New Product Development for meal replacements

Most people would prefer to lose a few pounds by balancing a balanced, low-fat diet with intermittent fasting and exercise. There are several diets available on the internet, and consumers watch their calories more frequently. However, this may not suit or might not work for everyone (1). Besides, nutritional deficiency due to lifestyle habits has been pointed out as the primary cause of loss of health. A meal replacement is a complete and nutritional food based on scientific research and understanding. A meal replacer delivers a balanced set of macronutrients (fats, carbohydrates, protein and fibre) and micronutrients  (vitamins and minerals). A meal replacement can be in the form of flavored powder mixes to which water, milk or fruit juice may be added. They are also available as ready-to- drink to support health and physical development as a post-workout drink, edible bar for a snack between meals or even a soup added with probiotics. Recent studies have evidenced that meal replacements, with 900kj, successfully used in several weight-loss trials. Hospitals and nursing homes also replaced blenderized meals for those who could not eat solid foods due to health or disease issues – with brands like Ensure and Sustacal – MRB formulations.

International food agencies such as European Food and Safety Agency (ESFA), World Health Organization (WHO), and US health agencies (FDA, USDA, HHS) recommend a daily intake of a 2,000-kcal diet. Therefore, meal replacers try to provide 25% of the daily recommended allowance (DRA) per serving so that four servings will cover recommended daily intake.

Flechtner-Mors, M., Ditschuneit, H. H., Johnson, T. D., Suchard, M. A.& Adler, G.(2000), Metabolic and weight loss eff

Meal replacements are available in different formats.

1 Meal Replacement Bars – Crunchy and Creamy formulations

Meal replacement bars are the most common replacements as they are very portable. Meal bars are similar to protein or snack bars but contain balanced nutrition. Meal bars also tend to be nutritionally subpar to other types of complete foods. Some manufacturers are developing instant granola products to offer a chewable experience to the consumer, with balanced nutrients. Few bars are tender with creamy consistency enriched with protein and dietary fibre and with different flavors salted caramel, strawberry ice cream, caramel Fudge, Iced Coffee etc.,

2. Ready to Drink (RTD) – Fortified Nutritional Beverages formulation using Plant-based Protein & Dairy.

RTD are similar to ready-made shakes and are ready for consumption. An ideal drink should contain about 180 – 400 calories, with less than 30% of fat, 8-10 grams of fibre and 17-33 grams of protein with added vitamins and minerals per serving. Due to high percentage of protein and high dietary fibre, it ensures sufficient feelings of satiety. Shakes or plant-based protein smoothie formulation also been prepared using plant extracts like papaya, curcuma, pomegranate, strawberry, BP blues, or matcha. However, such offerings are not easy to develop as it needs to tap into advances in food science, process and applications technologies.

Product formulations possess several challenges. For instance, formulating citrus juice concentration, the low pH limits the protein choice. Further, milk protein concentrates, Caseinates, milk protein isolates and most soy protein isolates, will not function at pH 4.0 due to isoelectric point related to precipitation. Similarly, from a sensory standpoint, whey and soy protein are astringent at pH 4.0. Thus, a high level of protein (>15 grams per serving) possess huge challenge as it is likely to be astringent and thereby result in a low consumer taste preference. However, food research lab from Chennai, India involves in the formulation of ready to drink beverages using plant-based proteins (e.g. Algae, Spirulina / Spirulina Biomass, Mushroom) and dairy (with blends of whey protein concentrate, whey protein isolate, casein and protein hydrolysate).

3. Powdered meal formulation

The food product is processed and blended and sold in bags as powder. Just hydrate the powder with water or milk and shake well to consume it. Plenny shake, Next-level meal are examples are powdered meals available in the market. The powdered meals are also placed in a bottle and usually contains just one serving per bottle. It is as portable and ready to go as RTD drinks. Vitaline and Feed brands are selling powdered meals in a bottle. The consumption of complete foods in solid versus liquid versions with similar energy contents led to older adults’ appetite responses. Therefore, they should not be viewed as equivalents and needs to be chosen based on requirements (2).

