Reducing Fat: A Cutting-Edge Strategy
March 1997 -- Cover Story By: Ronald C. Deis, Ph.D.
Contributing Editor Most recent consumer preference surveys for foods still rank fat reduction on the top of the list, closely followed by calorie reduction. Although there are some indications that what consumers want and what they actually buy may take divergent paths, many product designers are focusing on fat replacers that not only reduce fat content, but also decrease calories while still maintaining the quality of the finished product. Apparently consumers are not willing to forfeit quality or pay a significantly higher price for just reductions in fat levels. They have come to realize that fat reduction does not necessarily mean a calorie drop. They are also becoming increasingly aware of nutrition, so any product changes need to address the relevant issues. However, customers might be willing to pay higher prices if benefits and quality exist. Quality is equally, if not more important, as many in the fat-reduced market will attest. Recent changes in the cookie market illustrate this mindset. Reduced fat cookies -- led by Nabisco's Snackwell's, the Cinderella brand of two to three years ago -- rode the fat-reduction craze crest. But recent sales have trailed off, and the most likely explanation it that consumers became dissatisfied with its combination of cost, nutritional benefits and quality. New fat-reduction strategies can be found in those three words: "cost," "benefit" and "quality." Cost control is a constant consideration in product development, and the ingredients that have made inroads into the market have done so with a cost/benefit of the ingredient in mind. Quality improvement has caused product developers to maintain a watch for new and emerging ingredients that might provide a quality they need for certain formulations. Many say nothing new has emerged from ingredient technology during the last several years. This may seem the case on the surface, since regulatory approval is sometimes difficult, budgets are tight, and product development timelines do not always allow for evaluation of something new. Once developed, several years might transpire before a new ingredient "breaks through" in a market. But new products have emerged and new ideas incorporating old products have proven successful. In particular, fiber seems to be making a comeback, due to its low calories and nutritional benefits. The cast of thousands of ingredient companies is gone, so choices are a little more clear-cut, and these remaining suppliers have refined their products to fit certain categories, with new products emerging. Many of these ingredients also deliver functional benefits that increase their value to designers trying to formulate lower fat, lower calorie foods. Microbial web One example of a new fiber ingredient developed for fat reduction was introduced by NutraSweet Kelco Company, Deerfield, IL, at the 1996 Institute of Food Technologists (IFT) meeting in New Orleans: PrimaCel(. This unique cellulosic thickener and stabilizer is produced by the microbial fermentation of Acetobacter xylinum combined with sucrose and carboxymethylcellulose co-agents to promote dispersion. "This is the first of a family of ingredients based on this high-performance food cellulose which will be designed around customer needs," says Deane Clark, Ph.D., manager of ingredient development for NutraSweet Kelco, San Diego, CA. The technology for this food cellulose, also known as "microfibrous cellulose," was originally developed and patented by Weyerhaeuser Company. The product was previously known as Cellulon(, a name that has been retained for industrial applications. A generally recognized as safe (GRAS) petition was accepted for filing by the U.S. Food and Drug Administration in 1992. By current conventions, this opened the door for its use in food products. "Although the cellulose in PrimaCel is identical chemically to plant cellulose, it exhibits a much higher surface area," Clark says. "It has a reticulated structure with a minimal number of contact points -- similar to a spider web." PrimaCel fibers are extremely fine, with a 0.1 (m to 0.2 (m diameter. Due to its unique structure, PrimaCel forms a strong, stable colloidal network, providing a true yield stress to the food product. "You can think of it as a water organizer," Clark says, "but PrimaCel is also effective in thickening nonaqueous systems for use in low water activity foods." It acts as a general thickener and stabilizer, a foam stabilizer, and a freeze/thaw control agent as well. PrimaCel is pseudoplastic -- the fibers tend to align in flow direction, causing viscosity decreases with increased shear rate