Doing more with less was the overarching theme of this year’s IFT First, the Institute of Food Technologists’ annual meeting and food exposition, held July 14-17 in Chicago. More with less refers to formulating foods with fewer ingredients, reducing use of natural resources and relying on a smaller number of animals and humans. For the latter, think molecular farming and precision fermentation, both of which are influencing protein sourcing.
Some refer to these times as the “Fourth Industrial Revolution,” a nod to the rapid technological advancements being made almost daily. Artificial Intelligence (AI) is increasingly part of the team to make this happen.
“The modern food system is unhealthy and old,” said Nora Khaldi, chief executive officer, Nuritas, Dublin, Ireland, who spoke at the meeting. “It’s because of the ingredients being used in these foods. These foods were built for taste and cost, not nutrition.”
She said that over the past decade, she observed how the food industry is stuck. That’s because in order to develop new ingredients that are cost effective, taste neutral and healthy, it is expensive and can take decades. With AI, it can be less than two years, and that two years includes developing and commercializing the ingredient, along with clinical studies and regulatory reviews.
This type of high-tech food and food ingredient development was a focal point of the keynote by Jim Jones, deputy commissioner of human foods with the US Food and Drug Administration (FDA). He said that FDA is staying away from defining, clarifying or even addressing the conversation about ultra-processed foods, as there’s not enough research on the topic. However, the items the agency is focusing on, such as nutrition and the safety of food ingredients, indirectly address ultra-processed foods and will conceivably provide some clarity.
Jones explained how technology will assist food formulators with making more nutritious food. Technology will also enable the agency to revisit the safety of ingredients in the marketplace and, if necessary, take regulatory action on a national basis, rather than the current state-by-state legislation.
He promised that before the end of the year, there will be updated sodium reduction targets; the term “healthy” will be defined; and guidelines will be made available for front-of-pack nutrition content claims. There are also plans to finalize a “healthy” logo for qualified products.
Revyve, a food tech company based in The Netherlands, debuted an egg replacer ingredient for use in plant-based burgers at IFT First. (Source: Alessa Joseph)Improving meat alternatives
All of those promises from Jones will impact the plant-based meat and poultry category, which already had a challenging year with retail sales down from previous years when the newness of the category invited trial. While inflation played a part in unit sales decline, numerous consumer studies suggest it’s more about product quality. Hence, this was an area where many ingredient and process suppliers at IFT First focused.
“It is important for the flavor in plant-based meats to be supported by vegetable fats and oils,” said Megan Brazil, scientist, AAK USA, Edison, NJ. “Plant-based meats may contain up to 25% fat. The impact fat has on plant-based meats is contingent on the amount of fat included in the plant-based meat, the plant source of the fat or oil solution, the ratio of saturated and unsaturated fatty acids and the melt profile of the fat.”
AAK recently received Generally Recognized As Safe (GRAS) approval for the use of shea stearin in plant-based foods and was showcasing its use at IFT First. Shea stearin is used in confectionery applications due to its unique melting profile, which also may benefit meat and poultry alternatives.
“As a versatile plant-based fat, shea stearin can be utilized in various applications,” said Octavio Díaz de León Carrillo, president of AAK USA. “We see tremendous opportunity in creating functional food products that consumers will purchase, particularly within the popular segments of plant-based meat and poultry.”
Jeffrey Fine, senior director-customer innovation, added, “This offers a long-awaited alternative source of plant-derived solid fat with a considerably lower saturated fat content than the coconut oil that is widely used today.”
Suppliers are applying advanced technologies to create ingredients — including fats and oils — that focus on improving the sensory attributes, nutrition profile and economics of producing meat alternatives. This includes identifying ingredients that lower or even eliminate cholesterol, saturated fats and sodium.
What formerly took decades, even longer, can be shortened to about two years with help from AI, according to Khaldi. The “what” she refers to is new food ingredients, and AI is the tool to creating healthier, safer and more sustainable food systems. Khaldi explained how the current way of producing food needs to be updated, and quickly, in order to save the planet and feed the growing population.
Companies such as Alianza Team USA, Durham, NC., showed IFT First attendees how these technologies can be put to work for plant-based food development. The company highlighted its suite of AI tools, which were used to create a number of concepts in collaboration with Hi-Food USA, Glendale, NY. The technology optimizes the formulation time and processing of fat-based ingredients, some of which are intended for plant-based meats.
The companies co-developed a clean label and allergen-free solution for meat alternatives that combines Hi-Food’s plant proteins and fibers with Alianza’s vegetable fat. The solution received the Fi Europe Plant-Based Innovation Award in November 2023.