Key advantages:

Convenient & on the run:

Consumers seem to be running short on time specifically during breakfast or lunchtime. So Food scientist and manufacturers have developed complete food where consumers are not required to cook or go to a restaurant. Moreover, you can shake a meal in less than 2 minutes.  Consumers can take it wherever they want (hiking, travelling, gym) and doesn’t require much cleaning. It also allows keeping track of the calories more efficiently, compared to cooking low-calorie foods[u2] . Meal replacement provides a wide array of flavours and tastes based on the available brand and type of packaged foods, allowing customers to switch around the meals (3).

Better nutrition:

Meal replacements often contain carefully chosen ingredients, with balanced amounts of micro and macronutrients. Even well-prepared foods at home may not be nutritionally balanced most of the time. Complete foods allow you to follow Vegan, Keto and Paleo diets [u3] with much ease. The use of protein-enriched meal replacements has been shown to maintain a lean body mass during weight loss (4).

Cost-efficient & minimal wastage:

Most completed foods in this range are less than 2$ or £1.5; enabling students and office workers to save money on their food bills. Meal replacements minimize food waste, as they have a long shelf life when stored in a cool dry place. Moreover, they also aid in reducing overall waste such as packaging, wrapping, plastic bottles etc.

Common misconceptions:

Consumers need a clear understanding of what is not a complete food, as it may not contain all the necessary nutrients and recommended daily intake value.

Supplements (vitamins, antioxidants, omega-3 fatty acids) as the name suggests, supplement your overall diet and aids in boosting nutrient needs. Protein shakes [u4] are loaded with proteins with a minimal amount of carbohydrates and fats. Meal replacement is not only for people on extreme weight loss diets. Although meal replacements can help people on specific diets, it is designed for the majority of the population. American Diabetes Association (ADA) recommend meal replacement products[u5] , once or twice in a day for consumers with diabetes to maintain weight loss. The studies conducted on the effects of meal replacements on weight loss, for individuals with mental illness is not conclusive (5).

There are a few disadvantages to the meal replacements during food product development. A very few brands and flavour choices are available. Some meal replacements are high in saturated fatty acids or added sugars. Meal replacements reinforce the concept of diet as a temporary measure for sustained health when they should be lifelong. Meal replacement may contain stimulants such as caffeine, ginseng or guarana. Therefore, look for complete foods which are high in nutrient content that is tasty and agreeable with your digestive system. They also need to be affordable to be used consistently.

Table 1 provides a summary of main regulatory requirements in several countries and regions for meal replacement.

Table 1. Regulatory Requirements for Meal Replacement-Type Products
	Codex Standard[2]
Energy	200–400 kcal	NLT 203 kcal	200–400 kcal	NLT 225 kcal	200–400 kcal	200–400 kcal
Protein	25–50% of total energy in product, not to exceed 125 g/day	NLT 12 g	25–50% of total energy in product, not to exceed 125 g/day	20–40% of total energy in product	25–50% of total energy in product, not to exceed 125 g/day	25–50% of total energy in product
Fat and Linoleic Acid	30% of total energy in product from fat, including NLT 3% from linoleic acid	None specified	30% of total energy in product from fat, including NLT 3% from linoleic acid	35% of total energy in product from fat, including NLT 3% from linoleic acid	30% of total energy in product from fat, including NLT 3% from linoleic acid	30% of total energy in product from fat and NLT than 1 g of linoleic acid
Vitamins	25–33% of amounts specified in standard and depending on the number of recommended servings per day, i.e., 3 or 4	25% of amounts indicated in the regulation	NLT 33% of amounts indicated in the regulation	Specific range amounts as per standard	25–33 of amounts specified in regulation and depending on the number of recommended servings per day, i.e., 3 or 4	–
Minerals	25–33% of amounts specified standard and depending on the number of recommended servings per day, i.e., 3 or 4	25% of amounts indicated in the regulation	NLT 33% of amounts indicated in the regulation	Specific range amounts as per standard	25–33% of amounts specified in regulation and depending on the number of recommended servings per day, i.e., 3 or 4	NLT 30% of amounts specified in regulation
No Less Than (NLT)