and viscosity increases with decreased shear rate. No viscosity is permanently lost from applied shear. Viscosity also is stable to freezing because ice crystal growth is inhibited. From freezing to 60(C, viscosity is stable. It increases slightly from 60(C to 80(C, then decreases at temperatures greater than 80(C. Viscosity also is relatively unaffected by pH changes across a wide range -- 3.5 to 10.5 -- allowing it to cover virtually all food applications. Being nonionic, this ingredient remains unaffected by level changes in added ions in the form of sodium or potassium chloride. The manufacturer suggests a number of fat reduction applications for PrimaCel. It can thicken, act as a binder and stabilize fat-reduced products, such as pourable dressings, spoonable dressings, sauces, gravies, frostings, icings and cultured dairy products. Use levels range from 0.1% to 0.8%. It may be used as a starch extender, especially in salad dressings, since it can thicken without masking flavor. It can provide additional body and cling, and suspend herbs and spices. In whipped toppings and aerated desserts, PrimaCel can help to control overrun and offer foam stability. It is recommended for use in frozen dairy products to control ice crystal growth during storage, and to suspend particulates. As with any insoluble ingredient, PrimaCel must be dispersed through the product uniformly, which is readily accomplished with mild mixing. "For many applications, nothing out of the ordinary is needed to achieve PrimaCel's functionality," Clark says, "particularly if there is a high-shear mixing or homogenization step somewhere in the process. Some users will prefer to add a preliminary activation step to open up the colloidal network and realize maximum benefit from PrimaCel. Depending on the application, this may require a `Waring' type blender, a rotor/stator homogenizer, or a pressure-drop homogenizer." Another microbial product that performs as a fat reducer is NutraSweet Kelco's gellan gum (KelcoGel(tm)). The FDA approved gellan gum as a food additive in 1990. It is produced by Sphingomonas elodea (known earlier as Pseudomonas elodea). The company screened more than 1,000 micro-organisms that could produce gums, and settled on the development of three, including gellan. Gellan exists in two forms -- a native, acylated form, and the KelcoGel deacylated form. Both forms have a glucose, glucuronic acid, rhamnose backbone (2:1:1), forming a linear tetrasaccharide repeating unit. The acylated form provides elastic gels; the deacylated form provides a more brittle gel. Gellan is unique in that it forms gels with all ions, including hydrogen. Gellan must be heated with a sequestrant to achieve hydration, then gels are formed by adding ions such as sodium or calcium, followed by cooling. Gellan is compatible with a number of other gums (xanthan, locust bean), starches and gelatin to manipulate the type of gel, elasticity and stability. Uses of gellan are not fully explored, according to Clark. Totally new ingredients typically take several years to develop in markets, as the ingredient manufacturer transfers knowledge of the function and properties to product developers, and product developers work with the product to better understand how it fits into their applications. Approaching age 5 years, gellan is starting to spread its wings and achieve some application success. NutraSweet Kelco has recently discussed their work with "fluid gel" technology -- the disturbance of gels during formation to form discrete gel particles -- which could prompt re-examination of gelling agents for uses outside their traditional role. This technology extends the usefulness of ingredients previously considered exclusively as "gelling" agents into thickening tools. Gellan gum also can form strong brittle films exhibiting oil and moisture barrier properties, according to Cynthia Shanahan, scientist, food systems R&D, NutraSweet Kelco. Aqueous solutions of one form, a fine mesh grade that hydrates rapidly, applied as a dip or spray to a food substrate, or incorporated into the batter, has been shown to minimize fat absorption during deep-fat frying. In laboratory bench trials, applying a solution of gellan gum to battered fish pieces at concentrations as low as 0.05%, resulted in up to a 60% reduction in the amount of oil uptake during frying. Japanese imports Another fermentation-derived gum has found some success in Japan, and was recently given the green light in the United States. On Dec. 16, 1996, the FDA approved curdlan for use as a formulation aid, processing aid, stabilizer, thickener or texturizer in foods (21 CFR 172.809(b)). Curdlan is a unique polysaccharide with potential