar or confection.

You should certainly source one or more high-quality chocolates that will pair well with the flavor and aroma profile of whichever functional ingredient(s) you choose. And another thing…

Don’t try to cram maximum functional ingredients into every bite

Not only does that let your customer enjoy a few more bites of your delicious chocolate per dose, but decreasing the density of functional ingredient also automatically decreases the bitterness you have to deal with.

This can work on a marketing level too. Who sells more bars? The brand with 10 doses per bar, or the one that is super delicious and mouthwatering, costs less, and sacrifices only a few doses?

Summary: How does food science lead to better functional chocolate?

When it comes to formulating the best functional chocolate for the market, there are a lot of elements to consider.

  • Functional ingredients vendors
  • Format of the functional ingredients (oils, powders, etc.)
  • Dosage
  • Cocoa percentage
  • Mouthfeel
  • Appearance
  • Sweet, sour, bitter balance
  • Overall flavor bouquet

As a food scientist with a PhD in flavor chemistry, when it comes to functional chocolate formulation, one of my most important and unique tools is formal experimental-design. I have the software, lab experience, and deep knowledge of taste and flavor on a molecular level that you can’t get anywhere else.

And by the way, before becoming a functional food science consultant, I was for many years an award-winning chocolate maker and confectioner, with additional experience in formulation of bakery items, ice cream, beverages, and more.

Any worthwhile chocolate consultant could hopefully help you source a decent chocolate; but only food science can help you pinpoint the best possible version, based on multi-variable experiment setup, multi-objective optimization, and formal sensory analysis (including consumer testing, if you have the budget and time).  

So what it comes down to fundamentally is this: What are you trying to achieve?

Are you trying to make excellent-quality functional chocolate that loyal customers will buy over and over again because it’s so delicious?

Or are you just trying to get a bunch of one-time sales?

If you answered Yes to the first question, reach out and let’s formulate some gourmet functional chocolate at a quality level that still rarely exists in the functional foods market.

MORE: Want to see more about how functional chocolate formulation works? Follow us on LinkedIn!

Filed Under: All posts, CRAFT, SCIENCE Tagged With: chemistry, experimental design, flavor chemistry, food science, product development, science

Using Fruit Purees in Cannabis Gummies

July 7, 2022 by Paul Blumer

Bolstered by the coronavirus pandemic, sales of edibles – spearheaded by gummies – have skyrocketed to eclipse sales of marijuana flower, year-over-year, since 2020. Accounting for almost $1 billion in sales in 2020, the gummies market alone grew by a staggering 31% last year outpacing nearly every category of edibles. 

What started with weed brownies, rice krispies treats, and cookies has expanded exponentially to include products like weed-infused beef jerky, pretzels, and potato chips. Lately, the industry has also turned toward mints, hard candies, and especially gummies.

Why are gummies popular?

First and foremost, they’re delicious. Who doesn’t like gummy bears or Sour Patch Kids? But looking beyond their snackability, there are a few reasons why cannabis gummies have enjoyed such a meteoric rise in popularity. 

  • Precision dosing – Because of their production methods, each gummy is exactly the same size and contains exactly the right amount of THC or CBD so it doesn’t get easier to accurately dose than with gummies.
  • Convenience – It doesn’t require much appetite to eat a small piece of candy—but how often are you in the mood to eat a big fudgy brownie or chocolate-chip cookie? Especially for medical cannabis users, gummies are much more manageable.
  • Longer shelf life – Baked goods, such as brownies or cookies, go stale and lose their decadent chewy texture over time. But a sealed piece of candy can last almost indefinitely. 
  • They travel better – Going to the beach with chocolate edibles is not going to end up well. Not only will the melting of the edible ruin the chocolate, but it also ends up ruining the terpenes and cannabinoids. Gummies, especially those made with pectin instead of gelatin, have a much higher melting point making them a much better travel buddy. 

How cannabis gummies are made

Making gummies is not rocket science, but it is food science. At the most basic, all it takes is water, sugar, gelling agent (e.g. pectin), flavoring of some kind, and something to add color. 

