Developing Food Products for Consumers with Specific Dietary Needs

Steve Osborn, Wayne Morley

• Publisher: Woodhead Publishing
• Year: 2016
• Print ISBN: 9780081003299
• eBook ISBN: 9780081003404
• Topic: Technology & Engineering
• Subtopic: Nutrition, Dietics & Bariatrics
• Index: Technology & Engineering

Developing Food Products for Customers with Specific Dietary Needs explains the process for developing foods for customers who have specific dietary needs, further shining a light on the number of increasing medical conditions related to food intake that have emerged in the past few decades.From increased fat and sugar intake leading to higher levels of obesity, to greater levels of coeliac disease, the ingredients and nutritional content of food is becoming more and more important. Additionally, consumers are following particular diets for many different reasons, be it health related, or for religious or moral reasons.The first part of the book looks, in detail, at the organizational structure required within a company to allow for the development of food products which meet the needs of these customers, while the second part presents a number of case studies highlighting the development of food products for various dietary requirements.Precise coverage includes section on the development of low-sodium, low-sugar, low-fat, and low-carbohydrate products with the aim of producing healthier foods, as well as the development of organic and vegetarian products for consumers who are following diets for personal reasons.The potential solutions for developing foods for customers who have specific dietary needs are likely to include both ingredients and technology developments. The ingredients area includes simple reductions as well as replacement strategies, whilst technology will be applied to both the ingredient itself and the host food product. All are aimed at maintaining the product quality as perceived by the customer.- Provides an overview of the organizational structure required within a company to develop foods for specific customer needs- Includes section on the development of low-sodium, low-sugar, low-fat, and low-carbohydrate products with the aim of producing healthier foods- Presents case studies that deliver a best practice view on developing foods for customers with specific dietary needs- Written by industry professionals, this book offers in-depth coverage of this topic of ever increasing importance to the food industry

Part One

Organization to allow for development of foods for consumers with specific dietary needs

1: Differences between standard food product development and development of foods for consumers with specific dietary needs

2: Health beneficial consumer products—status and trends

3: Organizational structure and business and technology strategy of food companies to optimize development of foods for consumers with specific dietary needs

4: Commercialization of foods for customers with specific dietary needs

1

Differences between standard food product development and development of foods for consumers with specific dietary needs

Wayne Morley Food Innovation Consultant, East Grinstead, West Sussex, United Kingdom

Abstract

A great many articles and books have been written on the subject of product development. Most food companies will have their own version of a product development process, probably within the scope of a more generic innovation process, but in essence it can be considered to comprise three main steps: firstly the development of a concept at kitchen scale, secondly the production at pilot scale, and thirdly the manufacturing at production scale. The purpose of this chapter is not to review in detail the product development process itself, but to consider the key differences and considerations when developing products that either contain or omit certain specific ingredients.

Keywords

product development process

HACCP

development kitchen

pilot plant

factory

testing

shelf life

1. Introduction

1.1. Product development process

A great many articles and books have been written on the subject of product development. Most food companies will have their own version of a product development process, probably within the scope of a more generic innovation process, but in essence it can be considered to comprise three main steps: firstly the development of a concept at kitchen scale, secondly the production at pilot scale, and thirdly the manufacturing at production scale. The purpose of this chapter is not to review in detail the product development process itself, but to consider the key differences and considerations when developing products that either contain or omit certain specific ingredients. In most cases these are anticipated to be extensions of the systems and procedures that apply to the production of standard products, with the additional requirement to avoid cross-contamination of the specific ingredients. Such cross-contamination could be into the standard food products or into the food products for consumers with specific dietary needs.

1.2. Policies and procedures

The product development process in all food companies should have an underlying set of policies and procedures that when followed, ensures that the products meet all of the necessary requirements in relation to:

• The product development brief

• The on-pack information

• The claims that you make

• The consumer

The policies and procedures should incorporate the requirements for the development of products for consumers with specific dietary needs. For example the product development brief should clearly indicate which specific dietary needs are within the scope of the project, and which ingredients should be included or omitted. The products will clearly be targeted at a specific consumer group, and the on-pack information and claims should make the products instantly recognizable to this group, and ideally to the general population too. It goes without saying that the products themselves should meet the requirements of the target consumers, not only in terms of the specific dietary need, but also for the generic requirements of quality, safety, and cost.