uses as a texture modifier and/or gelling agent in processed meats, noodles, surimi-based foods, and processed cooked foods, according to Gerry McKiernan, vice president, Takeda USA, Inc., Orangeburg, NY. Discovered in 1966 at Osaka University, curdlan (common name) is a polysaccharide produced by Alcaligenes faecalis var. myxogenes. Curdlan is a linear (-1,3 glucan, insoluble in water, alcohol and most inorganic solvents, and is indigestible -- virtually 100% insoluble total dietary fiber (TDF). Since curdlan is relatively new to the U.S. market, its potential has not been fully explored. It is a gelling agent, unique in that it gels on heating alone. Carrageenan, agar-agar, HM pectin, gellan, and gelatin gel after heating, then cooling. Other ingredients, such as sodium alginate and LM pectin require addition of calcium ions in order to form a gel. Curdlan is insoluble, so proper dispersion is very important. Once suspended, curdlan produces a weak low-set gel if heated to 60(C and then cooled to below 40°C. Gel strength also increases with increased product concentration. If heated to greater than 80(C, a stronger, thermo-irreversible gel forms. Curdlan can gel though a wide pH range (2 to 10), and is stable to freeze-thaw. Syneresis does occur, but can be controlled by adding starch or other gums. As with other gelling agents, curdlan's characteristics also can be adjusted with the effects of other gums or starches -- something which would need to be explored in the specific application. McKiernan sees applications for curdlan in fat reduction and in a number of different areas: frozen and retorted chicken meat; breadings (to prevent oil migration or dryness); fish analogues. Like other gelling agents, curdlan is a good film-former. One possible use of this characteristic could be in fried chicken, decreasing the amount of oil which migrates into the chicken, and improving moisture retention on storage. Japanese technologists have succeeded in achieving usage of 0.2% to 1.0% in oriental-style noodles. This improves consistency and firming and decreases cloudiness in soups. Since meat is expensive in Japan, curdlan has been used as a binder in meats such as processed hams, McKiernan notes. Curdlan also has been used in fish analogues in Taiwan. Compared to other binders, it is reportedly less gritty, possesses a better flavor profile and increases elasticity. In addition to exploring uses in fat reduction applications, Japanese firms also have experimented with new food products, using curdlan as a prime ingredient. This has led to curdlan jellies that can be stored frozen, warmed in a microwave and then served hot. With processed tofu noodles -- now available in Japan and Korea -- a noodle-like gel is produced by discharging a curdlan-soy milk mixture through a die into hot water, producing noodles which can be served hot, cold, boiled or sautéed. The root of the problem Another Asian product, konjac flour, is a centuries-old old ingredient with new uses. Konjac is obtained by grinding the root of the Amorphophallus konjac plant (also known as elephant yam) and is used in Asia in noodles and similar products. Philadelphia-based FMC Corporation Food Ingredients Division has taken this old technology to a new level to by creating a product called Nutricol(tm) konjac flour, a high molecular weight glucomannan (mannose and glucose in a molar ratio of 1.6:1) with ( 1-4 linkages. Konjac is GRAS, and has been listed (FCC monograph) as konjac, konjac flour, konjac gum and konnyaku. Konjac's average molecular weight is 200,000 to 2 million daltons (average 1 million), with short side branches and acetyl groups positioned at C-6 every 6 to 20 sugar units. These acetyl groups control the degree of gelling: Removing them with a weak base and heat results in formation of thermally stable gels. Since konjac is nonionic, gels are not affected by ionic environmental changes, and are generally stable from pH 3 to 9. Konjac is able to form very strong, thermally reversible gels with carrageenan, xanthan gum and locust bean gum. Adding a base (potassium, sodium, or calcium hydroxide or potassium or sodium carbonate), forms a thermally stable, nonmelting gel. Konjac also forms a heat-stable gel with starch when it is cold-set by raising the pH. FMC experts believe these systems can mimic fat by forming gels (thermally reversible to heat-stable) with textures ranging from those resembling fat chunks to fine fat emulsions. For fat replacement, FMC experts recommend several potential model systems. Five percent konjac in water can form a heat-stable gel that can be ground into small pieces to simulate fat in ground-meat products. Color and flavor can be