Mix it up, heat it up, and pour it into a mold. 

Of course, making top-quality cannabis gummies requires a little more complexity. Temperature, pH, and various other factors need to be tuned just right. Otherwise you can wind up with a sloppy mess. But overall they’re easier to make than many types of edibles. Which means it’s not just consumers who love gummies—they’re also an attractive option for edibles producers as well.

When it comes to producing, let’s say chocolate bars, the amount of time and labor involved is exponentially greater than making gummies. Working with chocolate is a very hands-on process that requires training in the science of chocolate and pastry arts. 

Unlike gummies, chocolate needs to be tempered, using precise temperature controls. By heating, cooling, and reheating the chocolate, the chocolate maker can create a product with a delicate composition, uniform structure, and well-rounded flavor, along with the expected shiny exterior. 

As far as mass-production is concerned, an effective manufacturing set-up could produce tens of thousands more gummies in a day than one crafting fine chocolate bars.

But before you jump up to sweep the gummy market off its feet, there are several things to consider. Should you use flavor extracts, essential oils, or fresh fruit purée for your gummies? What about pectin vs. gelatin or agar? And what are the best flavor combinations?

Fruit purees vs. extracts for cannabis gummies

Like most things in life, there’s an easy way and a hard way when it comes to making gummies. Using extracts or essential oils may reduce your overall food costs, but by sacrificing flavor and quality you may be alienating a large portion of your customer base that is looking specifically for high-quality edibles using fresh ingredients.  

Now, not all fruit purées are created equal. Most recipes will specify which brand of fruit purée to use for cannabis gummies, since the sugar and acid levels vary from fruit to fruit. A kilo of passionfruit purée sold by Boiron will need a different amount of sugar, glucose, citric acid, and pectin than the same product from Perfect Purée. 

This may seem like a lot of extra work, but the end result will stand out from the crowd that uses extracts and essential oils. A vast majority of consumers today are looking for a higher-end experience and are willing to pay for it. Using fresh purées over extracts or oils provides a gummy full of healthy vitamins along with a dose of THC or CBD. 

A healthier choice

Eaze’s 2022 report found that edibles ranked number one in marijuana purchases for every generation except for Gen X who, according to polls, prefer to vape their weed. 

Of that crowd, Millennials represent the single largest cannabis customer base. They tend to be highly educated, and they know what they want when it comes to cannabis products. And they typically prefer products made with whole foods and healthy ingredients. In addition to vitamins and minerals from the fruit, gummies also contain way fewer calories per dose than other edibles.

So companies using fresh fruit purées in their gummies are more likely to attract the coveted 25-45 age demographic.

Pectin vs. agar

If you’ve ever made a homemade jam or marmalade, then you’re familiar with pectin, the gelling agent that gives jams and jellies their signature texture. For hundreds of years, pastry chefs have turned to pectin to create pâte de fruit, which are essentially very fancy gummies. 

Pectin is a naturally occurring substance that exists in the cell walls of fruits and plants, helping to bind the cells together to allow the organism to grow. Traditional pectin only activates and gels in the presence of both sugar and acid—so it’s important to understand your formulas for making gummies. 

Pectin is also naturally vegan (as opposed to gelatin, which is animal-derived) so it’s the preferred choice for making a product with mass appeal. 

However, unlike flavorless gelatin, pectin may add some small amount of bitterness to the recipe. Combined with naturally bitter cannabinoids and terpenes, this might require additional bitterness management, depending on the overall flavor balance of your gummies.

Another gelling agent option is agar-agar. Agar is a plant-based gelatin derived from seaweed. And while it may seem like agar and pectin are similar, they produce dramatically different end results. 

Due to its molecular structure, agar will continue to solidify over time, through a process called syneresis—which will squeeze out some of the incorporated liquid in your gummy, leaving a tough little agar chew covered in a sticky mess. 

Agar gummies also have a less pleasant mouthfeel, generally speaking, and the flavor release is by far less than ideal when compared to pectin. Especially if you’re making them with real fruit purees, pectin is the ideal gelling agent for cannabis gummies. 