To support more protein choices and eating occasions for alternative meats, ingredient suppliers continue to invest in technology to offer more options. ADM, Chicago, for example, introduced a line of low-sodium functional and dispersible pea protein powders, in addition to new textured pea proteins (conventional and low sodium).
“These introductions and extensions are crucial to supporting functional formulation needs, as well as nutritional value, including optionality for various lifestyle diets, protein content, protein diversification and the sensory experience,” said Jacquelyn Schuh, global senior director-product marketing for specialty ingredients at ADM. “This comes at a time when consumers are increasingly engaging in GLP-1 agonists. With smaller portion sizes, consumers will want to make purposeful decisions on what they eat to get the nutrient density they need. Foods with high-protein and fiber content are critical to this dietary need, and plant proteins have the potential to offer protein and fiber coming from a plant-derived source.”
Onego Bio Ltd. uses precision fermentation to manufacture a bio-identical egg protein. As a US-Finnish company, Onego is in the process of commercializing the production process in North America and is on track to submit a GRAS notice to FDA this year with hope of receiving a “no questions” letter in 2025. Founded in 2022 as a spinoff from VTT Technical Research Center of Finland, Onego is already working with major food companies on product innovation in everything from baked goods, snacks and pasta to sauces and meat alternatives.
Eggs are one of the world’s most used animal proteins. As an ingredient, they assist with binding, thickening, leavening, emulsifying and more; however, the current egg production system is not sustainable, according to Maija Itkonen, CEO of Onego.
“But there’s an alternative way with precision fermentation,” said Itkonen. “We can create proteins that are bio-identical to the foods we know and love. And we can do that using 90% less resources, without major risks such as pandemics.
“We have taken a microflora called Trichoderma reesei and trained it to produce ovalbumin, the main protein found in egg white, instead of its own enzymes,” Itkonen explained. “In a way, we have domesticated this hungry fungus and turned it into a living factory. And the fungus quite likes it. When we feed it plenty of glucose, it’s as happy as can be.”
Fungus can make protein with high efficiency and volume. Mycoprotein, also known as mycelium-based protein, for example, is produced from fungi using fermentation technology. Cargill is working with ENOUGH, Sas van Gent in The Netherlands, to produce large-scale mycoprotein ingredients. The ingredient is grown by feeding fungi with sugars from sustainably sourced grain that is then fermented in a natural production process. This mycelium has a texture and mouthfeel that mimics meat.
“The mycoprotein is a complete food ingredient that contains essential amino acids and is high in dietary fiber,” said Mark Fahlin, category marketing manager, health and nutrition, Cargill, Minneapolis. “It is produced through a zero-waste fermentation process, with Cargill’s glucose syrup as a main source.”
Reducing Food Waste
Ingredients made from side streams had a strong presence at IFT First. The process is referred to as upcycling. This is when the raw materials now being used to make ingredients would have otherwise not gone to human consumption. They are procured and produced using verifiable supply chains and have a positive impact on the environment, according to the Upcycled Foods Association, Denver, which defined the term in 2020.
Revyve, a food tech company based in Wageningen, The Netherlands, introduced its high-performance egg-replacement ingredient at IFT First. The texturizing ingredient is made from upcycled brewers’ yeast and is designed to be used in baked goods and plant-based meats. When paired with other ingredients, the ingredient can eliminate the need for methylcellulose, a common ingredient in plant-based burgers that has a “non-clean label” reputation.
“Yeast has been the star of the show in beer brewing, winemaking and bread baking for millennia,” said Edgar Suarez Garcia, chief technology officer and co-founder. “At Revyve, we have taken yeast functionality to the next level. Products manufactured with Revyve single-ingredient yeast proteins take on true-to-form textures. Revyve offers exceptional heat-set gelling, binding and emulsification. Burgers retain water and oil at hot and cold temperatures. They brown and sizzle on the grill and hold their shape when flipped and sandwiched in a bun.
“When burger producers ask how the ingredient performs, we explain that it behaves like egg whites,” he said. “When cooked in a patty mixture, Revyve becomes firm yet springy, forming a binding network around the other ingredients. The secret lies in the unique combination of functional proteins and fibers created by our patented technology.”
The ingredient also has application in animal-meat products such as meatballs and nuggets, as well as hybrid products. It allows formulators to eliminate egg allergens.
Angel Yeast Company, Hubei, China, also offers yeast protein ingredients that are extracted from natural brewers’ yeast. One of the company’s newest naturally fermented yeast protein ingredients contains all nine essential amino acids and possesses an 80% protein content. This ingredient is used to enhance the flavor and nutritional profile of vegan meat and other foods.
The future of food is all about doing more with less, as well as producing less waste. The end product should be safe, nutritious and delicious.