The key elements of the policies and procedures that apply to different aspects of the process for developing food products for consumers with specific dietary needs are outlined in the subsequent sections.

1.3. Labeling of samples

A typical product development project will result in a great number of samples being produced, and it is in this area that mistakes and omissions can be made in labeling. Accordingly the policies and procedures for the development of products for consumers with specific dietary needs should include the requirement for the appropriate labeling of samples. It may be that in a product development kitchen, the control of allergens is too difficult or expensive, in which case it must be made clear that all of the samples could contain all of the allergens that are used in the facility. Each individual sample must then be labeled appropriately. Alternatively if one or more allergens are actively controlled then the labeling of samples can reflect this.

The labeling of samples is not discussed further in the subsequent sections, but can be assumed to form an integral part of the relevant policies and procedures.

1.4. HACCP

Hazard analysis is an essential requirement in food manufacturing and the existing HACCP (hazard analysis critical control points) systems can be conveniently applied for foods for consumers with specific dietary needs. This is especially the case for foods that are free-from one or more of the allergens. Allergens are considered to be the fourth class of hazard after physical, chemical, and microbiological hazards, and should therefore be eliminated or controlled in order to prevent contamination. Much of the information presented in this chapter relating to allergens can be considered to be part of a comprehensive HACCP plan.

For other dietary needs areas the relevant component, whether being removed reduced or enhanced, should not present additional requirements for the HACCP plan. Some of these components may be high risk ingredients, for example having a particularly high microbiological load, but the existing control measures should be adequate. However in these cases, as with all formulation changes, it is good practise to review the HACCP plan and update it as necessary.

The general application of HACCP in food manufacturing is not covered in this chapter. Reference should be made to the relevant chapter in this book or to standard texts on HACCP for further information relating to foods for consumers with specific dietary needs.

1.5. Compromise

Compromise is an important principle in product development and especially in reformulation exercises when critical ingredients are removed or reduced in level. All reformulations lead to changes in one or more product attributes, either physical, chemical, and/or microbiological, which may or may not be noticeable to consumers. Even small changes, each of which do not affect consumer perception, should be treated with caution as multiple events can lead to a completely different product.

It is important in any reformulation exercise to be clear about the compromises that are acceptable and those that are not. For example in a salt reduction exercise it may be acceptable to reduce saltiness perception but not to reduce the shelf life. Therefore a product for consumers with low salt/sodium requirements may require the use of additional ingredients for microbiological stability and/or an enhanced thermal process for preservation.

The critical areas of compromise and appropriate intervention strategies are not covered in this chapter, although some examples are given. Reference should be made to the relevant chapter in this book or to standard texts on reformulation for further information relating to foods for consumers with specific dietary needs.

2. People

2.1. Experience and expertise

Any product development department should be resourced with suitably qualified and experienced personnel. It is preferred, but not essential, for this experience to be in the relevant area of interest, especially when highly specialized or rarely researched products are concerned. For example in applying new technologies, it may be important to apply the latest academic thinking from prestigious universities or specialist suppliers. Specific expertise in the selection of ingredients, and processing methodologies to avoid cross-contamination, will also be important.

2.2. Training

Whatever the area of product specialism, an organization should develop a rigorous training plan for employees in order to support the product development process. The training should encompass not only the product development and innovation processes themselves, but also the specific aspects of ingredients and processing that are relevant. Of course these should be constantly updated as new products and additional dietary needs areas come on-stream.

2.3. External experts and consultants

The use of external experts and consultants is recommended when the organization concerned has neither the expertise nor facilities for the development of specific dietary needs products. Such external providers should have an impressive track record and credibility with relevant ...

Table of contents

• Cover
• Title page
• Table of Contents
• Copyright
• List of contributors
• Woodhead Publishing Series in Food Science, Technology and Nutrition
• Preface
• Part One: Organization to allow for development of foods for consumers with specific dietary needs
• Part Two: Case studies in developing foods for consumers with specific dietary needs
• Index