Flavors

This is where the fun and creativity begins when it comes to making THC- or CBD-infused gummies. Deciding which fruit (or combination of fruits) to use as the flavoring means plenty of “quality control testing.” 

The fruit purée market is chock full of amazing fruit flavors ready to use for making gummies, from standards like raspberry, orange, and strawberry, to tropical fruits like passionfruit, guava, and lychee. 

If you happen to be using gelatin for your cannabis gummies, be wary of flavoring them with fresh pineapple as it contains an enzyme called bromelain. Bromelain (as well as papain in papaya) is a complex protein-digesting enzyme that will destroy the protein-derived gelatin. 

If you must use gelatin for pineapple or papaya gummies, cooking the fruit or juice first will denature the bromelain enzyme, preventing it from breaking down the collagen in the gelatin and thereby allowing the gel to set. 

Looking for flavor inspiration? Here’s 5 surprising cannabis gummy flavor combos that we think your consumers would love!

  1. Blueberry | Chamomile | Lavender 
  2. Pineapple | Coconut | Black Tea
  3. Blood orange | Passionfruit | Thyme
  4. Strawberry | Olive oil | Tarragon
  5. Sour Cherry | Lime | Mint

For more about making better cannabis gummies (with fruit puree or anything else) reach out and let us know what you’re working on.

Filed Under: All posts, CRAFT, SCIENCE Tagged With: edibles, fruit, gummies, product development

Product Formulation Optimization #3

October 19, 2021 by Alan McClure

The Troublesome Yet Terrific Tortilla (Part 3)

In part 3 of our look at the troublesome yet terrific tortilla, following as it does from a general description of the tortilla quandary in part 1, and some specific details regarding the tortilla challenges anticipated in part 2, finally I’ll begin to explain how I approached the task of optimizing the formulation, or in simple terms, how I made the very best tortilla.

What Is “Best?”

As mentioned previously, I’ve already defined that I am speaking of wheat-flour-based tortillas; so my goal in optimizing a tortilla formulation is to produce the wheat-flour-based tortilla with the best organoleptic characteristics. It’s worth taking a moment to consider what I mean by “best.” In this case, I am considering only my own preferences, whether I’m talking about aroma, overall flavor, mouthfeel, or even appearance. However, if I were developing this tortilla for a regional restaurant chain, it would make sense to do consumer evaluation that includes a sample of the regular customers of that chain, and perhaps also consumers that the chain is trying to convert to customers. My specific preferences, for example, may or may not overlap well with those of the restaurant customers. But luckily, since the tortillas in question are for me, I can more simply consider my own preferences.

All Wheat-Flour Tortillas Are Not Created Equal.

Also, it is important for me to clarify that I want a tortilla that tastes great when fresh. I’m not at all concerned about storing the finished product on the shelf, or in the fridge or freezer. I want a tortilla that I can griddle now, eat, enjoy thoroughly, and then move on. If I were developing a tortilla for a grocery chain, I would have to reconsider this approach, because in that case the end consumer has little chance of buying the tortillas fresh and hot. They will need to be reheated out of necessity, and they will likely need to be able to remain free of mold for at least a week on the shelves, and perhaps longer. Such a tortilla would have characteristics that are dramatically different from the type I want to eat for my own enjoyment.

Are there Additional Constraints?

There are plenty of other details to consider. Do I want to work with ingredients available at the local grocery? Am I interested milling grain into flour? Does the tortilla need to be vegetarian? What types of equipment are available for processing and cooking the tortillas? And speaking of production constraints, while I’m willing to deal with dough that is a bit sticky or stiff and difficult to roll out in order to achieve a better tortilla, there is a limit to my patience. I don’t want to make my life 50% more difficult just to squeak in an extra 1% increase in improved mouthfeel. So, as I’m rating the various sensory characteristics of each tortilla, I can also consider rating things like dough stickiness, dough toughness, and perhaps overall workability.

