Bakery Concentrates

Case study one

	Client	Mid-sized manufacturer of branded muffins.
	Application	Blueberry and Chocolate-chip muffins
	Objective	(1) Cost saving; (2) Resolve shelf life problem; (3) Removal of egg from factory
	Result	11.9% batter cost saving

Alleggra was approached by this client with a need to both reduce costs and improve the shelf life of its range of long-shelf life muffins (four months).

Following the brief from the client, our technical team in the Netherlands developed a recipe and prototype product using Alleggra’s muffin concentrate (MC129) which matched the functionality of the existing product in terms of shape, specific height, specific volume, firmness, elasticity, taste and eating performance. The prototype product was shown to the client combined with:

• commercial assessment showing a batter cost saving in excess of £80/tonne or 11% of prime batter costs
• water activity tests to demonstrate estimated mould free shelf life had increased from 92 days to 120 days
• label analysis showing no change in label length or declarable e-numbers or allergens

This recipe was tested on line, and following two plant trials which were needed to adjust the product’s peakiness (achieved via changing the baking profile), the recipe was taken into production. The products were then monitored during shelf life and demonstrated an improved quality toward the end of life, retaining a more moist mouthfeel.

These products are on-shelf. No eggs are now required.

Case study two

	Client	Large manufacturer of own brand and branded cakes.
	Application	Cup cakes
	Objective	(1) Cost saving; (2) Reduction of sodium
	Result	12% batter cost saving; reduction of sodium by 30%

Following the increase in commodity prices in early 2008 and a refusal by their clients to accept any price increases, this client asked Alleggra’s help in reformulating their existing product lines using Alleggra’s egg replacers to achieve maximum cost saving.

Alleggra’s technical team developed two comparable recipes:

• using egg-replacer (B129) to work alongside the existing concentrate (emuslifiers/raising agents)
• using Alleggra’s crème cake concentrate (CR130), which contains the egg functionality as well as a balanced system of raising agents and emulsifiers

After some fine-tuning, both recipes matched the functionality of the reference product in terms of shape, specific height, specific volume, firmness, elasticity, taste and eating performance. Commercial comparisons showed that the recipe using the egg-replacers offered a 5% saving, but that the concentrate version offered a 12% saving on prime batter cost (£71/tonne).

Both prototype products were shown to the client alongside:

• nutritional analysis showing reduction in sodium levels by 30% to 230mg/100g, plus a bonus of reduction in saturated fats by 15%.
• water activity tests to demonstrate estimated mould free shelf life in excess of requirements
• label analysis showing no significant change in label length or declarable e-numbers

The client decided to proceed with the enhanced cost savings using CR130 and agreed with the retailer to trial the new label product. Following two plant trials which were needed to adjust the product’s specific height (achieved via changing the baking profile), the recipe was taken into production. The products were monitored through shelf life and demonstrated an improved quality toward the end of life, retaining a more moist mouthfeel.

The products were signed off by both client and retailer and are now on shelf.