Putting Premixes Together

by Johnpaul Tata

Many factors must be considered when developing functional premixes for fortified food products. In general, the process typically begins with brainstorming sessions among various groups, including consumers, product developers and other decision makers. Once the numerous suggestions are funneled down into a single idea, a concept is born. The concept is then transformed into a formulation and, subsequently, laboratory-sized samples are produced and tested thoroughly. Finally, premix formulations are scaled to production-sized quantities, subjected to further analysis, and the cycle is completed.

The premix product development process typically begins by conducting market research to obtain feedback from consumers to meet their demands. Driven by value, convenience, health and overall wellness, consumer food products and their trends are always changing. Thus, running focus groups with consumers and gathering insight on competitive products are essential tactics to utilize during the initial phases of product development. Once the initial research has been completed, it is narrowed down to an actual concept that can be created.

Once a concept is formed, a multitude of variables must be taken into consideration for developing a successful premix. This is a critical point in the development process that requires a diversified and highly technical knowledge base of functional ingredients, processing conditions and macro/micro nutrient interaction. Furthermore, it is also essential to understand additional components of the premix that account for nutrient stability and targeted shelf-life periods. All while factoring in customer-driven requirements such as finished product label claims, regulatory issues, packaging and tight deadlines.

Next, an actual recipe or formulation must be constructed. In order to assemble a formulation that will be effective, minimum label claim values, expected processing condition losses, vitamin degradation from exposure to light and heat, and product packaging must be considered. Other factors such as United States Pharmacopeia (USP) activities and purities are measured to ensure adequate amounts of the raw materials are correctly added to achieve the standardized level requirements. After the formulation has been optimized for performance within its intended application, small R&D test samples are manufactured and subjected to a series of bench top trials.

Experimentation and testing of the premix is conducted to ensure the active components within the formulation will withstand the rigors of processing such as heat treatment and extrusion, all while maintaining stability throughout shelf life. Furthermore, sensory evaluations are performed. Attributes such as overall appearance, color, taste and aroma are assessed. If for any reason, the premix does not meet the product specifications, reformulation will commence. However, if the premix performs as intended, then production scale up will begin.

Commercialization is one of the final stages in the life cycle of a premix. Within this phase of the process, specific documents are created to support the launching of a premix into the food industry. Documents such as nutritional data per 100 g, material safety data sheets, country of origin and certificate of analysis (C of A) are formed to sustain the launch of a new product.

Obviously, many components go into developing a premix for a fortified food. As long as the necessary steps are conducted correctly, an appealing premix will be produced. Once this is achieved, the consumer and manufacturer will benefit tremendously. Consumers can benefit by improving their overall health by maintaining the appropriate levels of nutrition. Manufacturers can also profit by simplifying their food production procedures, including inventories of ingredients. Adding a premix to a food product can enhance that product by providing a single source of multiple nutrients, ultimately allowing them meet the consumer demands.

Johnpaul Tata is a food technologist in the Nutritional Ingredients Division of Watson Inc .