Pulling Everything Together.

I’ve said that I want to optimize the formulation for a wheat-flour-based tortilla that is best according to my own preferences. I want to be able to make it at home with a 4’x4′ maple butcher block serving as the work surface, a wooden rolling pin, a 6-qt stand mixer, an induction range, a cast-iron skillet, and a spatula. I would also generally like to use ingredients that are readily available (e.g., King Arthur AP wheat flour, sea salt, and filtered tap water), but I’m willing to put in a little extra work to improve the quality of the added fat.

Ingredients.

For the fat in the tortillas, I’ll render my own lard from the backfat of locally raised hogs. As part of the rendering process, I’ll use a temperature high enough to brown the cracklings once they are void of fat, which adds additional roasted complexity to the lard’s flavor profile. At the end of the rendering process, I’ll also add some smoked bacon to give the lard a subtle smoky note. I will not be using plant-based oils in this recipe, as I know from experience that they have bland or off flavors in tortillas. I will also not be using baking powder. As mentioned in part 2, baking powder is quite a common ingredient in modern tortillas, but I would prefer to depend upon steam–from the added water–to leaven and lighten the texture of the tortillas. In my experience, the mouthfeel of the end product is better than when baking powder is used. So now I’ve clearly defined the constraints for this project. What’s next?

Freshly griddled wheat-flour tortillas made with freshly rendered pork lard, filtered water, and sea salt

A Product Optimization Experiment.

We now have to take our known constraints and design an experiment that will allow us to optimize the tortilla formulation. How should we proceed? One variable at a time? Often seen as the acronym OVAT, this is thought by most non-scientists to describe how experiments are run according to the scientific method. Actually, even some scientists believe this. But here’s the thing, it’s dead wrong. Even in a relatively simple food like our tortillas with only four ingredients (i.e., flour, water, lard, salt), changing the amount of one variable at a time, let’s say the flour, while holding all else constant, is likely to be, at best, an incredibly inefficient way to determine what the optimal tortilla recipe is, and at worst, will never find it at all. In short, OVAT has significant disadvantages. Arguably, the most important disadvantage is that important “interactions” usually exist in foods, and will be missed with the OVAT approach.

Interactions!

In this project, if we simplify for a moment to say that our only goal is to improve the flavor of the tortilla on a scale from 1-10, then any positive main effect would be one related to any of the individual ingredients that increases quality. For example, maybe more lard increases quality on average. That’s lard’s main effect. But what happens when water and lard are both present? Does water, in addition to having its own main effect on quality also impact the degree to which lard has a positive impact? If so, then that would be an interaction effect. It might be the case that with smaller amounts of water, lard is hugely positive in its impact, but with more water it makes a much smaller positive difference. It is immediately clear why interactions can cause huge problems with the OVAT approach; because if you only change one variable/ingredient at a time, you can’t determine if interactions exist. And guess what? Interactions almost always exist to some degree, and sometimes they are hugely influential. So what can we do about this?

Optimal Design of Experiments.

When the OVAT approach can’t be trusted to work, which is usually, instead we can rely on the considerable theory in the field of statistics that supports what is called “design of experiments,” along with modern computers and software, to produce an optimal experimental design. Such a design is able to help determine what the optimal formulation would be of a tortilla, again from the flavor quality standpoint defined above, but more than that, such a design even allows the experienced product development expert to determine the optimal formulation while considering several characteristics at the same time. This is sometimes called multiple objective optimization. How it does this is easier to show with an example than to explain in prose, so we’ll take a look at a tortilla-development optimal design in the final part of this series (part 4).