added, and chunks can be cut to any size. A 2% konjac/2% hydrogenated soybean oil/96% water system can be used to simulate a shortening. If 2% Avicel(r) cellulose gel is combined with konjac in a water gel, this gel can provide a grease-like feel at low-use levels. Heat-stable, translucent beads which simulate fat emulsions can be formed by dropping a 1% xanthan gum/1% konjac/98% water solution into alkaline alcohol. Beefing up the bifido Inulin also is not a new dietary component -- but only during the last several years has it been heavily marketed in the United States. After starch, inulin is the most abundant nonstructural polysaccharide in nature -- being the energy reserve in thousands of plants. As an oligosaccharide, inulin is extremely well-known and widely used in the Orient. We can consume oligofructose on a daily basis in onions, asparagus, leeks, garlic, artichokes, bananas, wheat, rye and barley. For the purified form, manufacturers generally turn to the more concentrated sources -- chicory (>70% inulin on dry solids) and Jerusalem artichoke (also >70%). Chemically, inulin is a ((2®1) fructan with the general formula: Gfn where G = Glucosyl unit, f = Fructosyl unit, and n = number of Fructosyl units linked (n(2). The degree of polymerization (DP) ranges from 2 to 60. Oligofructose, another product on the U.S. market, contains a mixture of Gfn and independent fructosyl units, with an overall DP of 2 to 20. In 1992, Zumbro, Inc., Hayfield, MN, began marketing a Jerusalem artichoke flour. A 1991 FDA letter verifies that Jerusalem artichoke flour can be used as a food. The flour marketed by Zumbro contains 13.2% dietary fiber and 65.7% carbohydrates (78.4% (DP-2, 15.2% DP-2 as fructose/fructose and fructose/glucose). This product is labeled as "Jerusalem artichoke flour." Prior to 1992, a product known as NeoSugar was used in the United States, but as an additive to poultry and swine-feed to promote bifidobacteria. In 1993, Rhone Poulenc Food Ingredients, Wilmington, PA, announced an agreement with Raffinerie Tirlemontoise (Belgium) to market Raftiline( and Raftilose(, extracted from chicory roots, in the United States. Inulin also is available from Imperial-Suiker Unie, a division of Imperial Holly Corporation, SugarLand, TX, and under the trade name Fibruline( from Cosucra (through several U.S. distributors). Inulin can, and has, been used for fat replacement in food products in dry and gel form, because a 30% to 40% solids gel has a fatty feel. In fact, the developers of Raftilose created a patented technology called Raficreming(, using high shear to produce a particle gel. The gel strength can be varied to result in a low-calorie fat replacement for specific uses. Inulin in either a dry or gel form can be combined with emulsifiers, proteins and/or gums to provide specific properties needed for fat (and calorie) replacement in spreads, confectionery, processed cheeses, yogurt, ice cream, baked goods, and low fat meats and meat substitutes. Several studies indicate the caloric value of inulin is approximately 1.0 to 1.5 kcal/gram. An American Institute of Baking study reported a value of 1.48 kcal/gram. Not only does inulin function as a dietary fiber, it's also natural. Besides replacing the characteristics of fat, inulin can also increase the healthfulness of a food product. Inulin is metabolized preferentially by bifidobacteria in the colon, thereby providing many benefits. It stimulates bifidobacteria growth, reducing formation of toxic fermentation products, with implications for: pathogenic diarrhea and constipation prevention; serum cholesterol and blood pressure reduction; micro-nutrient production. However, inulin's uses in foods are still poorly understood. Many Oriental and European uses have focused on the nutritional benefits, which are unknown to the U.S. consumer. Since these companies have only been active in the United States for the past two to three years, perhaps we can expect more activity in the applications area to support this rich history of nutritional benefits. Also, to maximize use of these products, educating the U.S. consumer regarding these benefits will be important. Resisting fat use Another fiber-containing ingredient that can take the place of fat in foods is resistant starch. Because of its reduced caloric content, it functions mainly as a bulking agent, although it can have other beneficial effects in the finished product. Although the term "resistant starch" has only recently become well-known, it was coined in the early 1980s, and scientists discussed its dietary effects years before that time. Resistant starches are starches and products of starch degradation which resist enzymatic digestion