The real-deal dilemma
Numerous performance considerations influence how formulators work with inclusions. First and foremost, label claims must be part of initial product development. Inclusions can be quite complex, which may mean a busy ingredient legend.
“Consider label requirements such as natural, non-G.M.O., etc.,” said Brigham Sikora, R.&D. and applications director, bakery, Kerry. “It is important to determine if the inclusion needs to meet a Standard of Identity, such as real chocolate or real fruit.”
Some inclusions are made to look and taste like the real thing but to do a better job. This is particularly true of fruit-like bits. Real fruit introduces moisture into the product. In the case of cookies or snack bars, the excess water will have a negative impact on texture and shelf life. Inclusions, however, may be customized in moisture levels.
“These problems haven’t gone away, but today there are real fruit ingredients available that overcome this problem,” said Wayne Lutomski, vice-president, Welch’s Global Ingredients Group. “(The company’s new juice bits) are next-generation real fruit ingredients that mitigate moisture transfer between the inclusion and the rest of the product.”
Welch’s process involves concentrating the juice or purée of Concord and Niagara grapes into pieces and flakes without adding sugar. The technology also binds moisture, enabling use in dry applications.
“The crucial parameter is water activity, a measure of the ability of water to migrate from an ingredient into the surrounding food matrix,” Mr. Lutomski explained. “If you want to use real fruit in a dry product, it’s really important to ensure the water activity of the inclusion has been tailored specifically for the application. In this way, you can make sure that the fruit you use won’t ruin the recipe or cause product spoilage.”
Some inclusions may provide a cost-savings opportunity by supplementing or completely replacing more expensive whole food ingredient inclusions.
“For example, blueberry nuggets can be used to supplement or replace real whole blueberries,” Mr. Sikora said. “These nuggets allow real blueberry to be listed on the product label. They provide the appearance of blueberries without having the cost fluctuation or seasonality of blueberries.”
Other formulation considerations include time of addition to the baked good, as well as finished product appearance. Formulators should set reasonable expectations for the color, piece identity and degree of melt, if any.
“It’s important to decide if the inclusion will be used as a topping (after bake) or will it be mixed into the batter or dough and then baked,” said Claudia Granda, vice-president of R.&D., Pecan Deluxe. “If used after bake, there is some flexibility on bake stability. Still, a moisture barrier is often needed to keep the inclusion from melting or staling, especially if an icing is water-based. In addition, if the product will be refrigerated or frozen, and thawing is needed before serving, then a moisture barrier will help keep the ingredient’s integrity.”
If the inclusion is added to the batter or dough, bakers should consider the amount of agitation and dwell time. Bake time and temperature can also impact inclusion integrity.
“Processing may impact the final functionality and success of inclusions,” said Dennis Reid, vice-president, sales and marketing, Inclusion Technologies. “By knowing those processing parameters up front, inclusions can be formulated to complement the conditions.”
Another important consideration is stability of the flavors and colors after they go through the baking process.
“Formulators should take into consideration if they want inclusions to stay crunchy or soften in an application, and also whether or not they want inclusions to bleed,” said Mary Reynolds, research scientist, bakery applications, Kerry. “There is also the risk of colors migrating or losing piece identity under long residence time in batter or dough.”
To mitigate against this, inclusions may be coated with a lipid, hydrocolloid or sugar solution. This slows moisture movement, as well as color bleeding. In some instances, such coatings may assist with suspension in thin batters. This prevents inclusions from settling to the bottom.
“Lipid inclusions are made with a lipid base, with sugar or flour incorporated along with flavors and colors,” said Robert Mason, technical development manager, encapsulates and inclusions, SensoryEffects, a division of Balchem. “These lipid inclusions do not contribute moisture or affect water activity, and the lipid can delay a flavor’s release for better intensity.”