–Alan McClure

Filed Under: All posts, Food & Beverage Facts, Process Optimization Tagged With: food, optimal design, processing, product development, science, tortillas

Product Formulation Optimization #2

September 28, 2021 by Alan McClure

The Troublesome Yet Terrific Tortilla (Part 2)

Continuing on with the product formulation optimization theme, using tortilla formulation specifically as an example, we dig in further. As a reminder, tortilla formulation is more complicated than it may at first appear. As I wrote previously:

“From the standpoint of the uninitiated, a tortilla seems a simple beast. As a plain product on its own there are no fillings or inclusions, no added flavors, swirls of color, or fancy shapes. Even the plastic bags in which they’re sold ten at a time are nothing special. But the phrase “deceptively simple” does exist for a reason. And one could reasonably argue that it was coined as a product formulation expert was doing some deep thinking about the common, yet commonly unimpressive, tortilla.”

In this recent post I also spoke about the two different types of tortillas (corn and wheat flour), and noted some of the complexities of both of them including nixtamalization in the case of corn tortillas, and the presence of gluten and necessary added fat in the case of the wheat flour tortillas. Clearly, when done well, both types of tortillas are fantastic, but my family was handed down a wheat flour tortilla tradition from my Mexican great grandmother Guadalupe Otila Macias, and since I was a wee child I’ve been truly mesmerized by this type.

Watching my grandmother mix and knead them by hand, roll them out with a flick or two of the wrist, and then bake them on top of a cast-iron griddle on the stove–the incredible smell–and then passing one steaming and blistered with flavor from hand to hand with nearly burnt fingertips, taking bites and smiling uncontrollably. These are some of the most powerful memories of my childhood. Why would I ever want to change a single detail in my original family recipe?

As I mentioned previously, wheat flour tortillas can be tricky because the gluten proteins in wheat (i.e., glutenin and gliadin) when hydrated, help to create a stretchy and springy dough that is notoriously hard to roll out. To produce a less tough and easier to roll tortilla, people traditionally added some amount of fat to the dough in the form of freshly rendered pork lard. The added lard reduces the overall gluten development, and the tortillas become more aromatic and the mouthfeel more tender and less chewy. And when everything is just right, the tortillas puff magically like perfect little pillows, making them even lighter in texture. But what about when everything isn’t just right?

tortillas freshly cooked
Freshly griddled wheat-flour tortillas made with freshly rendered pork lard, filtered water, and sea salt

The Baking Powder Bandage

The problem is that getting the ratio of ingredients just right can be very tricky. If it is even a bit off, or the griddle temperature is not optimal, or the tortilla maker is just not paying the right amount of attention, the tortillas can end up dense and unpleasant. The solution to this problem used by most is an addition of baking powder. It allows the tortilla maker a bit more flexibility in all of the important conditions. However, the texture of a baking-powder-risen tortilla is not quite the same as one without, and it has been written more than once by tortilla aficionados that the baking powder version is simply not as good.

The Vegetable Oil Blunder

Another problem is that as refined plant-based vegetable oils have become much cheaper, and good fatback from which to make lard has become less readily available in the marketplace, recipes have begun to call for either liquid oil or hydrogenated oil, also called shortening. These oil-based tortillas simply aren’t capable of tasting as good as those made from the roasted and rendered fat of flavorful hogs.

So, the modern homemade wheat-flour tortilla, which itself is scarce compared to the store-bought versions with little personality, is itself a shadow of its former glorious self. But if these changes to the modern tortilla have led to a poverty of quality, what is to be done about it? How can we possibly attempt to recreate a product formulation that most of us have never tasted?

I’ll explain how I approached this challenge in an effort to do just that. Stay tuned for más detalles in Part 3.

–Alan McClure

Filed Under: Food & Beverage Facts, Process Optimization Tagged With: chemistry, food, Mexican, product development, science, tortillas

Product Formulation Optimization #1

September 15, 2021 by Alan McClure

The Troublesome Yet Terrific Tortilla (Part 1)

From the standpoint of the uninitiated, a tortilla seems a simple beast. As a plain product on its own there are no fillings or inclusions, no added flavors, swirls of color, or fancy shapes. Even the plastic bags in which they’re sold ten at a time are nothing special. But the phrase “deceptively simple” does exist for a reason. And one could reasonably argue that it was coined as a product formulation expert was doing some deep thinking about the common, yet commonly unimpressive, tortilla.