and act like dietary fiber. Resistant starch is present in many foods -- it is naturally found in coarsely ground or chewed cereals, grains or legumes as a physically inaccessible starch (RS1). It also can be found in bananas, high-amylose starch and raw potato as naturally resistant or ungelatinized granules (RS2). A third type of resistant starch (RS3) is generated by retrograding starch during food processing. This variety can occur naturally in products such as bread, cereals and cooked potatoes. Recently identified, another type is classified as RS4. This is representative of starch that has been rendered resistant by chemical modification. Currently, no commercial products of this type exist. As knowledge of TDF developed through the 1980s, resistant starches frequently were discussed, but no significant attempts were made to commercialize them until the 1990s. The first resistant starch released and marketed as a such was an RS2 based on a high-amylose corn starch hybrid. The product -- Hi-Maize( -- was developed by Starch Australasia Ltd. and won the 1995 Australia Institute of Food Science and Technology Industry Innovation Award in Australia. Hi-Maize contains approximately 20%-25% total dietary fiber, and has been introduced into several breads and extruded cereals as a functional fiber in Australia. It is marketed in the United States through Del-Val Food Ingredients, Bensalem, PA. Tom Jackson, president of Del-Val, notes that Hi-Maize was used in a high-fiber white bread in Australia, which captured 12% of the white-bread market within 16 weeks, increasing the total white-bread market 3% (a 1.4% increase for the total bread market). In 1991, Opta Food Ingredients, Bedford, MA, was granted a U.S. patent for a concentrated, process-tolerant source of RS3 resistant starch in food applications. Independently, National Starch and Chemical Company, Bridgewater, NJ, a major food-starch producer, also was granted a U.S. patent on a common process to produce RS3 starch. The companies agreed to cooperate to commercialize this higher TDF (30%) product, resulting in the 1994 launch of two new products marketed as resistant starches -- Crystalean( (an Opta Food Ingredients product) and Novelose( (a National Starch and Chemical Company product). Resistant starch represents a functional fiber alternative. The RS3 resistant starch, for example, has been shown to significantly improve expansion and eating quality for extruded cereals and snacks, according to National Starch and Chemical Company application data. In addition, the RS2 resistant starch performs well in baked goods due to its small granule size and low water-holding capacity. Resistant starch also is label-friendly, with Hi-Maize labeled as "cornstarch," and Crystalean and Novelose labeled as "maltodextrin," both already recognizable terms on many ingredient legends. They compare well to several natural grain sources, contain little fat, are white in color and neutral in flavor. A 1996 American Institute of Baking study ("Energy Value of Resistant Starch" -- G. S. Ranhotra, J. A. Gelroth, B. K. Glaser, Journal of Food Science, vol. 61, issue 2) determined that, while nearly one-third of the resistant RS3 starch consumed is fermented, it produces essentially no energy value. Resistant starch may be considered a valuable bulking agent in fat replacement applications due to the following: good bulking ability (essentially inert in baked goods, cereals, pasta and snacks, since water-holding capacity is very low); low impact on appearance. Getting trim with oats The U.S. Department of Agriculture's Agricultural Research Service has had an ongoing program for several years to develop usable products from agricultural byproducts such as grain hulls (oat, corn, rice, soybean, peas) and brans (corn, wheat). This has resulted in some new products that have exhibited potential as fat-replacing ingredients. A primary developer in this project has been George Inglett, a chemist at the USDA National Center for Agricultural Utilization Research. Inglett introduced oatrim in 1990, and has won several awards in the process of helping to commercialize his invention. Developed as a fat replacer, oatrim is USDA-patented and licensed to ConAgra, Quaker Oats and Rhône-Poulenc. Quaker Oats and Rhône-Poulenc joined forces and are marketing oatrim under the Beta-Trim brand of Quaker® Oatrim. Beta-Trim, a new and improved version of oatrim, is a neutral-flavored form well-suited for delicately flavored foods such as skim milk, cheese, ice cream and cream fillings. ConAgra (through Mountain Lake Manufacturing Company) has joined with A.E. Staley Co. to market TrimChoice, a line of hydrolyzed flours based on