Why Choose Food Research Lab's FRL as Your Food Product Development (FPD) Consultant and Partner?

There are several options in almost every product area in today’s market, and the difficulty is in coming up with unique items that stand out and connect with customers. Food Research Lab's Food Research Lab (FRL) takes a holistic approach to creating food and beverage products. We define, demographically target, and build effective goods through a sequential process for category selection and comprehension. The client can visit the lab to learn the process. We offer unlimited rounds of revisions to ensure customer satisfaction. The final product prototype, along with the documentation process, including the video (through email), will be shipped to the client, and in case the client is not satisfied with the video, a food technology consultant will visit the place for the product demo at the client’s costs.

What are the different forms that you deliver the Food Product Formulations?

The food industry is witnessing a new form of consumption. Keeping that in mind, we can formulate the products in the form of ready-to-eat, ready-to-drink, ready-to-mix, ready-to-serve, and ready-to-cook food products. We use ingredients that offer an added value to the development and improve its indulgence and sustainability in terms of its functional ingredients, plant-based food dyes, and natural preservatives with a clean label.

What are the sectors Food Research Lab cover?

We cover a wide range of sectors such as soups, sauces and dips, chips, tortillas, dry beverage powder, plant-based products, masalas, puddings, instant mixes and many more.

How is sensory testing been carried out?

Our sensory examination leads to the precise formulation and recipe recommendations. We develop data-driven design models based on sensory research and customer insights. The fact-based design methodology used by Food Research Lab reduces risk and gives our clients market confidence while cutting development time in half. With our dedicated sensory lab facility, our team takes satisfaction in creating and optimizing successful products in the marketplace, generating a favourable return on investment, and developing brand advocates.

Amplify Oil Stability & Reusability: FRL's Breakthrough Rancidity-Free Remedy

28 Sep

Amplify Oil Stability & Reusability: FRL’s Breakthrough Rancidity-Free Remedy

by Food Research Lab

in food, Sectors

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Background:

A major food manufacturing client approached Food Research Lab (FRL) with concerns regarding the stability and reusability of oils used in their production process. Their business involved producing fried snacks, and they encountered significant issues with oil rancidity after repeated use. The rancid oil not only affected the flavor and quality of their products but also increased production costs due to the need for frequent oil replacement. The client sought a solution to extend the shelf life of their frying oil, improve oil stability, and allow for multiple reuses without compromising product quality.

Objective:

The primary goal was to formulate a strategy that would:

Enhance oil stability and prevent rancidity.
Allow for multiple reuses of the oil without compromising the taste or safety of the final products.
Reduce overall production costs by decreasing the frequency of oil replacement.
Maintain compliance with food safety regulations concerning the reusability of oils.

Challenges:

Oxidation & Rancidity: Repeated heating of oils led to oxidation, which caused the oil to become rancid, altering the taste and texture of the fried snacks.
Thermal Breakdown: High frying temperatures degraded the oil’s quality over time, producing off-flavors and potentially harmful compounds.
Flavor Transfer: When oils were reused, the flavor of previously fried foods transferred to new batches, affecting taste consistency.

Food Safety Regulations: Ensuring compliance with food safety standards regarding the reuse of cooking oils was critical.

Solution & Formulation by Food Research Lab:

Antioxidant Additives:

We incorporated natural antioxidants into the oil. These antioxidants helped in stabilizing the oil by delaying the oxidation process, thus preventing rancidity.

Natural Acidifier Ingredient was also introduced in small amounts to reduce the pro-oxidant effects of any trace metals that might be present in the oil, which can accelerate oxidative rancidity.

Oil Selection:

The base oil was switched to a more stable option with higher oxidative stability, such as high-oleic sunflower oil. High-oleic oils have fewer polyunsaturated fats, which are prone to oxidation, and more monounsaturated fats, which are more resistant to heat.

We also blended this oil with a small percentage of palm oil for its high heat tolerance and ability to remain stable during repeated frying cycles.

Encapsulation of Antioxidants for Slow Release:

To maintain stability during prolonged frying, we used encapsulation technology for antioxidants. The encapsulated antioxidants were designed to release slowly during the frying process, providing continuous protection against oxidation throughout multiple frying cycles.

This method ensured that the antioxidant protection lasted longer, reducing the degradation of oil and preserving its quality over extended use.

Filtration System Implementation:

We recommended the installation of a continuous filtration system in the frying process. This system filtered out food particles and sediments that could accelerate oil degradation and cause off-flavors.

Filtration also helped maintain a cleaner oil with fewer impurities, allowing for more consistent frying results and extending the oil’s life.

Oil Monitoring Protocol:

A frying oil monitoring system was introduced, which involved regularly measuring the Total Polar Compounds (TPC) in the oil. TPC is a key indicator of oil degradation.

The client was advised to replace the oil only when the TPC level approached the safety limit, allowing for maximum reusability while ensuring safety and quality.

Improved Frying Conditions:

The frying temperature was optimized to prevent overheating of the oil. Lower frying temperatures reduced thermal breakdown, while still achieving the desired cooking results.

Batch frying was introduced, where small amounts of food were fried in each cycle. This minimized food residue in the oil and reduced the frequency of oil degradation.

Implementation:

After extensive testing of the antioxidant blends, encapsulation technology, and filtration systems, the oil stability was successfully enhanced. FRL conducted stability tests under real-world production conditions, where oil samples were taken at various frying cycles and analyzed for oxidative markers such as peroxide value, free fatty acids, and TPC levels.

Outcome:

The implementation of the enhanced oil stability formulation resulted in significant improvements:

Extended Oil Life: The frying oil could now be reused for up to three times more cycles compared to the previous practice. This significantly reduced the need for frequent oil replacement, thereby cutting down operational costs.
Improved Product Quality: The fried snacks maintained consistent flavor, texture, and appearance even after multiple frying cycles. The bitter, off-flavors associated with rancid oil were eliminated, and the snacks retained their fresh taste.
Cost Savings: The reduction in oil replacement frequency resulted in a 25% decrease in overall oil procurement costs, significantly improving the profitability of the client’s production process.
Regulatory Compliance: The oil remained within acceptable limits of TPC and other quality markers, ensuring compliance with food safety regulations for frying oil reuse.
Environmental Benefits: By reusing the oil for more cycles, the client reduced waste generation, contributing to a more environmentally friendly production process.

Conclusion:

Through a combination of antioxidant incorporation, encapsulation technology, optimized oil selection, and enhanced filtration, FRL was able to provide a comprehensive solution to improve the stability and reusability of the client’s frying oil. The client was able to reduce costs, enhance product quality, and maintain regulatory compliance, all while minimizing the environmental impact of their operations. This case study demonstrates how advanced oil stabilization techniques can be applied to extend the life of cooking oils in industrial settings without compromising on quality.