So where should we start to understand the product formulation challenge better? It’s often the case that the very best examples of foods are traditional ones. And certainly where tortillas are concerned, traditional versions are far better than the most familiar brands at the local grocer. For those who have had incredible tortillas, the kind that are calling out to be eaten, simply, steaming hot from the Mexican comal, fingers burning, we know this in our gut. But if one wants this beautiful experience far away from a Mexican market or abuela, is it even possible?

What is a tortilla anyway?

First, let’s simplify the issue. Tortillas come in two main types: corn- and wheat-flour-based. Corn tortillas are traditionally made from alkali-treated heirloom corn, called “nixtamal,” a Nahuatl term borrowed from the Aztec. This process, often referred to as nixtamalization, uses a relatively dilute solution of culinary lime, aka calcium hydroxide, in water to catalyze hydrolysis and conversion of various compounds in the corn kernels’ hull. This process makes the corn easier to digest, more nutritious, less likely to contain harmful mycotoxins, and most people would claim, myself included, more delicious. In fact, the flavor is so good, that traditional corn tortillas require nothing more than ground nixtamal, water, and bit of salt, to create a fabulous flat food fit for an Aztec king. But, as previously mentioned…

Corn is not the only way…

In northern Mexico and Texas, which also used to be part of Mexico, where wheat flour was more readily available, tortillas made from this grain were more common. And because the proteins in wheat, when hydrated, help to create a stretchy and springy dough that is notoriously hard to roll out, people added some amount of fat to the dough in the form of freshly rendered pork lard. The lard reduced the overall gluten development, making the thin disks of dough easier to roll out, and moreover, made the tortillas more aromatic and the mouthfeel more tender than chewy. And when the proportions of flour:water:lard are just right, the tortillas puff magically, making them lighter and more tender in texture, and giving the surface of the tortilla a deliciously mottled appearance, due to light charring of the steam-puffed pockets on the surface, thereby creating even more flavor–Maillard reaction pathways y’all.

tortillas freshly cooked
Freshly griddled wheat-flour tortillas made with freshly rendered pork lard, filtered water, and sea salt

Now, I’m a sucker for both types of tortilla, and I’ve made countless batches of both, nixtamalizing my own corn, experimenting with many of the countless heirloom Mexican varieties, and for the wheat tortillas, rendering my own lard, getting the roasted, almost smoky pork flavor just right. But I have to admit that having grown up with wheat flour tortillas in my family, a cultural contribution of my Mexican maternal great-grandmother, Guadalupe Otila Macias, who emigrated to Texas as a young girl, I have spent considerably more time thinking about, making, and certainly eating wonderful wheat flour tortillas. And I can assure you that even with four ingredients, they are tricky to perfect, or more technically, to optimize the product formulation.

But I’ll tell you what; recently I did just that. Stay tuned for más detalles in Part 2.

–Alan McClure

Filed Under: Food & Beverage Facts, Process Optimization Tagged With: chemistry, food, Mexican, product development, science, tortillas

Good, Better, Best?

August 7, 2021 by Alan McClure

Sage advice from the product developer:

How good is good enough? Is it just fine to be as good as the competition, or does a product always need to be even better to compete? And what if better isn’t even good enough? Developing award-winning products that utterly destroy the competition means aiming for the best possible version of a product. With all of the choice in the marketplace these days, it’s the only reasonable approach to ensure sales superiority and passion for the product on the part of consumers, tastemakers, and influencers. But how does one achieve the very best?

The little-known hard truth is that creativity, inspiration, passion and dedication simply aren’t enough. Every single product has an infinite number of possible iterations. Tweaking one ingredient at a time based on experience may give you a better product than the one before, but is it actually the very best? Without following well constructed optimally designed product development experiments, the answer is almost certainly “No.” Luckily for us, such experiments make the product development process more precise and more efficient, saving time and money while producing not just a better product, but the very best!

-Alan McClure

Filed Under: Product Development & Optimization Tagged With: beverage, food, optimal design, product development, science

Copyright © 2026 · Patric Food & Beverage Development