oats and corn. This product has found its way into several ConAgra Healthy Choice products such as ground beef, hot dogs, cheese and bologna. Oatrim is enzymatically hydrolyzed oat flour (later expanded to include other grains) containing 5% beta-glucan soluble fiber. The process is very similar to that used in the preparation of a corn syrup or maltodextrin: Starch in oat flour or bran is hydrolyzed by (-amylase to form a more soluble material (oat (-glucan-amylodextrins) labeled as "oatrim" or "hydrolyzed oat flour." Similar to other carbohydrate and protein fat replacers, oatrim can form a gel with water to mimic fat in a number of food applications. From a caloric standpoint, if the gel contains 25% oatrim at 4 kcal/gram and the remaining 75% is water at 0 kcal/gram, the gel is 1 kcal/gram. This means that the gel, not oatrim itself, produces significant calorie reduction, something often not clarified in many articles about gel-forming fat and calorie replacers. The combination of lower molecular weight polysaccharides and soluble (-glucan naturally present in oats ((-glucan is now normally present in oatrim at a 5% level) imparts a creamy mouthfeel in a range of food categories. USDA-conducted studies suggest oatrim might have some hypocholesterolemic benefits, but this product is not currently included in the list of oat products that can carry nutritional labeling to that effect. Oatrim has been used in several commercial products, most recently as a texturizing agent in milk, as part of a proprietary formula (Replace) marketed by Golden Jersey Products, Vero Beach, FL. The firm is marketing this ingredient in fat-free and cholesterol-free milks, and hopes to place it in yogurts, cheeses, creams and adult-flavored milks. Inglett believed an insoluble fiber was needed to blend with the soluble oatrim to provide optimum fat replacement. On Oct. 9, 1996, he announced the development of this product -- dubbed "Z-Trim" (for zero calories). Oatrim was developed from the inner, starch-containing part of the hull or bran, but Z-Trim was developed from the more cellulosic, outer portion. In a process similar to the alkaline/hydrogen peroxide process which led to a USDA-patented oat fiber also licensed by ConAgra, the hulls of oats are treated in a multistage process to remove the lignin. The resulting cellular fragments are purified, dried and milled. This dried powder can later be re-hydrated to form a gel or can be incorporated directly into a food. Rehydration requires some level of shear, but a water-holding capacity four to five times the level of the starting hulls can be achieved. Gels developed from different grain sources have different textures, and the product can be blended with gums to impart different properties. The USDA applied for a patent in 1995, and a license agreement is in process with Mountain Lakes Specialty Ingredients Co., Omaha, NE, a ConAgra/Staley co-venture. Application information is under development and will be available in early 1997, according to company officials. National Center for Agricultural Utilization Research scientists explored use of Z-Trim in cheese spread (containing 22 kcal per 28 grams); ham spread (containing 20 kcal per 28 grams); snack bars; brownies (containing 175 kcal and 3 grams of fat per 3 ounces); and ground beef (containing 190 kcal and 1.5 grams of fat per 3 ounces cooked patty). Patented approach In recent years, Peoria, IL-based National Center for Agricultural Utilization Research has been busy in the fat-replacement arena. On Dec. 5, 1996, two of its scientists, Kenneth Eskins and George F. Fanta received Agricultural Research Service awards for development and commercial transfer of Fantesk(, a starch-water-oil blend already targeted for foods, pharmaceuticals, cosmetics, adhesives and seed coatings. The name "Fantesk" has been trademarked by USDA, and officials applied for a patent less than three years ago. The discovery of Fantesk was a case of serendipity -- the two chemists were processing starch and oil in superheated steam under pressure. Their original intent was to form a co-polymer on which enzymes could attach to create an artificial membrane which could be used to form natural compounds ranging from flavorings to fungicides. They extracted a thick, gelled "mess," which did not show syneresis on cooling. The gel felt smooth, but not greasy. Based on USDA testing, the gel appears to be heat and freeze/thaw stable, and can be used as a gel, a liquid or it can be dried to flakes or a flowable powder. The inventors have worked with a 20 to 40 parts oil to 100 parts starch product, but they have been able to produce up to a 70:100 ratio for dried shortenings. In additional