Table 1 Standards and regulations for meal replacements in various international

 

Codex	Australia	Brazil	Canada	Chile	EU	Indonesia	Korea	US & China
Energy	200–400 kcal	≥200 kcal	≥200–400 kcal	≥225 kcal	≥200–400 kcal	200–250 kcal	≥200 kcal	≥200–400 kcal
Protein	25–50% of total energy; ≤125 g/day	≥12 g	25–50% energy of product and 125 g	20–40% energy of product	25–50% energy of product and 125 g	25–50% energy of product	≥12 g	≥10% NRV
Fat	≤30% of total energy	None	≤30% energy of product	≤35% energy of product	≤30% energy of product	≤30% energy of product	≤13 g	None
Fat from linoleic acid	≥3% of total energy of linoleic acid (glycderide form)	None	≥3% energy of product	≥3% energy of product	≥3% energy of product	≥1 g	None	None
Linoleic acid & linolenic acid ratio	None	None	None	4:1–10:1	None	None	None	None
Vitamin	33–25% of specified amount in Codex 181‐1991 (depend on # of servings/day)	Specific minimum indicated	Specific minimum indicated	Specific minimum indicated	Specific minimum indicated	≥30% NRV	≥25% RDA	≥25% NRV
Mineral	33–25% of specified amount in Codex 181‐1991 (depend on # of servings/day)	Specific minimum indicated	Specific minimum indicated	Specific minimum indicated	Specific minimum indicated	≥30% NRV w/ specific limit on Na & K No min limit: F, Cr, Cl, Mo	≥25% RDA	≥25% NRV
Essential amino acids	None	None	None	None	None	Yes—profile WHO 1985	None	None

*RDA- Recommended Daily Allowance, NRV- Nutrient Reference Value. Table adapted from (6).

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With many years of passion and experience in the industry, Food Research Lab serves as a one-stop solution for all your food business needs, from creating a new product or enhance an existing one. Our food technology experts will help you through a plethora of rules and regulations across the globe, to enable your product (food & nutraceuticals/supplements) to reach customers hands promptly. We will also help you with a cost analysis of new product for your specification and certification process of your product. Reach us at salessupport@foodresearchlab.com for food consulting services.

Reference:

1. Heymsfield, S., Van Mierlo, C. A. J., Van der Knaap, H. C. M., Heo, M., & Frier, H. I. (2003). Weight management using a meal replacement strategy: meta and pooling analysis from six studies. International journal of obesity, 27(5), 537-549.
2. Tieken, S. M., Leidy, H. J., Stull, A. J., Mattes, R. D., Schuster, R. A., & Campbell, W. W. (2007). Effects of solid versus liquid meal-replacement products of similar energy content on hunger, satiety, and appetite-regulating hormones in older adults. Hormone and metabolic research, 39(5), 389.
3. Bowen, J., Brindal, E., James-Martin, G., & Noakes, M. (2018). Randomized trial of a high protein, partial meal replacement program with or without alternate day fasting: similar effects on weight loss, retention status, nutritional, metabolic, and behavioral outcomes. Nutrients, 10(9), 1145.
4. Wycherley, T.P., et al.,(2012) Effects of energy‐restricted high‐protein, low‐fat compared with standard‐protein, low‐fat diets: a meta‐analysis of randomized controlled trials. Am J Clin Nutr. 96(6): pp. 1281–98.
5. Gelberg, Hollie A.; Kwan, Crystal L.; Mena, Shirley J.; Erickson, Zachary D.; Baker, Matthew R.; Chamberlin, Valery; Nguyen, Charles; Rosen, Jennifer A.; Shah, Chandresh; Ames, Donna (2015). “Meal replacements as a weight loss tool in a population with severe mental illness”. Eating Behaviors. 19: 61–64. doi:10.1016/j.eatbeh.2015.06.009. PMID 26172565.
6. Andrew Shao (2017). Role of Meal Replacements on Weight Management, Health and Nutrition, Superfood and Functional Food – An Overview of Their Processing and Utilization, Viduranga Waisundara and Naofumi Shiomi, IntechOpen, DOI: 10.5772/66331.