experiments, they were able to entrap volatile odors and flavors. Micro-photographs show oil droplets measuring 10 microns or less entrapped in the starch. Experiments conducted at the National Center for Agricultural Utilization Research showed potential for this ingredient in ice creams, low-fat snacks, lubricants, microencapsulated, as well as other non-food applications. The Agricultural Research Service has already developed several cooperative research and development agreements with companies interested in exploring market niches. Opta Foods, Bedford, MA, holds an exclusive license for using Fantesk in foods, and is developing a family of products to add to their line of texturizing agents. Fantesk technology is currently under evaluation in meat, ice cream and confections, but Opta has not announced a product-line launch date. Other companies hold licenses for the use of Fantesk in non-food applications such as adhesives, glues and coatings. Revising and refining For fat replacement, many companies have taken existing products and modified them to better fit the application. FMC officials have carried their Avicel&153; microcrystalline cellulose and cellulose gum technologies a step further, to provide more fat-replacement opportunities. Avicel was originally designed as a general stabilizer, although its fat mimetic properties were recognized even before the fat substitute market developed. Many of the Avicel grades contain varying percentages of CMC, but their new Novagel technology combines microcrystalline cellulose and guar gum in a co-processed product. RCN-10 (90% MCC, 10% guar) forms spherical particles which can deliver fat-like qualities to high-solids foods such as processed cheeses. RCN-15 (85% MCC, 15% guar) forms irregular-shaped particles (1 to 15 microns) for use in higher-moisture foods such as salad dressings. Other companies have combined familiar ingredients in novel ways in the search for a better fat replacer. For example, in June 1996, Opta introduced two new texturizing agents for reduced fat foods -- OptaMist and Optex® -- at the IFT Food Expo. OptaMist is an all-natural, starch-based texturizing agent which provides a creamy body (without strong gelling or high viscosity) to salad dressings, mayonnaise and dairy products. On an ingredient legend, it would be labeled "cornstarch." Optex is a texturizer and opacifying agent derived from cornstarch and monoglycerides. It is a blend of insoluble microparticles and soluble maltodextrin, and is labeled as "maltodextrin and monoglycerides." This product has been designed to replace up to 100% of the fat in spreads, sauces and spoonable dressings. Also introduced at IFT last year was OptaGlaze®, a water-based colloidal suspension of water-insoluble protein designed to replace oil-based glazes on bakery products and snack foods. This product is ready to use, and can be sprayed at room temperature to enhance gloss; adhere particulates such as seasonings, seeds, and nuts; preserve aromas and flavor; and retain moisture. Generally recognized as safe, Optex is labeled as "wheat gluten." According to Opta President and CEO Lew Paine the goal in developing these ingredients was "to optimize the texture, taste and appearance of our customers' products. We believe these new ingredients have given us more tools to solve formulation challenges in a practical, consumer-friendly way." Miracle ingredient Strategic developments for fat and caloric reduction in foods bring to mind an old ingredient which has found many new uses in foods. As product developers incorporate more water-binding ingredients into lower-fat products, these products become tougher and more rubbery, water activity increases, and shelf-life decreases (the product dries, stales, becomes damaged by ice crystals or becomes contaminated). What could potentially be used to lower water activity, act as a humectant, and serve as a plasticizer? What ingredient seems to be moving into more and more ingredient legends as fat-reduction continues to be important? And what ingredient has been used in a multitude of nonfood applications for years because of the qualities food companies now seek? The answer: "glycerine." A GRAS food ingredient, glycerine originally was formulated into dynamite in 1867 by the Swedish industrialist and philanthropist Alfred Bernhard Nobel. Discovered in olive oil in 1779, it was considered valuable because it was non-crystallizable, heat-resistant, non-fermentable and could be mixed with alcohol. It has since been used in: flavors, flavor pastes, chocolate syrups, distilled liquors, frozen eggs, meat casings, and frozen fish. Glycerine is well-known for its use in fruits and candies as a control for drying and graining, as well as softness control. It is used in jelly candies, fudge, cake icings, cookie fillings, dried fruits and citrus fruit peels. It prevents oil separation in peanut butter and acts as a softener and humectant in shredded coconut. It also is used to maintain the softness and pliability of cork liners in bottle caps and whole corks for wine. A significant indirect use is the reaction of glycerine with fats and fatty acids to form mono- and di- glycerides -- emulsifiers important to fat reduction. Beyond the basic emulsifiers, glycerine is used to produce polyglycerol esters, which have become prominent in many of the new entries into the reduced-fat arena. Foods and monoglycerides are only about 20% of glycerine's end-use. Other significant end-users are: oral care, tobacco, urethane foams, drugs, cosmetics, packaging, and alkyd resins. Most of the glycerine now produced is natural -- a byproduct of production of soaps, fatty acids and fatty acid esters. As demand for new uses of glycerine has increased in the 1990s, glycerine prices followed suit. Domestic use outstripped domestic production in 1994, despite increased production and imports. By 1995, the price of refined glycerine was $1/pound. This has decreased to $0.80-$0.85 per pound due to an increase in synthetic production, according to Jon Heimann, technical service representative for Henkel Corporation, Cincinnati, OH. Production should be stable or increasing in the near future, which should keep purchasers happy as food-use continues to rise. Successful blends Another strategy that is somewhat old, but has resulted in a number of useful products is the use of blends and co-processed ingredients. The number of these products seems to be increasing over the last couple of years as suppliers struggle to come up with more "user-friendly" or process-friendly fat-replacement systems. Several of these have found their way into fat replacement, and can be useful if a cost/benefit exists. If these ingredients are targeted toward one category (such as baked goods or ice cream), they are definitely worth assessing. If the product claims it "works in everything," one should question what else is needed in the formulation to support such a use. Fat does not have the same function in all foods, so it is unlikely that one blend could replace it across all categories. A number of blends have experienced some success, for example: stabilizer systems in ice creams and baked goods; cellulose gums; many natural blends derived from fruit concentrates and pastes; and a number of specialty ingredients designed to act as fat replacers. Most of these follow the systems approach, and therefore are combinations of hydrocolloids and fiber, hydrocolloids and emulsifiers, hydrocolloids and opacifiers, etc. The advantage in using blends or co-processed ingredients depends on the applications: If it works, and the cost is right -- why not? In the fast-track world of product development, this could mean the difference between success and failure. Blends also can be a way to better distribute small amounts of small-percentage ingredients on a functional carrier. Examples of this would include emulsifiers on a hydrocolloid carrier or enzyme-emulsifier co-processed ingredients. Flavors also are often incorporated into these ingredients. These can be flavors that help to supply missing notes that occur through the absence of a highly flavored fat such as butter or may include other flavoring systems. If the supplier will work with the product developer to customize these ingredients, the effort is well worth it. Technical service from the supplier is essential to maximize the ingredient's performance. "Across the category board" blends and co-processed ingredients should be avoided unless the supplier is willing to customize. Unless, of course, it does work in a particular application without modification, but generally this is the exception rather than the rule. New strategies to replacing fat in food do exist, but most are specifically focused -- by category, product, and/or company. Product designers are striving to improve the quality of low and no-fat products, and activity has occurred in the ingredient industry to increase available tools. Consumers expect more than just fat reduction. They have an increasing awareness that calories are just as important, if not more important, than fat levels, and that other elements of food are important in maintaining overall health. Many of these new ingredients also provide an added bonus -the presence of insoluble or soluble fiber for health benefits and calorie reduction. Back to top
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